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NASA NTRS1947

The Combination of Internal-Combustion Engine and Gas Turbine

While the gas turbine by itself has been applied in particular cases for power generation and is in a state of promising development in this field, it has already met with considerable success in two cases when used as an exhaust turbine in connection with a centrifugal compressor, namely, in the supercharging of combustion engines and in the Velox process, which is of particular application for furnaces. In the present paper the most important possibilities of combining a combustion engine with a gas turbine are considered. These "combination engines " are compared with the simple gas turbine on whose state of development a brief review will first be given. The critical evaluation of the possibilities of development and fields of application of the various combustion engine systems, wherever it is not clearly expressed in the publications referred to, represents the opinion of the author. The state of development of the internal-combustion engine is in its main features generally known. It is used predominantly at the present time for the propulsion of aircraft and road vehicles and, except for certain restrictions due to war conditions, has been used to an increasing extent in ships and rail cars and in some fields applied as stationary power generators. In the Diesel engine a most economical heat engine with a useful efficiency of about 40 percent exists and in the Otto aircraft engine a heat engine of greatest power per unit weight of about 0.5 kilogram per horsepower.

Zinner, K.↗

NASA NTRSDate not supplied

Updating the Thermal Vacuum Chambers at the NASA Johnson Space Center

Chambers A and B are two large thermal vacuum chambers at Johnson Space Center which enable space simulation for unmanned and human-rated missions, respectively. With the resurgence in deep space missions for scientific research and various private commercial ventures, these chambers are expected to be used frequently for at least the next decade. For qualifying the James Webb Space Telescope, upgrades to Chamber A were performed which included the addition of a 12.5 kW refrigeration system with helium shrouds capable of simulating deep space environment and an efficient and reliable LN2 natural flow thermosiphon system for the thermal shield. Continuous improvements since then have focused on ensuring operational readiness by modernizing the data acquisition, recording, controls, and visualization systems for both chambers and clean room. These upgrades will be the focus of this paper. Controlling the Cryochambers was enhanced by moving from a 32-bit SCADA system to a 64-bit architected system. Infrastructural changes involved installing redundant power circuits, adding new servers, network switches, and including load balancing with fail-over between servers to minimize downtime. Instead of distributed servers, 3 redundant servers are used to share configurations. Configurations are now kept in a shared SQL instance making it easy to deploy and maintain. During this upgrade process many sub-systems (PLCs and NI PXI interfaces to sensors) were upgraded from the prior OPC-DA to the more secure OPC-UA protocol. Cryo-system PLCs were updated to allow Ganni cycle floating pressure calculations from any cold box to be sent to any compressor. During the project, the team recreated over 70,000 live data points, 50000 historical data points, and 4000 alarms. Finally, the graphical interfaces were upgraded to support HTML 5 in conjunction shared pages were implemented reducing the total number of webpages by over 75%. These system updates reinvigorated the previous SCADA system which had reached its end of life. The same look and feel was maintained while providing operators with an updated interface to control, troubleshoot, and record. The new system architecture is more robust and easier to maintain creating a path forward to address remaining problem points and implement additional features.

Cody Schaefer↗

NASA NTRSDate not supplied

Updating the Thermal Vacuum Chambers at the NASA Johnson Space Center

Cody Schaefer↗

DOE OSTI2024

Investigation of powertrain system decarbonization using electrically assisted turbocharging and hybridization in off-road vehicles

In recent years, the causes, effects, and existential threat of a global anthropogenic climate shift have drawn significant attention and stimulated mitigation efforts from all genres of scientific, political, and industrial bodies. The greenhouse effect and the detrimental environmental impact of excess greenhouse gas (GHG) emissions, like carbon dioxide, is well studied and targeted as the primary culprit for aversive action. However, some fields exist where reducing GHG emissions is met by considerable challenges. One such field is the production and operations of off-road vehicles. Applications of these vehicles are highly diverse and are often characterized by rugged, especially transient, and power intensive duty cycles that make one-fits-all vehicle configuration solutions impractical. This research surveys existing literature to identify the modern technologies packages and challenges that face development and configuration of powertrain systems which currently navigate the regulated emissions and unique duty cycle requirements of this market space. A novel powertrain concept is proposed and evaluated with respect to the pinnacle objectives of load performance improvement, criteria pollutant reduction, and reducing the life cycle GHG intensity of its operation. A sure-fire path to vehicular GHG reduction is through improving the fuel efficiency of internal combustion engines (ICEs), an entrenched component of the off-road vehicle sector. Unfortunately, this is more easily said than done. An approach that has proven successful in this endeavor is engine downsizing and turbocharging, where a larger engine is replaced with a smaller one with added air system boosting via turbocharger to reduce frictional and pumping losses while also enabling access to additional fuel energy. However, practical realization of these potential benefits is often impeded by the transient response capability of the smaller engine across the operating space. For this reason, downsized ICE powertrains have turned to electrified forced induction systems (EFISs) for a decoupling of exhaust energy and engine speed from boost capability. Platformed on 48V hybrid technology, these systems introduce the need for more sophisticated controls around the engine gas-exchange process for the management of boost performance and exhaust gas emissions. On this account, simulation studies utilizing a GT-POWER model of a turbocharged 4.5 L engine outfit with an EFIS using an electrically driven compressor (eBooster®) are conducted to provide insight into the performance of this air handling architecture on an off-road engine. The results show that improvement in transient torque response time in sync with reduction in engine-out soot and NOx emissions are possible with an engine recalibration that leverages the transient air-fuel ratio authority of the eBooster®. Benefits are further demonstrated when duty cycle simulations of the 48V mild-hybrid engine concept are exercised, showing an acute decrease in cumulative fuel usage and soot production. Powertrain hybridization is another technological pathway achieving pronounced GHG reduction successes in modern on-road vehicle applications through integration of Li-ion battery technology. In the off-road vehicle segment, a review of available literature concludes that hybridized architectures are present but generally lack the depth of technologies that have both high specific energy and power capabilities, and thus are limited in their inclusion of Li-ion batteries for ICE assistance and enhanced energy storage capability. Therefore, building on the mild-hybrid engine results, the downsized and eBoosted engine concept was integrated into a larger high-voltage battery-hybrid series-electric powertrain system. Hybrid powertrain parameter sensitivity studies were carried out in a numerical charge-sustaining framework, providing novel insights into power flows between the battery and the engine and how their respective capabilities and operation contribute to GHG and criteria pollutant emissions of diverse duty cycles. Application of supervisory power management introduced robustness into the power sourcing and battery SOC control process and showed that optimum specification of battery properties can yield synergies between GHG emissions and battery energy capacity. Furthermore, examination of recent literature on Li-ion batteries has shown that pack manufacturing is a highly energy intensive process, thereby producing considerable quantities of GHGs that scale with energy storage capacity. Also scaling with a battery’s energy storage capacity is its investment cost. In consideration of these factors, an inclusive technoeconomic and GHG life cycle analysis is conducted. This analysis systematically compares the carbon footprint and total cost of ownership associated with the proposed hybrid powertrain concept to reference and alternative powertrain configurations, facilitating a thorough evaluation of the decarbonization effectiveness and economic viability.

99 GENERAL AND MISCELLANEOUS↗

NASA NTRS1997

Nonlinear Dynamic Analysis of Disordered Bladed-Disk Assemblies

In a effort to address current needs for efficient, air propulsion systems, we have developed some new analytical predictive tools for understanding and alleviating aircraft engine instabilities which have led to accelerated high cycle fatigue and catastrophic failures of these machines during flight. A frequent cause of failure in Jets engines is excessive resonant vibrations and stall flutter instabilities. The likelihood of these phenomena is reduced when designers employ the analytical models we have developed. These prediction models will ultimately increase the nation's competitiveness in producing high performance Jets engines with enhanced operability, energy economy, and safety. The objectives of our current threads of research in the final year are directed along two lines. First, we want to improve the current state of blade stress and aeromechanical reduced-ordered modeling of high bypass engine fans, Specifically, a new reduced-order iterative redesign tool for passively controlling the mechanical authority of shroudless, wide chord, laminated composite transonic bypass engine fans has been developed. Second, we aim to advance current understanding of aeromechanical feedback control of dynamic flow instabilities in axial flow compressors. A systematic theoretical evaluation of several approaches to aeromechanical feedback control of rotating stall in axial compressors has been conducted. Attached are abstracts of two .papers under preparation for the 1998 ASME Turbo Expo in Stockholm, Sweden sponsored under Grant No. NAG3-1571. Our goals during the final year under Grant No. NAG3-1571 is to enhance NASA's capabilities of forced response of turbomachines (such as NASA FREPS). We with continue our development of the reduced-ordered, three-dimensional component synthesis models for aeromechanical evaluation of integrated bladeddisk assemblies (i.e., the disk, non-identical bladeing etc.). We will complete our development of component systems design optimization strategies for specified vibratory stresses and increased fatigue life prediction of assembly components, and for specified frequency margins on the Campbell diagrams of turbomachines. Finally, we will integrate the developed codes with NASA's turbomachinery aeromechanics prediction capability (such as NASA FREPS).

McGee, Oliver G., III↗

DOE OSTI2024

Scalable and compact magnetocaloric heat pump technology

Magnetocaloric heat pumping (MCHP) promises to be more efficient than traditional vapor compression while also eliminating the deleterious effects of gaseous refrigerants. While MCHP devices have shown the temperature spans and efficiencies needed for different heating and cooling applications, they struggle to become commercially viable due to their large size and mass, and resultant high cost. This paper evaluates a baseline MCHP device and explores methods to boost its system power density (SPD). The key components of the baseline system are the gadolinium packed-particle bed active magnetic regenerator (AMR) and a magnetic source composed of permanent magnets and high permeability magnetic steel. To enhance the SPD, the paper evaluates maximizing the AMR volume, opting for first-order magnetocaloric materials, optimizing the magnet and AMR geometry, and reducing the size of magnets and magnetic steel parts. At larger thermal powers, increasing the AMR diameter and the number of magnetic poles were evaluated. Using finite element models, solid models, and estimates of magnetocaloric material performance, thermal powers ranging from 37 W to 44 kW at a nominal 10 K temperature span were projected, and SPD was estimated to improve from 6 W/kg to 81 W/kg. Neglecting end effects, an upper limit of 114 W/g is estimated. Compared to SPD of off-the-shelf compressors with similar environment temperatures, MCHP power density using gadolinium is competitive up to roughly 200 W of cooling power. This is extended to 1 kW when using LaFeSi alloys and up to 3 kW in the limiting case. In conclusion, these results indicate that the performance and mass of MCHP can match that of compressors, which is a critical step toward cost-competitive magnetocaloric technology.

42 ENGINEERING↗

NASA NTRS2012

Fast and Adaptive Lossless Onboard Hyperspectral Data Compression System

Modern hyperspectral imaging systems are able to acquire far more data than can be downlinked from a spacecraft. Onboard data compression helps to alleviate this problem, but requires a system capable of power efficiency and high throughput. Software solutions have limited throughput performance and are power-hungry. Dedicated hardware solutions can provide both high throughput and power efficiency, while taking the load off of the main processor. Thus a hardware compression system was developed. The implementation uses a field-programmable gate array (FPGA). The implementation is based on the fast lossless (FL) compression algorithm reported in Fast Lossless Compression of Multispectral-Image Data (NPO-42517), NASA Tech Briefs, Vol. 30, No. 8 (August 2006), page 26, which achieves excellent compression performance and has low complexity. This algorithm performs predictive compression using an adaptive filtering method, and uses adaptive Golomb coding. The implementation also packetizes the coded data. The FL algorithm is well suited for implementation in hardware. In the FPGA implementation, one sample is compressed every clock cycle, which makes for a fast and practical realtime solution for space applications. Benefits of this implementation are: 1) The underlying algorithm achieves a combination of low complexity and compression effectiveness that exceeds that of techniques currently in use. 2) The algorithm requires no training data or other specific information about the nature of the spectral bands for a fixed instrument dynamic range. 3) Hardware acceleration provides a throughput improvement of 10 to 100 times vs. the software implementation. A prototype of the compressor is available in software, but it runs at a speed that does not meet spacecraft requirements. The hardware implementation targets the Xilinx Virtex IV FPGAs, and makes the use of this compressor practical for Earth satellites as well as beyond-Earth missions with hyperspectral instruments.

Aranki, Nazeeh I.↗

DOE OSTI2020

Steady-state off-design modeling of the supercritical carbon dioxide recompression cycle for concentrating solar power applications with two-tank sensible-heat storage

Concentrating solar power researchers are evaluating the potential of the supercritical carbon dioxide recompression cycle to improve the thermal efficiency and decrease the capital costs of next-generation systems. This analysis investigates the steady-state off-design performance of a recompression cycle integrated with two-tank sensible-heat thermal energy storage as the ambient temperature and heat-transfer fluid (HTF) inlet conditions to the cycle change. This paper presents off-design component models and then cycle convergence and control models to maximize net cycle power output while constraining the high-side pressure and air-cooler fan power to their respective design values and fixing the cycle HTF outlet temperature to its design value. Results show that inventory control and air-cooler fan power are important control parameters that can be optimized to maximize off-design power output as the ambient temperature and HTF mass flow rate diverge from design. The high-side pressure and fan power constraints cause the cycle net power to degrade when the ambient temperature is warmer than the design value, and this study calculates a maximum mass flow rate for hot days above which the cycle cannot achieve the design HTF outlet temperature. Finally, the analysis shows that optimizing compressor shaft speeds can improve cold-day performance by around 1.5 percentage points and part-load performance by up to 2.5 percentage points versus a baseline case with no active compressor control.

14 SOLAR ENERGY↗

NASA NTRS2005

Investigation of Exoskeletal Engine Propulsion System Concept

An innovative approach to gas turbine design involves mounting compressor and turbine blades to an outer rotating shell. Designated the exoskeletal engine, compression (preferable to tension for high-temperature ceramic materials, generally) becomes the dominant blade force. Exoskeletal engine feasibility lies in the structural and mechanical design (as opposed to cycle or aerothermodynamic design), so this study focused on the development and assessment of a structural-mechanical exoskeletal concept using the Rolls-Royce AE3007 regional airliner all-axial turbofan as a baseline. The effort was further limited to the definition of an exoskeletal high-pressure spool concept, where the major structural and thermal challenges are represented. The mass of the high-pressure spool was calculated and compared with the mass of AE3007 engine components. It was found that the exoskeletal engine rotating components can be significantly lighter than the rotating components of a conventional engine. However, bearing technology development is required, since the mass of existing bearing systems would exceed rotating machinery mass savings. It is recommended that once bearing technology is sufficiently advanced, a "clean sheet" preliminary design of an exoskeletal system be accomplished to better quantify the potential for the exoskeletal concept to deliver benefits in mass, structural efficiency, and cycle design flexibility.

Roche, Joseph M.↗

NASA NTRS2012

Hardware Implementation of Lossless Adaptive Compression of Data From a Hyperspectral Imager

Efficient onboard data compression can reduce the data volume from hyperspectral imagers on NASA and DoD spacecraft in order to return as much imagery as possible through constrained downlink channels. Lossless compression is important for signature extraction, object recognition, and feature classification capabilities. To provide onboard data compression, a hardware implementation of a lossless hyperspectral compression algorithm was developed using a field programmable gate array (FPGA). The underlying algorithm is the Fast Lossless (FL) compression algorithm reported in Fast Lossless Compression of Multispectral- Image Data (NPO-42517), NASA Tech Briefs, Vol. 30, No. 8 (August 2006), p. 26 with the modification reported in Lossless, Multi-Spectral Data Comressor for Improved Compression for Pushbroom-Type Instruments (NPO-45473), NASA Tech Briefs, Vol. 32, No. 7 (July 2008) p. 63, which provides improved compression performance for data from pushbroom-type imagers. An FPGA implementation of the unmodified FL algorithm was previously developed and reported in Fast and Adaptive Lossless Onboard Hyperspectral Data Compression System (NPO-46867), NASA Tech Briefs, Vol. 36, No. 5 (May 2012) p. 42. The essence of the FL algorithm is adaptive linear predictive compression using the sign algorithm for filter adaption. The FL compressor achieves a combination of low complexity and compression effectiveness that exceeds that of stateof- the-art techniques currently in use. The modification changes the predictor structure to tolerate differences in sensitivity of different detector elements, as occurs in pushbroom-type imagers, which are suitable for spacecraft use. The FPGA implementation offers a low-cost, flexible solution compared to traditional ASIC (application specific integrated circuit) and can be integrated as an intellectual property (IP) for part of, e.g., a design that manages the instrument interface. The FPGA implementation was benchmarked on the Xilinx Virtex IV LX25 device, and ported to a Xilinx prototype board. The current implementation has a critical path of 29.5 ns, which dictated a clock speed of 33 MHz. The critical path delay is end-to-end measurement between the uncompressed input data and the output compression data stream. The implementation compresses one sample every clock cycle, which results in a speed of 33 Msample/s. The implementation has a rather low device use of the Xilinx Virtex IV LX25, making the total power consumption of the implementation about 1.27 W.

Keymeulen, Didlier↗

NASA NTRS2013

Computational Study of the CC3 Impeller and Vaneless Diffuser Experiment

Centrifugal compressors are compatible with the low exit corrected flows found in the high pressure compressor of turboshaft engines and may play an increasing role in turbofan engines as engine overall pressure ratios increase. Centrifugal compressor stages are difficult to model accurately with RANS CFD solvers. A computational study of the CC3 centrifugal impeller in its vaneless diffuser configuration was undertaken as part of an effort to understand potential causes of RANS CFD mis-prediction in these types of geometries. Three steady, periodic cases of the impeller and diffuser were modeled using the TURBO Parallel Version 4 code: 1) a k-epsilon turbulence model computation on a 6.8 million point grid using wall functions, 2) a k-epsilon turbulence model computation on a 14 million point grid integrating to the wall, and 3) a k-omega turbulence model computation on the 14 million point grid integrating to the wall. It was found that all three cases compared favorably to data from inlet to impeller trailing edge, but the k-epsilon and k-omega computations had disparate results beyond the trailing edge and into the vaneless diffuser. A large region of reversed flow was observed in the k-epsilon computations which extended from 70% to 100% span at the exit rating plane, whereas the k-omega computation had reversed flow from 95% to 100% span. Compared to experimental data at near-peak-efficiency, the reversed flow region in the k-epsilon case resulted in an under-prediction in adiabatic efficiency of 8.3 points, whereas the k-omega case was 1.2 points lower in efficiency.

Kulkarni, Sameer↗

NASA NTRS2013

Computational Study of the CC3 Impeller and Vaneless Diffuser Experiment

Centrifugal compressors are compatible with the low exit corrected flows found in the high pressure compressor of turboshaft engines and may play an increasing role in turbofan engines as engine overall pressure ratios increase. Centrifugal compressor stages are difficult to model accurately with RANS CFD solvers. A computational study of the CC3 centrifugal impeller in its vaneless diffuser configuration was undertaken as part of an effort to understand potential causes of RANS CFD mis-prediction in these types of geometries. Three steady, periodic cases of the impeller and diffuser were modeled using the TURBO Parallel Version 4 code: (1) a k-ε turbulence model computation on a 6.8 million point grid using wall functions, (2) a k-ε turbulence model computation on a 14 million point grid integrating to the wall, and (3) a k-ω turbulence model computation on the 14 million point grid integrating to the wall. It was found that all three cases compared favorably to data from inlet to impeller trailing edge, but the k-ε and k-ω computations had disparate results beyond the trailing edge and into the vaneless diffuser. A large region of reversed flow was observed in the k-ε computations which extended from 70 to 100 percent span at the exit rating plane, whereas the k-ω computation had reversed flow from 95 to 100 percent span. Compared to experimental data at near-peak-efficiency, the reversed flow region in the k-ε case resulted in an underprediction in adiabatic efficiency of 8.3 points, whereas the k-ω case was 1.2 points lower in efficiency.

Kulkarni, Sameer↗

NASA NTRS2004

Research Capabilities for Oil-Free Turbomachinery Expanded by New Rotordynamic Simulator Facility

A new test rig has been developed for simulating high-speed turbomachinery shafting using Oil-Free foil air bearing technology. Foil air journal bearings are self-acting hydrodynamic bearings with a flexible inner sleeve surface using air as the lubricant. These bearings have been used in turbomachinery, primarily air cycle machines, for the past four decades to eliminate the need for oil lubrication. More recently, interest has been growing in applying foil bearings to aircraft gas turbine engines. They offer potential improvements in efficiency and power density, decreased maintenance costs, and other secondary benefits. The goal of applying foil air bearings to aircraft gas turbine engines prompted the fabrication of this test rig. The facility enables bearing designers to test potential bearing designs with shafts that simulate the rotating components of a target engine without the high cost of building actual flight hardware. The data collected from this rig can be used to make changes to the shaft and bearings in subsequent design iterations. The rest of this article describes the new test rig and demonstrates some of its capabilities with an initial simulated shaft system. The test rig has two support structures, each housing a foil air journal bearing. The structures are designed to accept any size foil journal bearing smaller than 63 mm (2.5 in.) in diameter. The bearing support structures are mounted to a 91- by 152-cm (3- by 5-ft) table and can be separated by as much as 122 cm (4 ft) and as little as 20 cm (8 in.) to accommodate a wide range of shaft sizes. In the initial configuration, a 9.5-cm (3.75-in.) impulse air turbine drives the test shaft. The impulse turbine, as well as virtually any number of "dummy" compressor and turbine disks, can be mounted on the shaft inboard or outboard of the bearings. This flexibility allows researchers to simulate various engine shaft configurations. The bearing support structures include a unique bearing mounting fixture that rotates to accommodate a laserbased alignment system. This can measure the misalignment of the bearing centers in each of 2 translational degrees of freedom and 2 rotational degrees of freedom. In the initial configuration, with roughly a 30.5-cm- (12-in.-) long shaft, two simulated aerocomponent disks, and two 50.8-cm (2-in.) foil journal bearings, the rig can operate at 65,000 rpm at room temperature. The test facility can measure shaft displacements in both the vertical and horizontal directions at each bearing location. Horizontal and vertical structural vibrations are monitored using accelerometers mounted on the bearing support structures. This information is used to determine system rotordynamic response, including critical speeds, mode shapes, orbit size and shape, and potentially the onset of instabilities. Bearing torque can be monitored as well to predict the power loss in the foil bearings. All of this information is fed back and forth between NASA and the foil bearing designers in an iterative fashion to converge on a final bearing and shaft design for a given engine application. In addition to its application development capabilities, the test rig offers several unique capabilities for basic bearing research. Using the laser alignment system mentioned earlier, the facility will be used to map foil air journal bearing performance. A known misalignment of increasing severity will be induced to determine the sensitivity of foil bearings to misalignment. Other future plans include oil-free integral starter generator testing and development, and dynamic load testing of foil journal bearings.

Howard, Samuel A.↗

NASA NTRS2023

Neural-Based Compression Scheme for Solar Image Data

Studying the solar system and especially the Sun relies on the data gathered daily from space missions. These missions are data-intensive and compressing this data to make them efficiently transferable to the ground station is a twofold decision to make. Stronger compression methods, by distorting the data, can increase data throughput at the cost of accuracy which could affect scientific analysis of the data. On the other hand, preserving subtle details in the compressed data requires a high amount of data to be transferred, reducing the desired gains from compression. In this work, we propose a neural network-based lossy compression method to be used in NASA’s data-intensive imagery missions. We chose NASA’s Solar Dynamics Observatory (SDO) mission which transmits 1.4 terabytes of data each day as a proof of concept for the proposed algorithm. In this work, we propose an adversarially trained neural network, equipped with local and non-local attention modules to capture both the local and global structure of the image resulting in a better trade-off in rate-distortion (RD) compared to conventional hand-engineered codecs. The RD variational autoencoder used in this work is jointly trained with a channel-dependent entropy model as a shared prior between the analysis and synthesis transforms to make the entropy coding of the latent code more effective. We also studied how optimizing perceptual losses could help our neural compressor to preserve high-frequency details of the data in the reconstructed compressed image. Our neural image compression algorithm outperforms currently-in-use and state-of-the-art codecs such as JPEG and JPEG-2000 in terms of the RD performance when compressing extreme-ultraviolet (EUV) data. As a proof of concept for use of this algorithm in SDO data analysis, we have performed coronal hole (CH) detection using our compressed images, and generated consistent segmentations, even at a compression rate of ∼ 0.1 bits per pixel (compared to 8 bits per pixel on the original data) using EUV data from SDO.

Image coding↗

NASA NTRS2005

Analysis of Coupled Seals, Secondary and Powerstream Flow Fields in Aircraft and Aerospace Turbomachines

Higher power, high efficiency gas turbine engines require optimization of the seals and secondary flow systems as well as their impact on the powerstream. This work focuses on two aspects: 1. To apply the present day CFD tools (SCISEAL) to different real-life secondary flow applications from different original equipment manufacturers (OEM s) to provide feedback data and 2. Develop a computational methodology for coupled time-accurate simulation of the powerstream and secondary flow with emphasis on the interaction between the disk-cavity and rim seals flows with the powerstream (SCISEAL-MS-TURBO). One OEM simulation was of the Allison Engine Company T-56 turbine drum cavities including conjugate heat transfer with good agreement with data and provided design feedback information. Another was the GE aspirating seal where the 3-D CFD simulations played a major role in analysis and modification of that seal configuration. The second major objective, development of a coupled flow simulation capability was achieved by using two codes MS-TURBO for the powerstream and SCISEAL for the secondary flows with an interface coupling algorithm. The coupled code was tested against data from three differed configurations: 1. bladeless-rotor-stator-cavity turbine test rig, 2. UTRC high pressure turbine test rig, and, 3. the NASA Low-Speed-Air Compressor rig (LSAC) with results and limitations discussed herein.

Athavale, M. M.↗

NASA NTRS2010

Investing American Recovery and Reinvestment Act Funds to Advance Capability, Reliability, and Performance in NASA Wind Tunnels

The National Aeronautics and Space Administration's (NASA) Aeronautics Test Program (ATP) is implementing five significant ground-based test facility projects across the nation with funding provided by the American Recovery and Reinvestment Act (ARRA). The projects were selected as the best candidates within the constraints of the ARRA and the strategic plan of ATP. They are a combination of much-needed large scale maintenance, reliability, and system upgrades plus creating new test beds for upcoming research programs. The projects are: 1.) Re-activation of a large compressor to provide a second source for compressed air and vacuum to the Unitary Plan Wind Tunnel at the Ames Research Center (ARC) 2.) Addition of high-altitude ice crystal generation at the Glenn Research Center Propulsion Systems Laboratory Test Cell 3, 3.) New refrigeration system and tunnel heat exchanger for the Icing Research Tunnel at the Glenn Research Center, 4.) Technical viability improvements for the National Transonic Facility at the Langley Research Center, and 5.) Modifications to conduct Environmentally Responsible Aviation and Rotorcraft research at the 14 x 22 Subsonic Tunnel at Langley Research Center. The selection rationale, problem statement, and technical solution summary for each project is given here. The benefits and challenges of the ARRA funded projects are discussed. Indirectly, this opportunity provides the advantages of developing experience in NASA's workforce in large projects and maintaining corporate knowledge in that very unique capability. It is envisioned that improved facilities will attract a larger user base and capabilities that are needed for current and future research efforts will offer revenue growth and future operations stability. Several of the chosen projects will maximize wind tunnel reliability and maintainability by using newer, proven technologies in place of older and obsolete equipment and processes. The projects will meet NASA's goal of integrating more efficient, environmentally safer, and less energy consuming hardware and processes into existing tunnel systems. These include Environmental Protection Agency-approved refrigerants, energy efficient motors, and faster, flexible tunnel data systems.

Sydnor, Goerge H.↗

NASA NTRS1997

Hierarchical Modeling and Robust Synthesis for the Preliminary Design of Large Scale Complex Systems

Large-scale complex systems are characterized by multiple interacting subsystems and the analysis of multiple disciplines. The design and development of such systems inevitably requires the resolution of multiple conflicting objectives. The size of complex systems, however, prohibits the development of comprehensive system models, and thus these systems must be partitioned into their constituent parts. Because simultaneous solution of individual subsystem models is often not manageable iteration is inevitable and often excessive. In this dissertation these issues are addressed through the development of a method for hierarchical robust preliminary design exploration to facilitate concurrent system and subsystem design exploration, for the concurrent generation of robust system and subsystem specifications for the preliminary design of multi-level, multi-objective, large-scale complex systems. This method is developed through the integration and expansion of current design techniques: Hierarchical partitioning and modeling techniques for partitioning large-scale complex systems into more tractable parts, and allowing integration of subproblems for system synthesis; Statistical experimentation and approximation techniques for increasing both the efficiency and the comprehensiveness of preliminary design exploration; and Noise modeling techniques for implementing robust preliminary design when approximate models are employed. Hierarchical partitioning and modeling techniques including intermediate responses, linking variables, and compatibility constraints are incorporated within a hierarchical compromise decision support problem formulation for synthesizing subproblem solutions for a partitioned system. Experimentation and approximation techniques are employed for concurrent investigations and modeling of partitioned subproblems. A modified composite experiment is introduced for fitting better predictive models across the ranges of the factors, and an approach for constructing partitioned response surfaces is developed to reduce the computational expense of experimentation for fitting models in a large number of factors. Noise modeling techniques are compared and recommendations are offered for the implementation of robust design when approximate models are sought. These techniques, approaches, and recommendations are incorporated within the method developed for hierarchical robust preliminary design exploration. This method as well as the associated approaches are illustrated through their application to the preliminary design of a commercial turbofan turbine propulsion system. The case study is developed in collaboration with Allison Engine Company, Rolls Royce Aerospace, and is based on the Allison AE3007 existing engine designed for midsize commercial, regional business jets. For this case study, the turbofan system-level problem is partitioned into engine cycle design and configuration design and a compressor modules integrated for more detailed subsystem-level design exploration, improving system evaluation. The fan and low pressure turbine subsystems are also modeled, but in less detail. Given the defined partitioning, these subproblems are investigated independently and concurrently, and response surface models are constructed to approximate the responses of each. These response models are then incorporated within a commercial turbofan hierarchical compromise decision support problem formulation. Five design scenarios are investigated, and robust solutions are identified. The method and solutions identified are verified by comparison with the AE3007 engine. The solutions obtained are similar to the AE3007 cycle and configuration, but are better with respect to many of the requirements.

Koch, Patrick N.↗

NASA NTRS2010

Enabling IP Header Compression in COTS Routers via Frame Relay on a Simplex Link

NASA is moving toward a networkcentric communications architecture and, in particular, is building toward use of Internet Protocol (IP) in space. The use of IP is motivated by its ubiquitous application in many communications networks and in available commercial off-the-shelf (COTS) technology. The Constellation Program intends to fit two or more voice (over IP) channels on both the forward link to, and the return link from, the Orion Crew Exploration Vehicle (CEV) during all mission phases. Efficient bandwidth utilization of the links is key for voice applications. In Voice over IP (VoIP), the IP packets are limited to small sizes to keep voice latency at a minimum. The common voice codec used in VoIP is G.729. This new algorithm produces voice audio at 8 kbps and in packets of 10-milliseconds duration. Constellation has designed the VoIP communications stack to use the combination of IP/UDP/RTP protocols where IP carries a 20-byte header, UDP (User Datagram Protocol) carries an 8-byte header, and RTP (Real Time Transport Protocol) carries a 12-byte header. The protocol headers total 40 bytes and are equal in length to a 40-byte G.729 payload, doubling the VoIP latency. Since much of the IP/UDP/RTP header information does not change from IP packet to IP packet, IP/UDP/RTP header compression can avoid transmission of much redundant data as well as reduce VoIP latency. The benefits of IP header compression are more pronounced at low data rate links such as the forward and return links during CEV launch. IP/UDP/RTP header compression codecs are well supported by many COTS routers. A common interface to the COTS routers is through frame relay. However, enabling IP header compression over frame relay, according to industry standard (Frame Relay IP Header Compression Agreement FRF.20), requires a duplex link and negotiations between the compressor router and the decompressor router. In Constellation, each forward to and return link from the CEV in space is treated independently as a simplex link. Without negotiation, the COTS routers are prevented from entering into the IP header compression mode, and no IP header compression would be performed. An algorithm is proposed to enable IP header compression in COTS routers on a simplex link with no negotiation or with a one-way messaging. In doing so, COTS routers can enter IP header compression mode without the need to handshake through a bidirectional link as required by FRF.20. This technique would spoof the routers locally and thereby allow the routers to enter into IP header compression mode without having the negotiations between routers actually occur. The spoofing function is conducted by a frame relay adapter (also COTS) with the capability to generate control messages according to the FRF.20 descriptions. Therefore, negotiation is actually performed between the FRF.20 adapter and the connecting COTS router locally and never occurs over the space link. Through understanding of the handshaking protocol described by FRF.20, the necessary FRF.20 negotiations messages can be generated to control the connecting router, not only to turn on IP header compression but also to adjust the compression parameters. The FRF.20 negotiation (or control) message is composed in the FRF.20 adapter by interpreting the incoming router request message. Many of the fields are simply transcribed from request to response while the control field indicating response and type are modified.

Nguyen, Sam P.↗