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At least 865 records · Page 48

Electron Beam Freeform Fabrication: A Fabrication Process that Revolutionizes Aircraft Structural Designs and Spacecraft Supportability

The technological inception and challenges, as well as current applications of the electron beam freeform fabrication (EBF3) process are outlined. The process was motivated by the need for a new metals technology that would be cost-effective, enable the production of new alloys and that would could be used for efficient, lightweight structures. EBF3 is a rapid metal fabrication, layer-additive process that uses no molds or tools and which yields properties equivalent to wrought. The benefits of EBF3 include it near-net shape which minimizes scrap and reduces part count; efficiency in design which allows for lighter weight and enhanced performance; and, its "green" manufacturing process which yields minimal waste products. EBF3 also has a high tensile strength, while a structural test comparison found that EBF3 panels performed 5% lower than machined panels. Technical challenges in the EBF3 process include a need for process control monitoring and an improvement in localized heat response. Currently, the EBF3 process can be used to add details onto forgings and to construct and form complex shapes. However, it has potential uses in a variety of industries including aerospace, automotive, sporting goods and medical implant devices. The novel structural design capabilities of EBF3 have the ability to yield curved stiffeners which may be optimized for performance, low weight, low noise and damage tolerance applications. EBF3 has also demonstrated its usefulness in 0-gravity environments for supportability in space applications.

Taminger, Karen M.↗

An Overview of Active Flow Control Enhanced Vertical Tail Technology Development

This paper summarizes a joint NASA/Boeing research effort to advance Active Flow Control (AFC) technology to enhance aerodynamic efficiency of a vertical tail. Sweeping jet AFC technology was successfully tested on subscale and full-scale models as well as in flight. The subscale test was performed at Caltech on a ~14% scale model. More than 50% side force enhancement was achieved by the sweeping jet actuation when the momentum coefficient was 1.7%. AFC caused significant increases in suction pressure on the actuator side and associated side force enhancement. Subsequently, a full-scale Boeing 757 vertical tail model equipped with sweeping jets was tested at the National Full-Scale Aerodynamics Complex 40- by 80-Foot Wind Tunnel at NASA Ames Research Center. There, flow separation control optimization was performed at near flight conditions. Greater than 20% increase in side force were achieved for the maximum rudder deflection of 30deg at the key sideslip angles (0deg and -7.5deg) with a 31-actuator AFC configuration. Based on these tests, the momentum coefficient is shown to be a necessary, but not sufficient parameter to use for design and scaling of sweeping jet AFC from subscale tests to full-scale applications. Leveraging the knowledge gained from the wind tunnel tests, the AFC-enhanced vertical tail technology was successfully flown on the Boeing 757 ecoDemonstrator in the spring of 2015.

Lin, John C.↗

Effects of Varying Surface Inclines and Suit Pressure: Implications on Space Suit Design

Suited human performance studies in reduced gravity environments to date include limited observations from Apollo Lunar surface Extravehicular Activities (EVA) and from previous studies conducted in partial gravity simulation environments. The Constellation Program EVA Systems Project office has initiated tests to develop design requirements for the next generation Lunar EVA suit. Theses studies were conducted in the Space Vehicle Mock-Up Facility (SVMF) at Johnson Space Center from which the results provided recommendations for suit weight, mass, center of gravity, pressure, and suit kinematic constraints that optimize human performance in partial gravity environments.

Clowers, Kurt↗

Quasi-Linear Circuit

This work involved developing spacequalifiable switch mode DC/DC power supplies that improve performance with fewer components, and result in elimination of digital components and reduction in magnetics. This design is for missions where systems may be operating under extreme conditions, especially at elevated temperature levels from 200 to 300 degC. Prior art for radiation-tolerant DC/DC converters has been accomplished utilizing classical magnetic-based switch mode converter topologies; however, this requires specific shielding and component de-rating to meet the high-reliability specifications. It requires complex measurement and feedback components, and will not enable automatic re-optimization for larger changes in voltage supply or electrical loading condition. The innovation is a switch mode DC/DC power supply that eliminates the need for processors and most magnetics. It can provide a well-regulated voltage supply with a gain of 1:100 step-up to 8:1 step down, tolerating an up to 30% fluctuation of the voltage supply parameters. The circuit incorporates a ceramic core transformer in a manner that enables it to provide a well-regulated voltage output without use of any processor components or magnetic transformers. The circuit adjusts its internal parameters to re-optimize its performance for changes in supply voltage, environmental conditions, or electrical loading at the output

Bradley, William↗

Circumferentially segmented duct lines optimized for axisymmetric and standing wave sources

Optimum and off-optimum properties of circumferentially segmented duct liners are compared with those of uniform liners to identify any potential benefits of circumferentially segmented liners. High- and low-order spinning-mode sources are considered in the study. The solution for the segmented liner is obtained by a multimodal expansion of the segmented-liner eigenmodes in terms of a series of hardwall duct models. The coefficients in the hard-wall series are obtained by using Galerkin's method. Results show that for some frequencies and duct lengths, circumferentially segmented liners scatter energy equally between a higher and lower order circumferential wave number. Studies for higher order spinning-mode sources show that an optimized segmented liner with a hard-wall/soft-wal admittance variation representing an optimum configuration gives better performance than an optimized uniform liner. Overall, the greatest benefit of the segmented liner over the uniform liner occurs under off-optimum conditions. The optimized segmented liner gives more effective broadband performance than the optimized uniform liner.

Watson, W. R.↗

A Comparison of Probabilistic and Deterministic Campaign Analysis for Human Space Exploration

Human space exploration is by its very nature an uncertain endeavor. Vehicle reliability, technology development risk, budgetary uncertainty, and launch uncertainty all contribute to stochasticity in an exploration scenario. However, traditional strategic analysis has been done in a deterministic manner, analyzing and optimizing the performance of a series of planned missions. History has shown that exploration scenarios rarely follow such a planned schedule. This paper describes a methodology to integrate deterministic and probabilistic analysis of scenarios in support of human space exploration. Probabilistic strategic analysis is used to simulate "possible" scenario outcomes, based upon the likelihood of occurrence of certain events and a set of pre-determined contingency rules. The results of the probabilistic analysis are compared to the nominal results from the deterministic analysis to evaluate the robustness of the scenario to adverse events and to test and optimize contingency planning.

Merrill, R. Gabe↗

Flight Test of an Intelligent Flight-Control System

The F-15 Advanced Controls Technology for Integrated Vehicles (ACTIVE) airplane (see figure) was the test bed for a flight test of an intelligent flight control system (IFCS). This IFCS utilizes a neural network to determine critical stability and control derivatives for a control law, the real-time gains of which are computed by an algorithm that solves the Riccati equation. These derivatives are also used to identify the parameters of a dynamic model of the airplane. The model is used in a model-following portion of the control law, in order to provide specific vehicle handling characteristics. The flight test of the IFCS marks the initiation of the Intelligent Flight Control System Advanced Concept Program (IFCS ACP), which is a collaboration between NASA and Boeing Phantom Works. The goals of the IFCS ACP are to (1) develop the concept of a flight-control system that uses neural-network technology to identify aircraft characteristics to provide optimal aircraft performance, (2) develop a self-training neural network to update estimates of aircraft properties in flight, and (3) demonstrate the aforementioned concepts on the F-15 ACTIVE airplane in flight. The activities of the initial IFCS ACP were divided into three Phases, each devoted to the attainment of a different objective. The objective of Phase I was to develop a pre-trained neural network to store and recall the wind-tunnel-based stability and control derivatives of the vehicle. The objective of Phase II was to develop a neural network that can learn how to adjust the stability and control derivatives to account for failures or modeling deficiencies. The objective of Phase III was to develop a flight control system that uses the neural network outputs as a basis for controlling the aircraft. The flight test of the IFCS was performed in stages. In the first stage, the Phase I version of the pre-trained neural network was flown in a passive mode. The neural network software was running using flight data inputs with the outputs provided to instrumentation only. The IFCS was not used to control the airplane. In another stage of the flight test, the Phase I pre-trained neural network was integrated into a Phase III version of the flight control system. The Phase I pretrained neural network provided realtime stability and control derivatives to a Phase III controller that was based on a stochastic optimal feedforward and feedback technique (SOFFT). This combined Phase I/III system was operated together with the research flight-control system (RFCS) of the F-15 ACTIVE during the flight test. The RFCS enables the pilot to switch quickly from the experimental- research flight mode back to the safe conventional mode. These initial IFCS ACP flight tests were completed in April 1999. The Phase I/III flight test milestone was to demonstrate, across a range of subsonic and supersonic flight conditions, that the pre-trained neural network could be used to supply real-time aerodynamic stability and control derivatives to the closed-loop optimal SOFFT flight controller. Additional objectives attained in the flight test included (1) flight qualification of a neural-network-based control system; (2) the use of a combined neural-network/closed-loop optimal flight-control system to obtain level-one handling qualities; and (3) demonstration, through variation of control gains, that different handling qualities can be achieved by setting new target parameters. In addition, data for the Phase-II (on-line-learning) neural network were collected, during the use of stacked-frequency- sweep excitation, for post-flight analysis. Initial analysis of these data showed the potential for future flight tests that will incorporate the real-time identification and on-line learning aspects of the IFCS.

Davidson, Ron↗

Optimization of self-acting herringbone journal bearing for maximum stability

Groove parameters were determined to maximize the stability of herringbone grooved journal bearings. Parameters optimized were groove depth, width, length, and angle. Optimization was performed using a small eccentricity, infinite groove analysis in conjunction with: (1) a previously developed Newton-Raphson procedure for bearings with the smooth member rotating or with the grooved member rotating at low compressibility numbers, and (2) a newly-developed vector technique for bearings with the grooved member rotating at high compressibility numbers. The design curves enable one to choose the optimum bearing for a wide range of operating conditions. These include: (1) compressibility numbers from 0 (incompressible) to 80, (2) length to diameter ratios from 1/4 to 2, and (3) smooth or grooved member rotating. Compared to bearings optimized to maximize load capacity, bearings optimized for stability: (1) allow a thousandfold increase in bearing-supported mass in some cases before onset of instability (the most dramatic increase are for bearings with small L/D operating at high compressibility numbers), and (2) lose no more than 77-percent of their load capacity in any case studied. Stability is much greater when the grooved member rotates.

Fleming, D. P.↗

Optimization of self-acting herringbone journal bearings for maximum stability

Groove parameters were determined to maximize the stability of herringbone grooved journal bearings. Parameters optimized were groove depth, width, length, and angle. Optimization was performed using a small eccentricity, infinite groove analysis in conjunction with: (1) a previously developed Newton-Raphson procedure for bearings with the smooth member rotating or with the grooved member rotating at low compressibility numbers; (2) a newly-developed vector technique for bearings with the grooved member rotating at high compressibility numbers. The design curves in this report enable one to choose the optimum bearing for a wide range of operating conditions. These include: (1) compressibility numbers from 0 to 80; (2) length to diameter ratios from 1/4 to 2; and (3) smooth or grooved member rotating. Compared to bearings optimized to maximize load capacity, bearings optimized for stability allow a thousandfold increase in bearing-supported mass in some cases before onset of instability. Stability is much greater when the grooved member rotates.

Fleming, D. P.↗

Design of a communications system for multiple telemetry data channels operating simultaneously with a coherent turn-around ranging channel

This paper presents a simple technique to design a phase-modulated residual carrier communications link for optimum performance. The emphasis is on two data channels which are operated simultaneously with a ranging signal. The data channels employ PCM/PM and PCM/PSK/PM modulation schemes for high and low data rate channels, respectively. The technique proposed here selects the optimum (1) subcarrier frequency to minimize the interference between the two data channels, and (2) modulation indices for optimum balance of power between the two telemetry data channels and the coherent turn around ranging channel. The selected set of optimum modulation indices will allow for the specified bit error rate (BER) degradations in the two data channels. Although this technique is proposed to optimize the performance degradation for two data channels, generalizations can be made for more than two data channels.

Nguyen, Tien M.↗

Optimization of self-acting herringbone journal bearings for maximum stability

The stability of herringbone grooved journal bearings was increased by optimizing the groove depth, width, length, and angle. Optimization was performed on the basis of a small-eccentricity infinite-groove analysis in combination with a previously developed Newton-Raphson procedure for bearings with the smooth member rotating or with the grooved member rotating at low compressibility numbers. A newly-developed vector technique for bearings with the grooved member rotating at high compressibility numbers also was used in the analysis. The design curves obtained are suitable for choosing the optimum bearing for a wide range of operating conditions (compressibility numbers from 0 to 80, length to diameter ratios from 1/4 to 2, and smooth or grooved member rotating). Compared to bearings optimized for maximum load, bearings optimized for maximum stability are shown to provide a drastic increase in bearing-supported mass. Bearings with grooved member rotating are substantially more stable than bearing with smooth member rotating, particularly at high compressibility numbers.

Fleming, D. P.↗

Improving Control in a Joule-Thomson Refrigerator

A report discusses a modified design of a Joule-Thomson (JT) refrigerator under development to be incorporated into scientific instrumentation aboard a spacecraft. In most other JT refrigerators (including common household refrigerators), the temperature of the evaporator (the cold stage) is kept within a desired narrow range by turning a compressor on and off as needed. This mode of control is inadequate for the present refrigerator because a JT-refrigerator compressor performs poorly when the flow from its evaporator varies substantially, and this refrigerator is required to maintain adequate cooling power. The proposed design modifications include changes in the arrangement of heat exchangers, addition of a clamp that would afford a controlled heat leak from a warmer to a cooler stage to smooth out temperature fluctuations in the cooler stage, and incorporation of a proportional + integral + derivative (PID) control system that would regulate the heat leak to maintain the temperature of the evaporator within a desired narrow range while keeping the amount of liquid in the evaporator within a very narrow range in order to optimize the performance of the compressor. Novelty lies in combining the temperature- and cooling-power-regulating controls into a single control system.

Borders, James↗

The Role of Design-of-Experiments in Managing Flow in Compact Air Vehicle Inlets

It is the purpose of this study to demonstrate the viability and economy of Design-of-Experiments methodologies to arrive at microscale secondary flow control array designs that maintain optimal inlet performance over a wide range of the mission variables and to explore how these statistical methods provide a better understanding of the management of flow in compact air vehicle inlets. These statistical design concepts were used to investigate the robustness properties of low unit strength micro-effector arrays. Low unit strength micro-effectors are micro-vanes set at very low angles-of-incidence with very long chord lengths. They were designed to influence the near wall inlet flow over an extended streamwise distance, and their advantage lies in low total pressure loss and high effectiveness in managing engine face distortion. The term robustness is used in this paper in the same sense as it is used in the industrial problem solving community. It refers to minimizing the effects of the hard-to-control factors that influence the development of a product or process. In Robustness Engineering, the effects of the hard-to-control factors are often called noise , and the hard-to-control factors themselves are referred to as the environmental variables or sometimes as the Taguchi noise variables. Hence Robust Optimization refers to minimizing the effects of the environmental or noise variables on the development (design) of a product or process. In the management of flow in compact inlets, the environmental or noise variables can be identified with the mission variables. Therefore this paper formulates a statistical design methodology that minimizes the impact of variations in the mission variables on inlet performance and demonstrates that these statistical design concepts can lead to simpler inlet flow management systems.

Anderson, Bernhard H.↗

Progress in the Fabrication and Testing of Telescope Mirrors for the James Webb Space Telescope

The telescope of the James Webb Space Telescope (JWST) is an f/20, three mirror anastigmat design, passively cooled (40K) in an L2 orbit. The design provides diffraction limited performance (Strehl > or = 0.8) at .=2 m. To fit within the launch vehicle envelope (Arianne V), the 6.6 meter primary mirror and the secondary mirror support structure are folded for launch, then deployed and aligned in space. The primary mirror is composed of 18 individual, 1.3 meter (flat flat) hexagonal segments, each adjustable in seven degrees of freedom (six rigid body + radius of curvature) provided by a set of high precision actuators. The actuated secondary mirror (approx.0.74m) is similarly positioned in six degrees of rigid body motion. The approx..70x.51m, fixed tertiary and approx. 0.17m, flat fine steering mirror complete the telescope mirror complement. The telescope is supported by a composite structure optimized for performance at cryogenic temperatures. All telescope mirrors are made of Be with substantial light-weighting (21 kg for each 1.3M primary segment). Additional Be mounting and supporting structure for the high precision (approx.10nm steps) actuators are attached to the primary segments and secondary mirror. All mirrors undergo a process of thermal stabilization to reduce stress. An extensive series of interferometric measurements guide each step of the polishing process. Final polishing must account for any deformation between the ambient temperature of polishing and the cryogenic, operational temperature. This is accomplished by producing highly precise, cryo deformation target maps of each surface which are incorporated into the final polishing cycle. All flight mirrors have now completed polishing, coating with protected Au and final cryo testing, and the telescope is on track to meet all system requirements. We here review the measured performance of the component mirrors and the predicted performance of the flight telescope.

Bowers, Charles↗

Impact of mismodeled idle engine performance on calculation and tracking of optimal 4-D descent trajectories

Advanced flight management systems are being developed which are capable of calculating optimal 3-D and 4-D flight trajectories for arbitrary fuel and time costs. These systems require mathematical models of airplane performance in order to compute the optimal profiles. Mismodeled idle engine characteristics can result in descent trajectories requiring excessive throttle and/or speedbrake activity in order to achieve the desired end conditions. This paper evaluates the cost and fuel penalties, trajectory variations, and flight control requirements associated with typical idle engine modeling errors for a twin-jet transport airplane. Variations in idle power setting, thrust, fuel flow, and surge bleed operation were evaluated for a cruise/descent flight segment. The results of this analysis provide insight into the penalties associated with uncertainties in idle engine performance and suggest methods of modeling which minimize these penalties.

Williams, D. H.↗

Integrated Modeling for the Next Generation Space Telescope "Yardstick" Concept

The so-called NASA "Yardstick" design concept for the Next Generation Space Telescope presents unique challenges for systems-level analysis. Simulations that integrate controls, optics, thermal, and structural models are required to evaluate baseline performance, study design sensitivities, and perform design optimization. An integrated modeling approach was chosen using a combination of commercial off-the-shelf and "in-house" developed codes. The resulting capability provides a foundation for linear and non-linear analysis, using both the time and frequency-domain methods. It readily allows various combinations of design parameters and environmental loads to be evaluated directly in terms of key science-related metrics, in this case the scalar RMS (root mean square) line-of-sight and RMS wavefront errors. This presentation first addresses the development of the component, or discipline, models for the Yardstick design. It will then proceed to present the integration of the component models, using linear-systems approaches, in order to support two of the most critical baseline performance analyses: jitter and thermal-elastic stability of the optical telescope assembly (OTA). The results of the jitter analysis indicate that disturbances from the reaction wheels coupled with the lightly-damped and highly-flexible structure present significant challenges to the baseline line-of-sight control architecture. Vibration isolation will be required to meet jitter error requirements. The results of the thermal-elastic analysis indicate that the mirror segment displacements due to ground-to-orbit cool-down of the telescope are within the expected capture range of the segment rigid-body control actuators. This means we will be able to align and phase the primary mirror. However, the results for the analysis of the thermal transient response following an attitude maneuver (slew) show that this telescope design is not sufficiently stable, passively, to meet the wavefront error requirements. Structural re-design is one possibility; alternatively, active thermal control of the OTA may be considered. The Yardstick integrated models were successfully used to demonstrate the feasibility of two thermal control strategies.

Mosier, Gary E.↗

Exergy Based Analysis for the Environmental Control and Life Support Systems of the International Space Station

When optimizing the performance of complex systems, a logical area for concern is improving the efficiency of useful energy. The energy available for a system to perform work is defined as a system's energy content. Interactions between a system's subsystems and the surrounding environment can be accounted for by understanding various subsystem energy efficiencies. Energy balance of reactants and products, and enthalpies and entropies, can be used to represent a chemical process. Heat transfer energy represents heat loads, and flow energy represents system flows and filters. These elements allow for a system level energy balance. The energy balance equations are developed for the subsystems of the Environmental Control and Life Support (ECLS) system aboard the International Space Station (ISS). The use of these equations with system information would allow for the calculation of the energy efficiency of the system, enabling comparisons of the ISS ECLS system to other systems as well as allows for an integrated systems analysis for system optimization.

Clem, Kirk A.↗