Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “process design”

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

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

At least 883 records · Page 49

System Engineering Processes at Kennedy Space Center for Development of the SLS and Orion Launch Systems

There are over 40 subsystems being developed for the future SLS and Orion Launch Systems at Kennedy Space Center. These subsystems developed at the Kennedy Space Center Engineering Directorate follow a comprehensive design process which requires several different product deliverables during each phase of each of the subsystems. This Paper describes this process and gives an example of where the process has been applied.

Schafer, Eric J.↗

Performance Analysis and Data Processing for the Mars Sample Recovery Helicopter in the Jet Propulsion Laboratory 25-ft Space Simulator

On April 19, 2021, Ingenuity became the first helicopter to fly on Mars at Jezero Crater, completing a total of 72 flights by the end of its mission. The success of Ingenuity resulted in various research efforts to further explore Mars via vertical flight, including two optimized Ingenuity-sized helicopters proposed to retrieve samples for the 2028 Mars Sample Return mission. To aid in the design process for the two proposed Sample Retrieval Helicopters, both heritage and optimized, increased diameter rotors were tested at the NASA Jet Propulsion Laboratory in the 25-ft Space Simulator. Three test campaigns were performed using the Ingenuity rotors and optimized Sample Retrieval Helicopter (SRH) rotors for several rotor speeds, densities, configurations, and collectives to identify performance limitations. These three test campaigns included the Ingenuity Engineering Design Model 1 (EDM-1) with and without a cruciform box, Transonic Rotor Test (TRT) rig, and SRH Dual Rotor Test (DRT). Experimental setup, test matrix, data processing, data quality, and performance results for EDM-1, TRT, and DRT campaigns are presented and discussed. Experimental results from the test campaigns will aid in future experimental methods and validation efforts for planetary rotorcraft exploration.

Data Processing↗

Aerothermal modeling program, phase 2. Element B: Flow interaction experiment

The design process was improved and the efficiency, life, and maintenance costs of the turbine engine hot section was enhanced. Recently, there has been much emphasis on the need for improved numerical codes for the design of efficient combustors. For the development of improved computational codes, there is a need for an experimentally obtained data base to be used at test cases for the accuracy of the computations. The purpose of Element-B is to establish a benchmark quality velocity and scalar measurements of the flow interaction of circular jets with swirling flow typical of that in the dome region of annular combustor. In addition to the detailed experimental effort, extensive computations of the swirling flows are to be compared with the measurements for the purpose of assessing the accuracy of current and advanced turbulence and scalar transport models.

Nikjooy, M.↗

Conservation of design knowledge

This paper presents an approach for acquiring knowledge about a design during the design process. The objective is to increase the efficiency of the lifecycle management of a space-borne system by providing operational models of the system's structure and behavior, as well as the design rationale, to human and automated operators. A design knowledge acquisition system is under development that compares how two alternative design versions meet the system requirements as a means for automatically capturing rationale for design changes.

Sivard, Cecilia↗

Cockpit System Situational Awareness Modeling Tool

This project explored the possibility of predicting pilot situational awareness (SA) using human performance modeling techniques for the purpose of evaluating developing cockpit systems. The Improved Performance Research Integration Tool (IMPRINT) was combined with the Adaptive Control of Thought-Rational (ACT-R) cognitive modeling architecture to produce a tool that can model both the discrete tasks of pilots and the cognitive processes associated with SA. The techniques for using this tool to predict SA were demonstrated using the newly developed Aviation Weather Information (AWIN) system. By providing an SA prediction tool to cockpit system designers, cockpit concepts can be assessed early in the design process while providing a cost-effective complement to the traditional pilot-in-the-loop experiments and data collection techniques.

Keller, John↗

Aeroheating Design Issues for Reusable Launch Vehicles: A Perspective

An overview of basic aeroheating design issues for Reusable Launch Vehicles (RLV), which addresses the application of hypersonic ground-based testing, and computational fluid dynamic (CFD) and engineering codes, is presented. Challenges inherent to the prediction of aeroheating environments required for the successful design of the RLV Thermal Protection System (TPS) are discussed in conjunction with the importance of employing appropriate experimental/computational tools. The impact of the information garnered by using these tools in the resulting analyses, ultimately enhancing the RLV TPS design is illustrated. A wide range of topics is presented in this overview; e.g. the impact of flow physics issues such as boundary-layer transition, including effects of distributed and discrete roughness, shockshock interactions, and flow separation/reattachment. Also, the benefit of integrating experimental and computational studies to gain an improved understanding of flow phenomena is illustrated. From computational studies, the effect of low-density conditions and of uncertainties in material surface properties on the computed heating rates are highlighted as well as the significant role of CFD in improving the Outer Mold Line (OML) definition to reduce aeroheating while maintaining aerodynamic performance. Appropriate selection of the TPS design trajectories and trajectory shaping to mitigate aeroheating levels and loads are discussed. Lastly, an illustration of an aeroheating design process is presented whereby data from hypersonic wind-tunnel tests are integrated with predictions from CFD codes and engineering methods to provide heating environments along an entry trajectory as required for TPS design.

Zoby, E. Vincent↗

Aeroheating Design Issues for Reusable Launch Vehicles: A Perspective

An overview of basic aeroheating design issues for Reusable Launch Vehicles (RLV), which addresses the application of hypersonic ground-based testing, and computational fluid dynamic (CFD) and engineering codes, is presented. Challenges inherent to the prediction of aeroheating environments required for the successful design of the RLV Thermal Protection System (TPS) are discussed in conjunction with the importance of employing appropriate experimental/computational tools. The impact of the information garnered by using these tools in the resulting analyses, ultimately enhancing the RLV TPS design is illustrated. A wide range of topics is presented in this overview; e.g. the impact of flow physics issues such as boundary-layer transition, including effects of distributed and discrete roughness, shock-shock interactions, and flow separation/reattachment. Also, the benefit of integrating experimental and computational studies to gain an improved understanding of flow phenomena is illustrated. From computational studies, the effect of low-density conditions and of uncertainties in material surface properties on the computed heating rates a r e highlighted as well as the significant role of CFD in improving the Outer Mold Line (OML) definition to reduce aeroheating while maintaining aerodynamic performance. Appropriate selection of the TPS design trajectories and trajectory shaping to mitigate aeroheating levels and loads are discussed. Lastly, an illustration of an aeroheating design process is presented whereby data from hypersonic wind-tunnel tests are integrated with predictions from CFD codes and engineering methods to provide heating environments along an entry trajectory as required for TPS design.

Zoby, E. Vincent↗

Development of Parametric Mass and Volume Models for an Aerospace SOFC/Gas Turbine Hybrid System

In aerospace power systems, mass and volume are key considerations to produce a viable design. The utilization of fuel cells is being studied for a commercial aircraft electrical power unit. Based on preliminary analyses, a SOFC/gas turbine system may be a potential solution. This paper describes the parametric mass and volume models that are used to assess an aerospace hybrid system design. The design tool utilizes input from the thermodynamic system model and produces component sizing, performance, and mass estimates. The software is designed such that the thermodynamic model is linked to the mass and volume model to provide immediate feedback during the design process. It allows for automating an optimization process that accounts for mass and volume in its figure of merit. Each component in the system is modeled with a combination of theoretical and empirical approaches. A description of the assumptions and design analyses is presented.

Tornabene, Robert↗

Ares V: Enabling Unprecedented Payloads for Space in the 21st Century

Numerous technical and programmatic studies since the U.S. space program began in the 1960s has emphasized the need for a heavy lift capability for exploration beyond low Earth orbit (LEO). The Saturn V once embodied that capability until it was retired. Now the Ares V cargo launch vehicle (CaLV) promises to restore and improve on that capability, providing unprecedented opportunities for human and robotic exploration, science, national security and commercial uses. This paper provides an overview of the capabilities of Ares V, both as an opportunity for payloads of increased mass and/or volume, and as a means of reducing risk in the payload design process. The Ares V is part of NASA s Constellation Program, which also includes the Ares I crew launch vehicle (CLV), Orion crew exploration vehicle (CEV), and Altair lunar lander. This architecture is designed to carry out the national space policy goals of completing the International Space Station (ISS), retiring the Space Shuttle fleet, and expanding human exploration beyond LEO. The Ares V is designed to loft upper stages and/or cargo, such as the Altair lander, into LEO. The Ares I is designed to put Orion into LEO with a crew of up to four for rendezvous with the ISS or with the Ares V Earth departure stage for journeys to the Moon. While retaining the goals of heritage hardware and commonality, the Ares V configuration continues to be refined through a series of internal trades. The current reference configuration was recommended by the Ares Projects and approved by the Constellation Program during the Lunar Capabilities Concept Review (LCCR) June 2008. The reference configuration defines the Ares V as 381 feet (116m) tall with a gross lift-off mass (GLOM) of 8.1 million pounds (3,704.5 mT). Its first stage will generate 11 million pounds of sea-level liftoff thrust. It will be capable of launching 413,800 pounds (187.7 mT) to LEO, 138,500 pounds (63 mT) direct to the Moon or 156,700 pounds (71.1 mT) in its dual-launch architecture role with Ares I. It could also launch 123,100 pounds (55.8 mT) to Sun-Earth L2. Assessment of astronomy payload requirements since Spring 2008 has indicated that Ares V has the potential to support a range of payloads and missions. Some of these missions were impossible in the absence of Ares V s capabilities. Collaborative design/architecture inputs, exchanges, and analyses have already begun between scientists and payload developers. A 2008 study by a National Research Council (NRC) panel, as well as analyses presented by astronomers and planetary scientists at two weekend conferences in 2008, support the position that Ares V has benefit to a broad range of planetary and astronomy missions. This early dialogue with Ares V engineers is permitting the greatest opportunity for payload/transportation/mission synergy and with the least financial impact to Ares V development. In addition, independent analyses suggest that Ares V has the opportunity to enable more cost-effective mission design. 1

Creech, Steve↗

Validation of a Mid-Fidelity Approach for Aircraft Stability and Control Characterization

This paper describes an efficient computational approach for aircraft aerodynamic model development intended for use in flight dynamics simulations. A commercial surface-vorticity flow solver called FlightStream is employed to predict performance, stability, and control characteristics for a NASA subscale electric vertical takeoff and landing aircraft in its isolated-airframe configuration. A framework is described to rapidly convert OpenVSP geometry into a form compatible with the FlightStream software. FlightStream predictions for the variation of aerodynamic force and moment coefficients with airflow angles and control surface deflection angles are compared to static wind-tunnel data to illustrate the process and assess the accuracy of FlightStream solutions. The results and approach presented in this paper are encouraging for use in rapid aerodynamic modeling and flight dynamics simulation development early in the aircraft design process.

aerodynamic modeling↗

Trajectory Engineering with Modular Patched Conics for Entry Systems and TPS (TEMPEST)

Brief Presenter Biography (35 word limit): Bohdan Wesely is an Aerospace Engineer in the Entry Systems and Technology Division at Ames. He has worked on a variety of projects for NASA including integrated TPS (thermal protection system) flight hardware deliveries and testing services for commercial partners. Introduction: TEMPEST is a new trajectory analysis framework that is designed to fill the gap between dedicated flight mechanics tools and aerothermal and TPS sizing tools. The project started as an SJSU master’s thesis and has since evolved into a general conceptual design tool capable of studying a wide variety of entry problems. Development is ongoing in the Entry Systems and Technology Division at NASA ARC. Why TEMPEST: Space missions involving entry into a planetary atmosphere involve a series of unique requirements across multiple disciplines. Whether it is traditional entry descent and landing (EDL), or aerocapture, the vehicle must navigate to its target landing location or orbit state, and the TPS must protect the payload during entry. The design process typically involves iterative handoffs between various flight mechanics, flow solver, and material response level tools. During the early conceptual phase, a wide variety of feasible trajectories are simulated in a Monte Carlo scenario which broadly satisfy the mission or landing requirements. Next, computational fluid dynamics (CFD), direct simulation Monte Carlo (DSMC), and other flow solver analyses are performed at various key trajectory points to generate an aero-database, heating and TPS design requirements also emerge at this stage. At this point, with updated aerodynamics from the various flow solvers, trajectories can be re-run, this in turn can change the required freestream conditions for the CFD tools, and as a project progresses, these analyses converge, and uncertainty is reduced. However, there is always a “hand-off” occurring between two inherently coupled phenomena. Analysis Description: One of the goals with TEMPEST is to use a variety of first principles estimation methods coupled with an atmosphere model to predict vehicle aerothermodynamics across the entire flight regime while propagating a 3 or 6 degree of freedom (DoF) trajectory. Aerodynamics methods include modified Newtonian, Maxwell and Cercignani- Lampis-Lord (CLL) for continuum, transitional, and free molecular flow regimes. Aerothermodynamics include boundary layer and reference enthalpy methods, and Mutation++ for non-equilibrium chemistry modeling. TEMPEST is also capable of stitching multiple trajectory segments together to study mission scenarios like multi-pass aerocapture and aero-gravity assists. Most of the program is implemented in MATLAB using modern system objects, it relies on several C++ shared libraries for supporting tools like Gmsh, the Global Reference Atmospheric Model (GRAM), and Mutation++. The various first principles aerothermal estimation methods are discretized across either a structured axisymmetric panel mesh or an unstructured tri-mesh generated from an open-source tool such as Gmsh, this allows solutions on the same mesh to be compared across tools such as CB-Aero. CFD Coupling. A physics-aware, gaussian process CFD anchoring scheme is proposed to adjust the various first principles methods as a CFD database is populated. One goal for this anchoring module is to inform the project where CFD should be run. Full knowledge of the entire trajectory, atmosphere, and aerothermodynamics allows for easier identification of high sensitivity areas and uncertainty quantification. While the first principles effects are well known and proven accurate in existing tools such as CB- Aero and Cart3D, a physics aware CFD anchoring scheme increases tool credibility across a project lifecycle. Material Response Modeling. Correct TPS sizing is critical for optimizing mass for science payloads and ensuring mission success. The process typically involves a thermal analysis along the trajectory with surface heating environments as a boundary condition. Several design constraints are maximum bondline temperature and maximum recession with various margining techniques. The material response tool FIAT, developed out of NASA Ames, is currently being integrated into the TEMPEST environment. TPS recession, shape change, mass loss, and mass property alteration are all factors that can perturb an entry trajectory. For missions like Mars 2020, recession was minimal and was safely handled separately as a post process. For missions such as Jupiter Galileo with a high TPS mass fraction or asteroid entries, recession plays a major role. The proposed fully coupled scheme is to use an epoch-based approach where the trajectory integration is halted after a recession threshold, the energy balance and FIAT are solved at each panel, the mesh, aerodynamics, and mass properties are updated, and the trajectory continues. Several computational tradeoffs have been made during the development of TEMPEST to limit the cost of a single trajectory and preserve its utility as a conceptual, rapid iteration tool. Conclusion: Development of TEMPEST is ongoing and the project is still in its infancy. This talk aims to showcase its unique capabilities to support future NASA entry systems missions.

Bohdan O Wesely↗

TRO-2D - A code for rational transonic aerodynamic optimization

Features and sample applications of the transonic rational optimization (TRO-2D) code are outlined. TRO-2D includes the airfoil analysis code FLO-36, the CONMIN optimization code and a rational approach to defining aero-function shapes for geometry modification. The program is part of an effort to develop an aerodynamically smart optimizer that will simplify and shorten the design process. The user has a selection of drag minimization and associated minimum lift, moment, and the pressure distribution, a choice among 14 resident aero-function shapes, and options on aerodynamic and geometric constraints. Design variables such as the angle of attack, leading edge radius and camber, shock strength and movement, supersonic pressure plateau control, etc., are discussed. The results of calculations of a reduced leading edge camber transonic airfoil and an airfoil with a natural laminar flow are provided, showing that only four design variables need be specified to obtain satisfactory results.

Davis, W. H., Jr.↗

Triton 2 (1B)

The goal of this project was to perform a detailed design analysis on a conceptually designed preliminary flight trainer. The Triton 2 (1B) must meet the current regulations in FAR Part 23. The detailed design process included the tasks of sizing load carrying members, pulleys, bolts, rivets, and fuselage skin for the safety cage, empennage, and control systems. In addition to the regulations in FAR Part 23, the detail design had to meet established minimums for environmental operating conditions and material corrosion resistance.

Clark, Michelle L.↗

Constrained Multipoint Aerodynamic Shape Optimization Using an Adjoint Formulation and Parallel Computers

An aerodynamic shape optimization method that treats the design of complex aircraft configurations subject to high fidelity computational fluid dynamics (CFD), geometric constraints and multiple design points is described. The design process will be greatly accelerated through the use of both control theory and distributed memory computer architectures. Control theory is employed to derive the adjoint differential equations whose solution allows for the evaluation of design gradient information at a fraction of the computational cost required by previous design methods. The resulting problem is implemented on parallel distributed memory architectures using a domain decomposition approach, an optimized communication schedule, and the MPI (Message Passing Interface) standard for portability and efficiency. The final result achieves very rapid aerodynamic design based on a higher order CFD method. In order to facilitate the integration of these high fidelity CFD approaches into future multi-disciplinary optimization (NW) applications, new methods must be developed which are capable of simultaneously addressing complex geometries, multiple objective functions, and geometric design constraints. In our earlier studies, we coupled the adjoint based design formulations with unconstrained optimization algorithms and showed that the approach was effective for the aerodynamic design of airfoils, wings, wing-bodies, and complex aircraft configurations. In many of the results presented in these earlier works, geometric constraints were satisfied either by a projection into feasible space or by posing the design space parameterization such that it automatically satisfied constraints. Furthermore, with the exception of reference 9 where the second author initially explored the use of multipoint design in conjunction with adjoint formulations, our earlier works have focused on single point design efforts. Here we demonstrate that the same methodology may be extended to treat complete configuration designs subject to multiple design points and geometric constraints. Examples are presented for both transonic and supersonic configurations ranging from wing alone designs to complex configuration designs involving wing, fuselage, nacelles and pylons.

Reuther, James↗

NASA's Vision for Jet Noise Engineering

Until recently, the design of jet engines for quiet operation was limited by engineers' ability to predict the jet noise generated by a nozzle exhaust system. More importantly, the 'intermediate steps' between nozzle design and noise had not been understood, limiting the design process to small variations around existing solutions. In recent years NASA's Quiet Aircraft Technology (QAT) Program has advanced the understanding and modeling of jet noise to give engineers the tools they need to design quiet nozzle systems for subsonic exhaust systems. The presentation discusses the approach followed for QAT and argues that a similar effort aimed at supersonic jet exhaust systems will be needed to allow designs of quiet military aircraft in the future.

Kinzie, Kevin W.↗

Constellation's Command, Control, Communications and Information (C3I) Architecture

Operations concepts are highly effective for: 1) Developing consensus; 2) Discovering stakeholder needs, goals, objectives; 3) Defining behavior of system components (especially emergent behaviors). An interoperability standard can provide an excellent lever to define the capabilities needed for system evolution. Two categories of architectures are needed in a program of this size are: 1) Generic - Needed for planning, design and construction standards; 2) Specific - Needed for detailed requirement allocations, interface specs. A wide variety of architectural views are needed to address stakeholder concerns, including: 1) Physical; 2) Information (structure, flow, evolution); 3) Processes (design, manufacturing, operations); 4) Performance; 5) Risk.

constellation↗

Understanding Workforce Agility at NASA Kennedy Space Center

NASA leads the world in space research and provides other government agencies, educational institutions, and companies opportunities to explore, launch, and conduct research in and around space. NASA has 11 formal locations based around the United States, and each has different goals and objectives to help NASA meet its overall mission. 2004, President George Bush announced a new vision for the Space Exploration program. During his grand announcement, he discussed that the Space Shuttles would retire due to the 2003 Space Shuttle Columbia accident, where the crew and the space vehicle were lost. The Kennedy Space Center (KSC) would no longer manage the day-to-day operations of maintaining the US Space Shuttle fleet. Our NASA teams would continue working to finish the Space Shuttle program's mission to build the International Space Station. Afterward, NASA would transition to develop and test a new spacecraft, the Crew Exploration Vehicle. The third goal was to return to the moon by 2020 as the launching point for missions beyond, to get humans from lower Earth orbit to the moon and Mars. (Secretary, 2004) The KSC engineering workforce had to prepare to transition from Operational support of the Space Shuttle program to the design and development of over 50 subsystems for the future SLS and Orion Launch Systems at the Kennedy Space Center. These subsystems developed at the Kennedy Space Center Engineering Directorate followed a comprehensive design process that required several different product deliverables during various phases for each subsystem. (Schafer et al., 2013) What allowed these systems to be successful? What enabled NASA KSC to complete over 130 Artemis 1 Design Certification and System Acceptance Reviews, closing over 21,656 Requirements to deem the Artemis 1 rocket ready for launch? Little is known about the NASA engineering workforce agility characteristics that enabled the organization to transition from the Space Shuttle program that ended in 2011 and launch the Artemis Program's SLS rocket on November 16, 2022.

Workforce Agility↗