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NASA NTRS1998

A Control Law Design Method Facilitating Control Power, Robustness, Agility, and Flying Qualities Tradeoffs: CRAFT

A multi-input, multi-output control law design methodology, named "CRAFT", is presented. CRAFT stands for the design objectives addressed, namely, Control power, Robustness, Agility, and Flying Qualities Tradeoffs. The methodology makes use of control law design metrics from each of the four design objective areas. It combines eigenspace assignment, which allows for direct specification of eigenvalues and eigenvectors, with a graphical approach for representing the metrics that captures numerous design goals in one composite illustration. Sensitivity of the metrics to eigenspace choice is clearly displayed, enabling the designer to assess the cost of design tradeoffs. This approach enhances the designer's ability to make informed design tradeoffs and to reach effective final designs. An example of the CRAFT methodology applied to an advanced experimental fighter and discussion of associated design issues are provided.

Murphy, Patrick C.↗
NASA NTRS1995

DREAMS and IMAGE: A Model and Computer Implementation for Concurrent, Life-Cycle Design of Complex Systems

Computing architectures are being assembled that extend concurrent engineering practices by providing more efficient execution and collaboration on distributed, heterogeneous computing networks. Built on the successes of initial architectures, requirements for a next-generation design computing infrastructure can be developed. These requirements concentrate on those needed by a designer in decision-making processes from product conception to recycling and can be categorized in two areas: design process and design information management. A designer both designs and executes design processes throughout design time to achieve better product and process capabilities while expanding fewer resources. In order to accomplish this, information, or more appropriately design knowledge, needs to be adequately managed during product and process decomposition as well as recomposition. A foundation has been laid that captures these requirements in a design architecture called DREAMS (Developing Robust Engineering Analysis Models and Specifications). In addition, a computing infrastructure, called IMAGE (Intelligent Multidisciplinary Aircraft Generation Environment), is being developed that satisfies design requirements defined in DREAMS and incorporates enabling computational technologies.

Hale, Mark A.↗
NASA NTRS1998

A Web Based Collaborative Design Environment for Spacecraft

In this era of shrinking federal budgets in the USA we need to dramatically improve our efficiency in the spacecraft engineering design process. We have come up with a method which captures much of the experts' expertise in a dataflow design graph: Seamlessly connectable set of local and remote design tools; Seamlessly connectable web based design tools; and Web browser interface to the developing spacecraft design. We have recently completed our first web browser interface and demonstrated its utility in the design of an aeroshell using design tools located at web sites at three NASA facilities. Multiple design engineers and managers are now able to interrogate the design engine simultaneously and find out what the design looks like at any point in the design cycle, what its parameters are, and how it reacts to adverse space environments.

Dunphy, Julia↗
NASA NTRS2000

Developing Conceptual Hypersonic Airbreathing Engines Using Design of Experiments Methods

Designing a hypersonic vehicle is a complicated process due to the multi-disciplinary synergy that is required. The greatest challenge involves propulsion-airframe integration. In the past, a two-dimensional flowpath was generated based on the engine performance required for a proposed mission. A three-dimensional CAD geometry was produced from the two-dimensional flowpath for aerodynamic analysis, structural design, and packaging. The aerodynamics, engine performance, and mass properties arc inputs to the vehicle performance tool to determine if the mission goals were met. If the mission goals were not met, then a flowpath and vehicle redesign would begin. This design process might have to be performed several times to produce a "closed" vehicle. This paper will describe an attempt to design a hypersonic cruise vehicle propulsion flowpath using a Design of' Experiments method to reduce the resources necessary to produce a conceptual design with fewer iterations of the design cycle. These methods also allow for more flexible mission analysis and incorporation of additional design constraints at any point. A design system was developed using an object-based software package that would quickly generate each flowpath in the study given the values of the geometric independent variables. These flowpath geometries were put into a hypersonic propulsion code and the engine performance was generated. The propulsion results were loaded into statistical software to produce regression equations that were combined with an aerodynamic database to optimize the flowpath at the vehicle performance level. For this example, the design process was executed twice. The first pass was a cursory look at the independent variables selected to determine which variables are the most important and to test all of the inputs to the optimization process. The second cycle is a more in-depth study with more cases and higher order equations representing the design space.

Ferlemann, Shelly M.↗
NASA NTRS2000

NASA's Design and Development of a Field Goniometer Instrument Using Solid Works

With NASA suffering severe funding cutbacks, engineers at NASA are required to produce state-of-the-art hardware with limited personnel and financial resources. In light of these constraints, the new NASA mandate is to build better, faster and cheaper. In April of 1998, Stennis Space Center's Commercial Remote Sensing Program contracted to the Systems Engineering Division at NASA Ames Research Center to develop a device known as a Field Goniometer. A Field Goniometer is a device that measures bi-directional reflectance of a target, such as vegetation, relative to the sun and an imaging system in an aircraft or spacecraft. The device is able to provide a spectral fingerprint of the surface it is measuring in wavelengths from 350nm-2500nm using a hyperspectral imager. To accomplish this project, several obstacles had to be overcome. First, the design had to be completed in less than four months. Second, due to the complexity of the design, the use of solid modeling was highly desirable but most of the group's solid modelers were assigned to other jobs. Third, the amount of funding available from the customer was one half to one third the funding typically expended for a job of this nature. Our choices for this project were to design with standard 2-D CAD systems currently used in-house or train additional engineers on our existing solids package or purchase a new solid model package. The use of a 2D CAD system was very undesirable due to the complexity of the design. Using our existing solids modeler would have required a learning curve for our engineers that would be incompatible with our schedule. Prior to this project, a member of our design group researched the solid modeling industry and decided to purchase SolidWorks. After examining the product for ease of use, modeling capability, training time required and cost, we decided our highest probability of success would be to design with Solidworks. During the design phase, our fabrication group was able to provide input at the very early stages, which added significant benefit to the final product. Fabrication cost and schedule savings have been realized by having complex part geometries translated directly from the SolidWorks design models to Surfcam and other computer-aided manufacturing (CAM) software. This direct model translation capability optimized the fabrication processes. The end result was that we were able to successfully complete the project on time and on budget. Other advantages of using SolidWorks, as cited by the design team, include a rapid negotiation of the initial learning curve, the ability to develop solid model hardware prototypes (used to communicate the design intent to both the customer and the fabricator), and the ability to work as a team collaborating on a large, complex model. These types of tools and efforts represent our response to NASA's challenge to produce higher quality products within shorter design and fabrication times.

Turner, Mark↗
NASA NTRS2003

Mechanical Design of a Performance Test Rig for the Turbine Air-Flow Task (TAFT)

To support development of the Boeing-Rocketdyne RS84 rocket engine, a fill-flow, reaction turbine geometry was integrated into the NASA-MSFC turbine air-flow test facility. A mechanical design was generated which minimized the amount of new hardware while incorporating all test and instrUmentation requirements. This paper provides details of the mechanical design for this Turbine Air-Flow Task (TAFT) test rig. The mechanical design process utilized for this task included the following basic stages: Conceptual Design. Preliminary Design. Detailed Design. Baseline of Design (including Configuration Control and Drawing Revision). Fabrication. Assembly. During the design process, many lessons were learned that should benefit future test rig design projects. Of primary importance are well-defined requirements early in the design process, a thorough detailed design package, and effective communication with both the customer and the fabrication contractors. The test rig provided steady and unsteady pressure data necessary to validate the computational fluid dynamics (CFD) code. The rig also helped characterize the turbine blade loading conditions. Test and CFD analysis results are to be presented in another JANNAF paper.

Xenofos, George↗
NASA NTRS2004

Mechanical Design of a Performance Test Rig for the Turbine Air-Flow Task (TAFT)

To support development of the Boeing-Rocketdyne RS84 rocket engine, a full-flow, reaction turbine geometry was integrated into the NASA-MSFC turbine air-flow test facility. A mechanical design was generated which minimized the amount of new hardware while incorporating all test and instrumentation requirements. This paper provides details of the mechanical design for this Turbine Air-Flow Task (TAFT) test rig. The mechanical design process utilized for this task included the following basic stages: Conceptual Design. Preliminary Design. Detailed Design. Baseline of Design (including Configuration Control and Drawing Revision). Fabrication. Assembly. During the design process, many lessons were learned that should benefit future test rig design projects. Of primary importance are well-defined requirements early in the design process, a thorough detailed design package, and effective communication with both the customer and the fabrication contractors.

Forbes, John C.↗
NASA NTRS2005

Enhancing the Design Process for Complex Space Systems through Early Integration of Risk and Variable-Fidelity Modeling

An important enabler of the new national Vision for Space Exploration is the ability to rapidly and efficiently develop optimized concepts for the manifold future space missions that this effort calls for. The design of such complex systems requires a tight integration of all the engineering disciplines involved, in an environment that fosters interaction and collaboration. The research performed under this grant explored areas where the space systems design process can be enhanced: by integrating risk models into the early stages of the design process, and by including rapid-turnaround variable-fidelity tools for key disciplines. Enabling early assessment of mission risk will allow designers to perform trades between risk and design performance during the initial design space exploration. Entry into planetary atmospheres will require an increased emphasis of the critical disciplines of aero- and thermodynamics. This necessitates the pulling forward of EDL disciplinary expertise into the early stage of the design process. Radiation can have a large potential impact on overall mission designs, in particular for the planned nuclear-powered robotic missions under Project Prometheus and for long-duration manned missions to the Moon, Mars and beyond under Project Constellation. This requires that radiation and associated risk and hazards be assessed and mitigated at the earliest stages of the design process. Hence, RPS is another discipline needed to enhance the engineering competencies of conceptual design teams. Researchers collaborated closely with NASA experts in those disciplines, and in overall space systems design, at Langley Research Center and at the Jet Propulsion Laboratory. This report documents the results of this initial effort.

Mavris, Dimitri↗
NASA NTRS2004

Application of Simulated Annealing and Related Algorithms to TWTA Design

Simulated Annealing (SA) is a stochastic optimization algorithm used to search for global minima in complex design surfaces where exhaustive searches are not computationally feasible. The algorithm is derived by simulating the annealing process, whereby a solid is heated to a liquid state and then cooled slowly to reach thermodynamic equilibrium at each temperature. The idea is that atoms in the solid continually bond and re-bond at various quantum energy levels, and with sufficient cooling time they will rearrange at the minimum energy state to form a perfect crystal. The distribution of energy levels is given by the Boltzmann distribution: as temperature drops, the probability of the presence of high-energy bonds decreases. In searching for an optimal design, local minima and discontinuities are often present in a design surface. SA presents a distinct advantage over other optimization algorithms in its ability to escape from these local minima. Just as high-energy atomic configurations are visited in the actual annealing process in order to eventually reach the minimum energy state, in SA highly non-optimal configurations are visited in order to find otherwise inaccessible global minima. The SA algorithm produces a Markov chain of points in the design space at each temperature, with a monotonically decreasing temperature. A random point is started upon, and the objective function is evaluated at that point. A stochastic perturbation is then made to the parameters of the point to arrive at a proposed new point in the design space, at which the objection function is evaluated as well. If the change in objective function values (Delta)E is negative, the proposed new point is accepted. If (Delta)E is positive, the proposed new point is accepted according to the Metropolis criterion: rho((Delta)f) = exp((-Delta)E/T), where T is the temperature for the current Markov chain. The process then repeats for the remainder of the Markov chain, after which the temperature is decremented and the process repeats. Eventually (and hopefully), a near-globally optimal solution is attained as T approaches zero. Several exciting variants of SA have recently emerged, including Discrete-State Simulated Annealing (DSSA) and Simulated Tempering (ST). The DSSA algorithm takes the thermodynamic analogy one step further by categorizing objective function evaluations into discrete states. In doing so, many of the case-specific problems associated with fine-tuning the SA algorithm can be avoided; for example, theoretical approximations for the initial and final temperature can be derived independently of the case. In this manner, DSSA provides a scheme that is more robust with respect to widely differing design surfaces. ST differs from SA in that the temperature T becomes an additional random variable in the optimization. The system is also kept in equilibrium as the temperature changes, as opposed to the system being driven out of equilibrium as temperature changes in SA. ST is designed to overcome obstacles in design surfaces where numerous local minima are separated by high barriers. These algorithms are incorporated into the optimal design of the traveling-wave tube amplifier (TWTA). The area under scrutiny is the collector, in which it would be ideal to use negative potential to decelerate the spent electron beam to zero kinetic energy just as it reaches the collector surface. In reality this is not plausible due to a number of physical limitations, including repulsion and differing levels of kinetic energy among individual electrons. Instead, the collector is designed with multiple stages depressed below ground potential. The design of this multiple-stage collector is the optimization problem of interest. One remaining problem in SA and DSSA is the difficulty in determining when equilibrium has been reached so that the current Markov chain can be terminated. It has been suggested in recent literature that simulating the thermodynamic properties opecific heat, entropy, and internal energy from the Boltzmann distribution can provide good indicators of having reached equilibrium at a certain temperature. These properties are tested for their efficacy and implemented in SA and DSSA code with respect to TWTA collector optimization.

Radke, Eric M.↗
NASA NTRS2005

Design Methods and Practices for Fault Prevention and Management in Spacecraft

Integrated Systems Health Management (ISHM) is intended to become a critical capability for all space, lunar and planetary exploration vehicles and systems at NASA. Monitoring and managing the health state of diverse components, subsystems, and systems is a difficult task that will become more challenging when implemented for long-term, evolving deployments. A key technical challenge will be to ensure that the ISHM technologies are reliable, effective, and low cost, resulting in turn in safe, reliable, and affordable missions. To ensure safety and reliability, ISHM functionality, decisions and knowledge have to be incorporated into the product lifecycle as early as possible, and ISHM must be considered as an essential element of models developed and used in various stages during system design. During early stage design, many decisions and tasks are still open, including sensor and measurement point selection, modeling and model-checking, diagnosis, signature and data fusion schemes, presenting the best opportunity to catch and prevent potential failures and anomalies in a cost-effective way. Using appropriate formal methods during early design, the design teams can systematically explore risks without committing to design decisions too early. However, the nature of ISHM knowledge and data is detailed, relying on high-fidelity, detailed models, whereas the earlier stages of the product lifecycle utilize low-fidelity, high-level models of systems and their functionality. We currently lack the tools and processes necessary for integrating ISHM into the vehicle system/subsystem design. As a result, most existing ISHM-like technologies are retrofits that were done after the system design was completed. It is very expensive, and sometimes futile, to retrofit a system health management capability into existing systems. Last-minute retrofits result in unreliable systems, ineffective solutions, and excessive costs (e.g., Space Shuttle TPS monitoring which was considered only after 110 flights and the Columbia disaster). High false alarm or false negative rates due to substandard implementations hurt the credibility of the ISHM discipline. This paper presents an overview of the current state of ISHM design,and a review of formal design methods to make recommendations about possible approaches to enable the ISHM capabilities to be designed-in at the system-level, from the very beginning of the vehicle design process.

Tumer, Irem Y.↗
NASA NTRS2007

A Return to Innovative Engineering Design, Critical Thinking and Systems Engineering

I believe we are facing a critical time where innovative engineering design is of paramount importance to the success of our aerospace industry. However, the very qualities and attributes necessary for enhancing, educating, and mentoring a creative spirit are in decline in important areas. The importance of creativity and innovation in this country was emphasized by a special edition of the Harvard Business Review OnPoint entitled: "The Creative Company" which compiled a series of past and present articles on the subject of creativity and innovation and stressed its importance to our national economy. There is also a recognition of a lack of engineering, critical thinking and problem-solving skills in our education systems and a trend toward trying to enhance those skills by developing K-12 educational programs such as Project Lead the Way, "Science for All Americans", Benchmarks 2061 , etc. In addition, with respect to spacecraft development, we have a growing need for young to mid-level engineers with appropriate experience and skills in spacecraft design, development, analysis, testing, and systems engineering. As the Director of Engineering at NASA's Johnson Space Center, I realized that sustaining engineering support of an operational human spacecraft such as the Space Shuttle is decidedly different than engineering design and development skills necessary for designing a new spacecraft such as the Crew Exploration Vehicle of the Constellation Program. We learned a very important lesson post Columbia in that the Space Shuttle is truly an experimental and not an operational vehicle and the strict adherence to developed rules and processes and chains of command of an inherently bureaucratic organizational structure will not protect us from a host of known unknowns let alone unknown unknowns. There are no strict rules, processes, or procedures for understanding anomalous results of an experiment, anomalies with an experimental spacecraft like Shuttle, or in the conceptual design of a spacecraft. Engineering design is as much an art as it is a science. The critical thinking skills necessary to uncover lurking problems in an experimental design and creatively develop solutions are some of the same skills necessary to design a new spacecraft. Thus, I believe engineers unfamiliar with or removed from design and development need time to transition and develop the required skill set to be effective spacecraft designers. I believe the creative process necessary in design can be enhanced and even taught as early as grades K-12 and should continue to be nurtured and developed at the university level and beyond. I am going to present a strategy for developing learning teams to address complex multidisciplinary problems and to creatively develop solutions to those problems rapidly at minimal cost. I will frame a real problem, the development of on-orbit thermal protection system repair of the Space Shuttle, and step through the series of skills necessary to enhance the creative process. The case study I will illustrate is based on a real project, the R&D Reinforced Carbon-Carbon (RCC) Repair Team's development of on-orbit repair concepts for damaged Space Shuttle RCC nose cap and/or leading edges.

Camarda, Charles J.↗
NASA NTRS2005

Collaborative Mission Design at NASA Langley Research Center

NASA Langley Research Center (LaRC) has developed and tested two facilities dedicated to increasing efficiency in key mission design processes, including payload design, mission planning, and implementation plan development, among others. The Integrated Design Center (IDC) is a state-of-the-art concurrent design facility which allows scientists and spaceflight engineers to produce project designs and mission plans in a real-time collaborative environment, using industry-standard physics-based development tools and the latest communication technology. The Mission Simulation Lab (MiSL), a virtual reality (VR) facility focused on payload and project design, permits engineers to quickly translate their design and modeling output into enhanced three-dimensional models and then examine them in a realistic full-scale virtual environment. The authors were responsible for envisioning both facilities and turning those visions into fully operational mission design resources at LaRC with multiple advanced capabilities and applications. In addition, the authors have created a synergistic interface between these two facilities. This combined functionality is the Interactive Design and Simulation Center (IDSC), a meta-facility which offers project teams a powerful array of highly advanced tools, permitting them to rapidly produce project designs while maintaining the integrity of the input from every discipline expert on the project. The concept-to-flight mission support provided by IDSC has shown improved inter- and intra-team communication and a reduction in the resources required for proposal development, requirements definition, and design effort.

Gough, Kerry M.↗
NASA NTRS2010

Design and Testing of a Prototype Lunar or Planetary Surface Landing Research Vehicle (LPSLRV)

This handbook describes a two-semester senior design course sponsored by the NASA Office of Education, the Exploration Systems Mission Directorate (ESMD), and the NASA Space Grant Consortium. The course was developed and implemented by the Mechanical and Aerospace Engineering Department (MAE) at Utah State University. The course final outcome is a packaged senior design course that can be readily incorporated into the instructional curriculum at universities across the country. The course materials adhere to the standards of the Accreditation Board for Engineering and Technology (ABET), and is constructed to be relevant to key research areas identified by ESMD. The design project challenged students to apply systems engineering concepts to define research and training requirements for a terrestrial-based lunar landing simulator. This project developed a flying prototype for a Lunar or Planetary Surface Landing Research Vehicle (LPSRV). Per NASA specifications the concept accounts for reduced lunar gravity, and allows the terminal stage of lunar descent to be flown either by remote pilot or autonomously. This free-flying platform was designed to be sufficiently-flexible to allow both sensor evaluation and pilot training. This handbook outlines the course materials, describes the systems engineering processes developed to facilitate design fabrication, integration, and testing. This handbook presents sufficient details of the final design configuration to allow an independent group to reproduce the design. The design evolution and details regarding the verification testing used to characterize the system are presented in a separate project final design report. Details of the experimental apparatus used for system characterization may be found in Appendix F, G, and I of that report. A brief summary of the ground testing and systems verification is also included in Appendix A of this report. Details of the flight tests will be documented in a separate flight test report. This flight test report serves as a complement to the course handbook presented here. This project was extremely ambitious, and achieving all of the design and test objectives was a daunting task. The schedule ran slightly longer than a single academic year with the complete design closure not occurring until early April. Integration and verification testing spilled over into late May and the first flight did not occur until mid to late June. The academic year at Utah State University ended on May 8, 2010. Following the end of the academic year, testing and integration was performed by the faculty advisor, paid research assistants, and volunteer student help

Murphy, Gloria A.↗
NASA NTRS2010

Modified Universal Design Survey: Enhancing Operability of Launch Vehicle Ground Crew Worksites

Operability is a driving requirement for next generation space launch vehicles. Launch site ground operations include numerous operator tasks to prepare the vehicle for launch or to perform preflight maintenance. Ensuring that components requiring operator interaction at the launch site are designed for optimal human use is a high priority for operability. To promote operability, a Design Quality Evaluation Survey based on Universal Design framework was developed to support Human Factors Engineering (HFE) evaluation for NASA s launch vehicles. Universal Design per se is not a priority for launch vehicle processing however; applying principles of Universal Design will increase the probability of an error free and efficient design which promotes operability. The Design Quality Evaluation Survey incorporates and tailors the seven Universal Design Principles and adds new measures for Safety and Efficiency. Adapting an approach proven to measure Universal Design Performance in Product, each principle is associated with multiple performance measures which are rated with the degree to which the statement is true. The Design Quality Evaluation Survey was employed for several launch vehicle ground processing worksite analyses. The tool was found to be most useful for comparative judgments as opposed to an assessment of a single design option. It provided a useful piece of additional data when assessing possible operator interfaces or worksites for operability.

Blume, Jennifer L.↗
NASA NTRS2006

Modern Design of Resonant Edge-Slot Array Antennas

Resonant edge-slot (slotted-waveguide) array antennas can now be designed very accurately following a modern computational approach like that followed for some other microwave components. This modern approach makes it possible to design superior antennas at lower cost than was previously possible. Heretofore, the physical and engineering knowledge of resonant edge-slot array antennas had remained immature since they were introduced during World War II. This is because despite their mechanical simplicity, high reliability, and potential for operation with high efficiency, the electromagnetic behavior of resonant edge-slot antennas is very complex. Because engineering design formulas and curves for such antennas are not available in the open literature, designers have been forced to implement iterative processes of fabricating and testing multiple prototypes to derive design databases, each unique for a specific combination of operating frequency and set of waveguide tube dimensions. The expensive, time-consuming nature of these processes has inhibited the use of resonant edge-slot antennas. The present modern approach reduces costs by making it unnecessary to build and test multiple prototypes. As an additional benefit, this approach affords a capability to design an array of slots having different dimensions to taper the antenna illumination to reduce the amplitudes of unwanted side lobes. The heart of the modern approach is the use of the latest commercially available microwave-design software, which implements finite-element models of electromagnetic fields in and around waveguides, antenna elements, and similar components. Instead of building and testing prototypes, one builds a database and constructs design curves from the results of computational simulations for sets of design parameters. The figure shows a resonant edge-slot antenna designed following this approach. Intended for use as part of a radiometer operating at a frequency of 10.7 GHz, this antenna was fabricated from dimensions defined exclusively by results of computational simulations. The final design was found to be well optimized and to yield performance exceeding that initially required.

Gosselin, R. B.↗
NASA NTRS2015

Design Process of Flight Vehicle Structures for a Common Bulkhead and an MPCV Spacecraft Adapter

Design and manufacturing space flight vehicle structures is a skillset that has grown considerably at NASA during that last several years. Beginning with the Ares program and followed by the Space Launch System (SLS); in‐house designs were produced for both the Upper Stage and the SLS Multipurpose crew vehicle (MPCV) spacecraft adapter. Specifically, critical design review (CDR) level analysis and flight production drawing were produced for the above mentioned hardware. In particular, the experience of this in‐house design work led to increased manufacturing infrastructure for both Marshal Space Flight Center (MSFC) and Michoud Assembly Facility (MAF), improved skillsets in both analysis and design, and hands on experience in building and testing (MSA) full scale hardware. The hardware design and development processes from initiation to CDR and finally flight; resulted in many challenges and experiences that produced valuable lessons. This paper builds on these experiences of NASA in recent years on designing and fabricating flight hardware and examines the design/development processes used, as well as the challenges and lessons learned, i.e. from the initial design, loads estimation and mass constraints to structural optimization/affordability to release of production drawing to hardware manufacturing. While there are many documented design processes which a design engineer can follow, these unique experiences can offer insight into designing hardware in current program environments and present solutions to many of the challenges experienced by the engineering team.

Aggarwal, Pravin↗
NASA NTRS2017

Computational Assessment of a 3-Stage Axial Compressor Which Provides Airflow to the NASA 11- by 11-Foot Transonic Wind Tunnel, Including Design Changes for Increased Performance

A 24 foot diameter 3-stage axial compressor powered by variable-speed induction motors provides the airflow in the closed-return 11- by 11-Foot Transonic Wind Tunnel (11-Foot TWT) Facility at NASA Ames Research Center at Moffett Field, California. The facility is part of the Unitary Plan Wind Tunnel, which was completed in 1955. Since then, upgrades made to the 11-Foot TWT such as flow conditioning devices and instrumentation have increased blockage and pressure loss in the tunnel, somewhat reducing the peak Mach number capability of the test section. Due to erosion effects on the existing aluminum alloy rotor blades, fabrication of new steel rotor blades is planned. This presents an opportunity to increase the Mach number capability of the tunnel by redesigning the compressor for increased pressure ratio. Challenging design constraints exist for any proposed design, demanding the use of the existing driveline, rotor disks, stator vanes, and hub and casing flow paths, so as to minimize cost and installation time. The current effort was undertaken to characterize the performance of the existing compressor design using available design tools and computational fluid dynamics (CFD) codes and subsequently recommend a new compressor design to achieve higher pressure ratio, which directly correlates with increased test section Mach number. The constant cross-sectional area of the compressor leads to highly diffusion factors, which presents a challenge in simulating the existing design. The CFD code APNASA was used to simulate the aerodynamic performance of the existing compressor. The simulations were compared to performance predictions from the HT0300 turbomachinery design and analysis code, and to compressor performance data taken during a 1997 facility test. It was found that the CFD simulations were sensitive to endwall leakages associated with stator buttons, and to a lesser degree, under-stator-platform flow recirculation at the hub. When stator button leakages were modeled, pumping capability increased by over 20 of pressure rise at design point due to a large reduction in aerodynamic blockage at the hub. Incorporating the stator button leakages was crucial to matching test data. Under-stator-platform flow recirculation was thought to be large due to a lack of seals. The effect of this recirculation was assessed with APNASA simulations recirculating 0.5, 1, and 2 of inlet flow about stators 1 and 2, modeled as axisymmetric mass flux boundary conditions on the hub before and after the vanes. The injection of flow ahead of the stators tended to re-energize the boundary layer and reduce hub separations, resulting in about 3 increased stall margin per 1 of inlet flow recirculated. In order to assess the value of the flow recirculation, a mixing plane simulation of the compressor which gridded the under-stator cavities was generated using the ADPAC CFD code. This simulation indicated that about 0.65 of the inlet flow is recirculated around each shrouded stator. This collective information was applied during the redesign of the compressor. A potential design was identified using HT0300 which improved overall pressure ratio by removing pre-swirl into rotor 1, replacing existing NASA 65 series rotors with double circular arc sections, and re-staggering rotors and the existing stators. The performance of the new design predicted by APNASA and HT0300 is compared to the existing design.

Turbomachinery↗
NASA NTRS2018

Incorporating Test Data for Small UAS at the Conceptual Design Level

Increasing demand for improved capabilities of small unmanned aircraft systems (sUAS) has generated interest in improving the design techniques for these vehicles. sUAS have typically been designed using iterative methods with multiple prototypes, but advancements in aircraft design software will make it possible to generate conceptual designs of very small VTOL aircraft with reduced hardware prototyping. This paper describes a research effort to generate a conceptual design of an approximately 6-lb quadcopter using the NASA rotorcraft design software NDARC. Wind tunnel and hover test data are used to validate and refine the conceptual design results. The effects of parametric design variations on vehicle scale are shown. The design study described herein shows that the NDARC software, which was designed for full-scale rotorcraft, can be used to design and evaluate sUAS vehicles.

Russell, Carl R.↗