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Applying optimization software libraries to engineering problems

Nonlinear programming, preliminary design problems, performance simulation problems trajectory optimization, flight computer optimization, and linear least squares problems are among the topics covered. The nonlinear programming applications encountered in a large aerospace company are a real challenge to those who provide mathematical software libraries and consultation services. Typical applications include preliminary design studies, data fitting and filtering, jet engine simulations, control system analysis, and trajectory optimization and optimal control. Problem sizes range from single-variable unconstrained minimization to constrained problems with highly nonlinear functions and hundreds of variables. Most of the applications can be posed as nonlinearly constrained minimization problems. Highly complex optimization problems with many variables were formulated in the early days of computing. At the time, many problems had to be reformulated or bypassed entirely, and solution methods often relied on problem-specific strategies. Problems with more than ten variables usually went unsolved.

Healy, M. J.↗

Aerodynamics model for a generic ASTOVL lift-fan aircraft

This report describes the aerodynamics model used in a simulation model of an advanced short takeoff and vertical landing (ASTOVL) lift-fan fighter aircraft. The simulation model was developed for use in piloted evaluations of transition and hover flight regimes, so that only low speed (M approximately 0.2) aerodynamics are included in the mathematical model. The aerodynamic model includes the power-off aerodynamic forces and moments and the propulsion system induced aerodynamic effects, including ground effects. The power-off aerodynamics data were generated using the U.S. Air Force Stability and Control Digital DATCOM program and a NASA Ames in-house graphics program called VORVIEW which allows the user to easily analyze arbitrary conceptual aircraft configurations using the VORLAX program. The jet-induced data were generated using the prediction methods of R. E. Kuhn et al., as referenced in this report.

Birckelbaw, Lourdes G.↗

Dynamic analysis of astronaut motions in microgravity: Applications for Extravehicular Activity (EVA)

Simulations of astronaut motions during extravehicular activity (EVA) tasks were performed using computational multibody dynamics methods. The application of computational dynamic simulation to EVA was prompted by the realization that physical microgravity simulators have inherent limitations: viscosity in neutral buoyancy tanks; friction in air bearing floors; short duration for parabolic aircraft; and inertia and friction in suspension mechanisms. These limitations can mask critical dynamic effects that later cause problems during actual EVA's performed in space. Methods of formulating dynamic equations of motion for multibody systems are discussed with emphasis on Kane's method, which forms the basis of the simulations presented herein. Formulation of the equations of motion for a two degree of freedom arm is presented as an explicit example. The four basic steps in creating the computational simulations were: system description, in which the geometry, mass properties, and interconnection of system bodies are input to the computer; equation formulation based on the system description; inverse kinematics, in which the angles, velocities, and accelerations of joints are calculated for prescribed motion of the endpoint (hand) of the arm; and inverse dynamics, in which joint torques are calculated for a prescribed motion. A graphical animation and data plotting program, EVADS (EVA Dynamics Simulation), was developed and used to analyze the results of the simulations that were performed on a Silicon Graphics Indigo2 computer. EVA tasks involving manipulation of the Spartan 204 free flying astronomy payload, as performed during Space Shuttle mission STS-63 (February 1995), served as the subject for two dynamic simulations. An EVA crewmember was modeled as a seven segment system with an eighth segment representing the massive payload attached to the hand. For both simulations, the initial configuration of the lower body (trunk, upper leg, and lower leg) was a neutral microgravity posture. In the first simulation, the payload was manipulated around a circular trajectory of 0.15 m radius in 10 seconds. It was found that the wrist joint theoretically exceeded its ulnal deviation limit by as much as 49. 8 deg and was required to exert torques as high as 26 N-m to accomplish the task, well in excess of the wrist physiological limit of 12 N-m. The largest torque in the first simulation, 52 N-m, occurred in the ankle joint. To avoid these problems, the second simulation placed the arm in a more comfortable initial position and the radius and speed of the circular trajectory were reduced by half. As a result, the joint angles and torques were reduced to values well within their physiological limits. In particular, the maximum wrist torque for the second simulation was only 3 N-m and the maximum ankle torque was only 6 N-m.

Newman, Dava J.↗

Modeling Molecules

The molecule modeling method known as Multibody Order (N) Dynamics, or MBO(N)D, was developed by Moldyn, Inc. at Goddard Space Flight Center through funding provided by the SBIR program. The software can model the dynamics of molecules through technology which stimulates low-frequency molecular motions and properties, such as movements among a molecule's constituent parts. With MBO(N)D, a molecule is substructured into a set of interconnected rigid and flexible bodies. These bodies replace the computation burden of mapping individual atoms. Moldyn's technology cuts computation time while increasing accuracy. The MBO(N)D technology is available as Insight II 97.0 from Molecular Simulations, Inc. Currently the technology is used to account for forces on spacecraft parts and to perform molecular analyses for pharmaceutical purposes. It permits the solution of molecular dynamics problems on a moderate workstation, as opposed to on a supercomputer.

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Ares I-X Flight Test Validation of Control Design Tools in the Frequency-Domain

A major motivation of the Ares I-X flight test program was to Design for Data, in order to maximize the usefulness of the data recorded in support of Ares I modeling and validation of design and analysis tools. The Design for Data effort was intended to enable good post-flight characterizations of the flight control system, the vehicle structural dynamics, and also the aerodynamic characteristics of the vehicle. To extract the necessary data from the system during flight, a set of small predetermined Programmed Test Inputs (PTIs) was injected directly into the TVC signal. These PTIs were designed to excite the necessary vehicle dynamics while exhibiting a minimal impact on loads. The method is similar to common approaches in aircraft flight test programs, but with unique launch vehicle challenges due to rapidly changing states, short duration of flight, a tight flight envelope, and an inability to repeat any test. This paper documents the validation effort of the stability analysis tools to the flight data which was performed by comparing the post-flight calculated frequency response of the vehicle to the frequency response calculated by the stability analysis tools used to design and analyze the preflight models during the control design effort. The comparison between flight day frequency response and stability tool analysis for flight of the simulated vehicle shows good agreement and provides a high level of confidence in the stability analysis tools for use in any future program. This is true for both a nominal model as well as for dispersed analysis, which shows that the flight day frequency response is enveloped by the vehicle s preflight uncertainty models.

Johnson, Matthew↗

Electrochemical Impedance Spectroscopy of Alloys in a Simulated Space Shuttle Launch Environment

Corrosion studies began at NASA/Kennedy Space Center in 1966 during the Gemini/Apollo Programs with the evaluation of long-term protective coatings for the atmospheric protection of carbon steel. An outdoor exposure facility on the beach near the launch pad was established for this purpose at that time. The site has provided over 35 years of technical information on the evaluation of the long-term corrosion performance of many materials and coatings as well as on maintenance procedures. Results from these evaluations have helped NASA find new materials and processes that increase the safety and reliability of our flight hardware, launch structures, and ground support equipment. The launch environment at the Kennedy Space Center (KSC) is extremely corrosive due to the combination of ocean salt spray, heat, humidity, and sunlight. With the introduction of the Space Shuttle in 1981, the already highly corrosive conditions at the launch pad were rendered even more severe by the acidic exhaust from the solid rocket boosters. Over the years, many materials have been evaluated for their corrosion performance under conditions similar to those found at the launch pads. These studies have typically included atmospheric exposure and evaluation with conventional electrochemical methods such as open circuit potential (OCP) measurements, polarization techniques, and electrochemical impedance spectroscopy (EIS). The atmosphere at the Space Shuttle launch site is aggressive to most metals and causes severe pitting in many of the common stainless steel alloys such as type 304L stainless steel (304L SS). A study was undertaken to find a more corrosion resistant material to replace the existing 304L SS tubing. This paper presents the results from atmospheric exposure as well as electrochemical measurements on the corrosion resistance of AL-6XN (UNS N08367) and 254-SMO (UNS S32154). Type 304L SS (UNS S30403) was used as a control. Conditions at the Space Shuttle launch pad were simulated by using a hydrochloric acid (HC1) and alumina (Al203) slurry rinse for the atmospheric exposure and an electrolyte consisting of 3.55% sodium chloride (NaC1) with increased concentrations of hydrochloric acid (HC1) for the electrochemical measurements. The results from both types of measurements revealed the superior corrosion performance of the higher-alloyed materials. Unlike 304L SS, 254-SMO and AL-6XN exhibited a significantly improved resistance to corrosion as the concentration of hydrochloric acid in he 3.55% NaCl electrolyte solution was increased.

Calle, L. M.↗

Simulation of mixing in the quick quench region of a rich burn-quick quench mix-lean burn combustor

A computer program was developed to study the mixing process in the quick quench region of a rich burn-quick quench mix-lean burn combustor. The computer program developed was based on the density-weighted, ensemble-averaged conservation equations of mass, momentum (full compressible Navier-Stokes), total energy, and species, closed by a k-epsilon turbulence model with wall functions. The combustion process was modeled by a two-step global reaction mechanism, and NO(x) formation was modeled by the Zeldovich mechanism. The formulation employed in the computer program and the essence of the numerical method of solution are described. Some results obtained for nonreacting and reacting flows with different main-flow to dilution-jet momentum flux ratios are also presented.

Shih, Tom I.-P.↗

Jet Noise Modeling for Suppressed and Unsuppressed Aircraft in Simulated Flight

This document describes the development of further extensions and improvements to the jet noise model developed by Modern Technologies Corporation (MTC) for the National Aeronautics and Space Administration (NASA). The noise component extraction and correlation approach, first used successfully by MTC in developing a noise prediction model for two-dimensional mixer ejector (2DME) nozzles under the High Speed Research (HSR) Program, has been applied to dual-stream nozzles, then extended and improved in earlier tasks under this contract. Under Task 6, the coannular jet noise model was formulated and calibrated with limited scale model data, mainly at high bypass ratio, including a limited-range prediction of the effects of mixing-enhancement nozzle-exit chevrons on jet noise. Under Task 9 this model was extended to a wider range of conditions, particularly those appropriate for a Supersonic Business Jet, with an improvement in simulated flight effects modeling and generalization of the suppressor model. In the present task further comparisons are made over a still wider range of conditions from more test facilities. The model is also further generalized to cover single-stream nozzles of otherwise similar configuration. So the evolution of this prediction/analysis/correlation approach has been in a sense backward, from the complex to the simple; but from this approach a very robust capability is emerging. Also from these studies, some observations emerge relative to theoretical considerations. The purpose of this task is to develop an analytical, semi-empirical jet noise prediction method applicable to takeoff, sideline and approach noise of subsonic and supersonic cruise aircraft over a wide size range. The product of this task is an even more consistent and robust model for the Footprint/Radius (FOOTPR) code than even the Task 9 model. The model is validated for a wider range of cases and statistically quantified for the various reference facilities. The possible role of facility effects will thus be documented. Although the comparisons that can be accomplished within the limited resources of this task are not comprehensive, they provide a broad enough sampling to enable NASA to make an informed decision on how much further effort should be expended on such comparisons. The improved finalized model is incorporated into the FOOTPR code. MTC has also supported the adaptation of this code for incorporation in NASA s Aircraft Noise Prediction Program (ANOPP).

Stone, James R.↗

Development of Constraint Force Equation Methodology for Application to Multi-Body Dynamics Including Launch Vehicle Stage Seperation

The objective of this report is to develop and implement a physics based method for analysis and simulation of multi-body dynamics including launch vehicle stage separation. The constraint force equation (CFE) methodology discussed in this report provides such a framework for modeling constraint forces and moments acting at joints when the vehicles are still connected. Several stand-alone test cases involving various types of joints were developed to validate the CFE methodology. The results were compared with ADAMS(Registered Trademark) and Autolev, two different industry standard benchmark codes for multi-body dynamic analysis and simulations. However, these two codes are not designed for aerospace flight trajectory simulations. After this validation exercise, the CFE algorithm was implemented in Program to Optimize Simulated Trajectories II (POST2) to provide a capability to simulate end-to-end trajectories of launch vehicles including stage separation. The POST2/CFE methodology was applied to the STS-1 Space Shuttle solid rocket booster (SRB) separation and Hyper-X Research Vehicle (HXRV) separation from the Pegasus booster as a further test and validation for its application to launch vehicle stage separation problems. Finally, to demonstrate end-to-end simulation capability, POST2/CFE was applied to the ascent, orbit insertion, and booster return of a reusable two-stage-to-orbit (TSTO) vehicle concept. With these validation exercises, POST2/CFE software can be used for performing conceptual level end-to-end simulations, including launch vehicle stage separation, for problems similar to those discussed in this report.

Pamadi, Bandu N.↗

Free-Space Optical Communication for Spacecraft and Satellites including CubeSats in Low Earth Orbit (LEO)

A new method for optical data transmissions from satellites using laser arrays for laser beam pointing. Combines a lens system and a vertical cavity surface-emitting laser (VCSEL)/Photodetector Array, both mature technologies, in a novel way. With further development, possible applications include communications from the Earth to spacecraft in Earth orbit and in deep space, such as at the moon and Mars. A possible application is to the Artemis Program for CubeSats in low-Lunar Orbit (LLO), which use body pointing, by providing a fine pointing capability. This system has been applied to satellites in low-Earth orbit, (LEO), in a study using computer simulations of the laser beam propagation.

Goorjian, Peter M.↗

Combined Bernstein Polynomial, Optimal Reciprocal Collision Avoidance, Differential Dynamic Programming for Trajectory Replanning and Collision Avoidance for UAM Vehicles

This paper presents an integration of Differential Dynamic Programming (DDP) with the Optimal Reciprocal Collision Avoidance (ORCA) algorithm as the basis for a new algorithm, titled Combined Bernstein Polynomial Optimal Reciprocal Collision Avoidance DDP (COBRA-DDP), for trajectory replanning and collision avoidance for Urban Air Mobility (UAM) vehicles. State-constrained variants of DDP provide the ability to plan trajectories while avoiding obstacles, but these methods require a large increase in computational time per iteration which hinders the overall speed of the algorithm. ORCA utilizes simplified dynamics to recognize potential collisions along a trajectory and provides an optimal velocity for the avoidance of multiple vehicles. These velocity commands, however, may not result in a dynamically feasible trajectory for DDP to plan around. As such, a Bernstein polynomial curve that considers the general dynamic constraints of the vehicle is generated to approximate a trajectory based on the velocity commands. COBRA-DDP optimizes this suggested trajectory via unconstrained DDP to provide a dynamically feasible trajectory that provides collision avoidance. This new trajectory can be applied to the vehicle or used to warm start the state constrained DDP algorithms to decrease computation time. Its benefits and effectiveness of the algorithm are demonstrated on a UAM Vertical Takeoff and Landing (VTOL) vehicle simulation with highly nonlinear dynamics.

Optimal Reciprocal Collision Avoidance↗

Results of the 1995 JPL balloon flight solar cell calibration program

The Jet Propulsion Laboratory (JPL) solar cell calibration program was conceived to produce reference standards for the purpose of accurately setting solar simulator intensities. The concept was to fly solar cells on a high-altitude balloon, to measure their output at altitudes near 120,000 ft (36.6 km), to recover the cells, and to use them as reference standards. The procedure is simple. The reference cell is placed in the simulator beam, and the beam intensity is adjusted until the reference cell reads the same as it read on the balloon. As long as the reference cell has the same spectral response as the cells or panels to be measured, this is a very accurate method of setting the intensity. But as solar cell technology changes, the spectral response of the solar cells changes also, and reference standards using the new technology must be built and calibrated. Until the summer of 1985, there had always been a question as to how much the atmosphere above the balloon modified the solar spectrum. If the modification was significant, the reference cells might not have the required accuracy. Solar cells made in recent years have increasingly higher blue responses, and if the atmosphere has any effect at all, it would be expected to modify the calibration of these newer blue cells much more so than for cells made in the past. JPL has been flying calibration standards on high-altitude balloons since 1963 and continues to organize a calibration balloon flight at least once a year. The 1995 flight was the 48th flight in this series. The 1995 flight incorporated 46 solar cell modules from 7 different participants. The payload included Si, amorphous Si, GaAs, GaAs/Ge, dual junction cells, top and bottom sections of dual junction cells, and a triple junction cell. A new data acquisition system was built for the balloon flights and flown for the first time on the 1995 flight. This system allows the measurement of current-voltage (I-V) curves for 20 modules in addition to measurement of modules with fixed loads as had been done in the past.

Anspaugh, B. E.↗

Three-Dimensional Reconstruction of Asteroids from Radar Observations

A program of research has recently been initiated under the NASA Innovative Research Program to develop and test techniques for reconstructing the three-dimensional shapes of asteroids from ground-based radar observations. Presently, no methods exist to do this and the full scientific potential of current radar data sets lies untapped. The situation will become even more pronounced in approximately two years when the upgraded Arecibo radar system becomes capable of regularly producing asteroid data sets with very fine spatial resolution and high signal-to-noise ratios. If successful, the proposed research will significantly increase our knowledge of these objects. The potential and limitations of the techniques developed will be rigorously tested in a series of computer simulations and optical scattering experiments with scale models.

Hudson, Scott↗

Applications of Intelligent Tutoring Systems to Human-Robotic Exploration of Mars

Space missions with small crews extending over several years with time-delay preventing normal conversations with people on earth will raise many challenges for training. Of special interest are possible three-year missions to Mars, requiring refresher instruction and learning new skills based on unexpected problems with machines and environmental conditions. For example, the crew will be required to monitor and repair more complex life support systems for air and water recycling than we even know how to build today. Highly educated astronauts, often with several doctorate degrees, require a very different mode of interaction than we have developed for school children or even typical college students. Explanation methods may need to differ-using analogies and techniques from different domains-depending on whether the astronaut is an astrophysicist, a pilot, or a geologist.Virtual reality (e.g., for Hubble repair missions) and "integrated" simulations (involving role-playing and emphasizing failure scenarios) are the most common advanced forms of instruction used in space flight today. The emphasis is on collaborative, embodied interaction with the same workstations and tools used in practice (e.g., a cockpit simulator). Otherwise, computerized instructional technology used by NASA is not model-based or tutorial in nature. This discussion will review some of the key instructional methods used at NASA over the past two decades and consider why ITS methods have not been exploited. Some of the problems and opportunities for training for Mars missions are examined, including how using robots in exploration activities will help but raise new training problems. These ideas will be illustrated with examples from the BrahmsVE system in which a browser- based virtual reality display with avatars allows interacting with a distributed multiagent system, in which agents can be people, robots, or software programs. Using BrahmsVE may provide a way for astronauts to interact with proxies of people who serve as instructional coaches on Mars.

Clancey, William J.↗

Reducing the Time and Cost of Testing Engines

Producing a new aircraft engine currently costs approximately $1 billion, with 3 years of development time for a commercial engine and 10 years for a military engine. The high development time and cost make it extremely difficult to transition advanced technologies for cleaner, quieter, and more efficient new engines. To reduce this time and cost, NASA created a vision for the future where designers would use high-fidelity computer simulations early in the design process in order to resolve critical design issues before building the expensive engine hardware. To accomplish this vision, NASA's Glenn Research Center initiated a collaborative effort with the aerospace industry and academia to develop its Numerical Propulsion System Simulation (NPSS), an advanced engineering environment for the analysis and design of aerospace propulsion systems and components. Partners estimate that using NPSS has the potential to dramatically reduce the time, effort, and expense necessary to design and test jet engines by generating sophisticated computer simulations of an aerospace object or system. These simulations will permit an engineer to test various design options without having to conduct costly and time-consuming real-life tests. By accelerating and streamlining the engine system design analysis and test phases, NPSS facilitates bringing the final product to market faster. NASA's NPSS Version (V)1.X effort was a task within the Agency s Computational Aerospace Sciences project of the High Performance Computing and Communication program, which had a mission to accelerate the availability of high-performance computing hardware and software to the U.S. aerospace community for its use in design processes. The technology brings value back to NASA by improving methods of analyzing and testing space transportation components.

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Alternatives for jet engine control

Alternatives to linear quadratic regulator theory in the linear case are examined along with nonlinear modelling and optimization approaches for global control. Context for the studies has been set by the DYNGEN digital simulator and by models generated for various phases of the F100 Multivariable Control Synthesis Program. With respect to the linear alternatives, the multivariable frequency domain is stressed. Progress is reported in both the direct algebraic approach to exact model matching, by means of stimulating work on the basic computational issues, and in the indirect generalized Nyquist approach. With respect to nonlinear modelling and optimization, the emphasis is twofold: the development of analytical nonlinear models of the jet engine and the use of these models in conjunction with techniques of mathematical programming in order to study global control over nonincremental portions of the flight envelope. The possibility of using tensor methods is explored.

Sain, M. K.↗

Overview of the NASA Subsonic Rotary Wing Aeronautics Research Program in Rotorcraft Crashworthiness

This paper provides an overview of rotorcraft crashworthiness research being conducted at NASA Langley Research Center under sponsorship of the Subsonic Rotary Wing (SRW) Aeronautics Program. The research is focused in two areas: development of an externally deployable energy attenuating concept and improved prediction of rotorcraft crashworthiness. The deployable energy absorber (DEA) is a composite honeycomb structure, with a unique flexible hinge design that allows the honeycomb to be packaged and remain flat until needed for deployment. The capabilities of the DEA have been demonstrated through component crush tests and vertical drop tests of a retrofitted fuselage section onto different surfaces or terrain. The research on improved prediction of rotorcraft crashworthiness is focused in several areas including simulating occupant responses and injury risk assessment, predicting multi-terrain impact, and utilizing probabilistic analysis methods. A final task is to perform a system-integrated simulation of a full-scale helicopter crash test onto a rigid surface. A brief description of each research task is provided along with a summary of recent accomplishments.

Jackson, Karen E.↗

Overview of the NASA Subsonic Rotary Wing Aeronautics Research Program in Rotorcraft Crashworthiness

This paper provides an overview of rotorcraft crashworthiness research being conducted at NASA Langley Research Center under sponsorship of the Subsonic Rotary Wing (SRW) Aeronautics Program. The research is focused in two areas: development of an externally deployable energy attenuating concept and improved prediction of rotorcraft crashworthiness. The deployable energy absorber (DEA) is a composite honeycomb structure, with a unique flexible hinge design that allows the honeycomb to be packaged and remain flat until needed for deployment. The capabilities of the DEA have been demonstrated through component crush tests and vertical drop tests of a retrofitted fuselage section onto different surfaces or terrain. The research on improved prediction of rotorcraft crashworthiness is focused in several areas including simulating occupant responses and injury risk assessment, predicting multi-terrain impact, and utilizing probabilistic analysis methods. A final task is to perform a system-integrated simulation of a full-scale helicopter crash test onto a rigid surface. A brief description of each research task is provided along with a summary of recent accomplishments.

Jackson, Karen E.↗