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NASA NTRS1990

Design of an unmanned, reusable vehicle to de-orbit debris in Earth orbit

The space debris problem is becoming more important because as orbital missions increase, the amount of debris increases. It was the design team's objective to present alternative designs and a problem solution for a deorbiting vehicle that will alleviate the problem by reducing the amount of large debris in earth orbit. The design team was asked to design a reusable, unmanned vehicle to de-orbit debris in earth orbit. The design team will also construct a model to demonstrate the system configuration and key operating features. The alternative designs for the unmanned, reusable vehicle were developed in three stages: selection of project requirements and success criteria, formulation of a specification list, and the creation of alternatives that would satisfy the standards set forth by the design team and their sponsor. The design team selected a Chain and Bar Shot method for deorbiting debris in earth orbit. The De-orbiting Vehicle (DOV) uses the NASA Orbital Maneuvering Vehicle (OMV) as the propulsion and command modules with the deorbiting module attached to the front.

Aziz, Shahed↗

NASA NTRS1992

Optimal design of geodesically stiffened composite cylindrical shells

An optimization system based on the finite element code Computations Structural Mechanics (CSM) Testbed and the optimization program, Automated Design Synthesis (ADS), is described. The optimization system can be used to obtain minimum-weight designs of composite stiffened structures. Ply thickness, ply orientations, and stiffener heights can be used as design variables. Buckling, displacement, and material failure constraints can be imposed on the design. The system is used to conduct a design study of geodesically stiffened shells. For comparison purposes, optimal designs of unstiffened shells and shells stiffened by rings and stingers are also obtained. Trends in the design of geodesically stiffened shells are identified. An approach to include local stress concentrations during the design optimization process is then presented. The method is based on a global/local analysis technique. It employs spline interpolation functions to determine displacements and rotations from a global model which are used as 'boundary conditions' for the local model. The organization of the strategy in the context of an optimization process is described. The method is validated with an example.

Gendron, G.↗

NASA NTRS1990

Design, Evaluation and Experimental Effort Toward Development of a High Strain Composite Wing for Navy Aircraft

This design development effort addressed significant technical issues concerning the use and benefits of high strain composite wing structures (Epsilon(sub ult) = 6000 micro-in/in) for future Navy aircraft. These issues were concerned primarily with the structural integrity and durability of the innovative design concepts and manufacturing techniques which permitted a 50 percent increase in design ultimate strain level (while maintaining the same fiber/resin system) as well as damage tolerance and survivability requirements. An extensive test effort consisting of a progressive series of coupon and major element tests was an integral part of this development effort, and culminated in the design, fabrication and test of a major full-scale wing box component. The successful completion of the tests demonstrated the structural integrity, durability and benefits of the design. Low energy impact testing followed by fatigue cycling verified the damage tolerance concepts incorporated within the structure. Finally, live fire ballistic testing confirmed the survivability of the design. The potential benefits of combining newer/emerging composite materials and new or previously developed high strain wing design to maximize structural efficiency and reduce fabrication costs was the subject of subsequent preliminary design and experimental evaluation effort.

Bruno, Joseph↗

NASA NTRS1992

CAN-DO, CFD-based Aerodynamic Nozzle Design and Optimization program for supersonic/hypersonic wind tunnels

A design program is developed which incorporates a modern approach to the design of supersonic/hypersonic wind-tunnel nozzles. The approach is obtained by the coupling of computational fluid dynamics (CFD) with design optimization. The program can be used to design a 2D or axisymmetric, supersonic or hypersonic, wind-tunnel nozzles that can be modeled with a calorically perfect gas. The nozzle design is obtained by solving a nonlinear least-squares optimization problem (LSOP). The LSOP is solved using an iterative procedure which requires intermediate flowfield solutions. The nozzle flowfield is simulated by solving the Navier-Stokes equations for the subsonic and transonic flow regions and the parabolized Navier-Stokes equations for the supersonic flow regions. The advantages of this method are that the design is based on the solution of the viscous equations eliminating the need to make separate corrections to a design contour, and the flexibility of applying the procedure to different types of nozzle design problems.

Korte, John J.↗

NASA NTRS1992

Maximum life spiral bevel reduction design

Optimization is applied to the design of a spiral bevel gear reduction for maximum life at a given size. A modified feasible directions search algorithm permits a wide variety of inequality constraints and exact design requirements to be met with low sensitivity to initial values. Gear tooth bending strength and minimum contact ratio under load are included in the active constraints. The optimal design of the spiral bevel gear reduction includes the selection of bearing and shaft proportions in addition to gear mesh parameters. System life is maximized subject to a fixed back-cone distance of the spiral bevel gear set for a specified speed ratio, shaft angle, input torque, and power. Significant parameters in the design are: the spiral angle, the pressure angle, the numbers of teeth on the pinion and gear, and the location and size of the four support bearings. Interpolated polynomials expand the discrete bearing properties and proportions into continuous variables for gradient optimization. After finding the continuous optimum, a designer can analyze near optimal designs for comparison and selection. Design examples show the influence of the bearing lives on the gear parameters in the optimal configurations. For a fixed back-cone distance, optimal designs with larger shaft angles have larger service lives.

Savage, M.↗

NASA NTRS1993

An optimization-based integrated controls-structures design methodology for flexible space structures

An approach for an optimization-based integrated controls-structures design is presented for a class of flexible spacecraft that require fine attitude pointing and vibration suppression. The integrated design problem is posed in the form of simultaneous optimization of both structural and control design variables. The approach is demonstrated by application to the integrated design of a generic space platform and to a model of a ground-based flexible structure. The numerical results obtained indicate that the integrated design approach can yield spacecraft designs that have substantially superior performance over a conventional design wherein the structural and control designs are performed sequentially. For example, a 40-percent reduction in the pointing error is observed along with a slight reduction in mass, or an almost twofold increase in the controlled performance is indicated with more than a 5-percent reduction in the overall mass of the spacecraft (a reduction of hundreds of kilograms).

Maghami, Peiman G.↗

NASA NTRS1992

Design of a resistive exercise device for use on the Space Shuttle

The National Aeronautics and Space Administration in conjunction with the Universities Space Research Association sponsored the design of a Resistive Exercise Device (RED) for use on the Space Shuttle. The device must enable the astronauts to perform a number of exercises to prevent skeletal muscle atrophy and neuromuscular deconditioning in microgravity environments. The RED must fit the requirements for limited volume and weight and must provide a means of restraint during exercise. The design team divided the functions of the device into three major groups: methods of supplying force, methods of adjusting force, and methods of transmitting the force to the user. After analyzing the three main functions of the RED and developing alternatives for each, the design team used a comparative decision process to choose the most feasible components for the overall design. The design team selected the constant force spring alternative for further embodiment. The device consists of an array of different sized constant force springs which can be pinned in different combinations to produce the required output forces. The force is transmitted by means of a shaft and gear system. The final report is divided into four sections. An introduction section discusses the sponsor background, problem background and requirements of the device. The second section covers the alternative designs for each of the main functions. The design solution and pertinent calculations comprises the third section. The final section contains design conclusions and recommendations including topics of future work.

Carlson, Dennis L.↗

NASA NTRS1992

Space Station Furnace Facility. Volume 2: Requirements definition and conceptual design study

The Space Station Freedom Furnace (SSFF) Project is divided into two phases: phase 1, a definition study phase, and phase 2, a design and development phase. TBE was awarded a research study entitled, 'Space Station Furnace Facility Requirements Definition and Conceptual Design Study' on June 2, 1989. This report addresses the definition study phase only. Phase 2 is to be complete after completion of phase 1. The contract encompassed a requirements definition study and culminated in hardware/facility conceptual designs and hardware demonstration development models to test these conceptual designs. The study was divided into two parts. Part 1 (the basic part of the effort) encompassed preliminary requirements definition and assessment; conceptional design of the SSFF Core; fabrication of mockups; and preparation for the support of a conceptional design review (CoDR). Part 2 (the optional part of the effort) included detailed definition of the engineering and design requirements, as derived from the science requirements; refinement of the conceptual design of the SSFF Core; fabrication and testing of the 'breadboards' or development models; and preparation for and support of a requirements definition review.

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NASA NTRS1993

Three-dimensional flow in radial turbomachinery and its impact on design

In the two papers on the 'Theory of Blade Design for Large Deflections' published in 1984, a new inverse design technique was presented for designing the shape of turbomachinery blades in three-dimensional flow. The technique involves the determination of the blade profile from the specification of a distribution of the product of the radius and the pitched averaged tangential velocity (i.e., r bar-V(sub theta), the mean swirl schedule) within the bladed region. This is in contrast to the conventional inverse design technique for turbomachinery blading in two dimensional flow in which the blade surface pressure or velocity distribution is specified and the blade profile determined as a result; this is feasible in two-dimensional flow because the streamlines along the blade surfaces are known a priori. However, in three-dimensional flow, the stream surface is free to deform within the blade passage so that the streamlines on the blade surfaces are not known a priori; thus it is difficult and not so useful to prescribe the blade surface pressure or velocity distribution and determine the resulting blade profile. It therefore seems logical to prescribe the swirl schedule within the bladed region for designing a turbomachinery blade profile in three-dimensional flow. Furthermore, specifying r bar-V(sub theta) has the following advantages: (1) it is related to the circulation around the blade (i.e., it is an aerodynamic quantity); (2) the work done or extracted is approximately proportional to the overall change in r bar-V(sub theta) across a given blade row (Euler turbine equation); and (3) the rate of change of r bar-V(sub theta) along the mean streamline at the blade is related to the pressure jump across the blade and therefore the blade loading. Since the publications of those two papers, the technique has been applied to the design of a low speed as well as a high speed radial inflow turbine (for turbocharger applications) both of which showed definite improvements in performance over that of wheels of conventional designs, the design study of a high pressure ratio radial inflow turbine with and without splitter blades.

Tan, Choon S.↗

NASA NTRS1993

Techniques for designing rotorcraft control systems

This report summarizes the work that was done on the project from 1 Apr. 1992 to 31 Mar. 1993. The main goal of this research is to develop a practical tool for rotorcraft control system design based on interactive optimization tools (CONSOL-OPTCAD) and classical rotorcraft design considerations (ADOCS). This approach enables the designer to combine engineering intuition and experience with parametric optimization. The combination should make it possible to produce a better design faster than would be possible using either pure optimization or pure intuition and experience. We emphasize that the goal of this project is not to develop an algorithm. It is to develop a tool. We want to keep the human designer in the design process to take advantage of his or her experience and creativity. The role of the computer is to perform the calculation necessary to improve and to display the performance of the nominal design. Briefly, during the first year we have connected CONSOL-OPTCAD, an existing software package for optimizing parameters with respect to multiple performance criteria, to a simplified nonlinear simulation of the UH-60 rotorcraft. We have also created mathematical approximations to the Mil-specs for rotorcraft handling qualities and input them into CONSOL-OPTCAD. Finally, we have developed the additional software necessary to use CONSOL-OPTCAD for the design of rotorcraft controllers.

Levine, William S.↗

NASA NTRS1991

The design of two-stage-to-orbit vehicles

Two separate student design groups developed conceptual designs for a two-stage-to-orbit vehicle, with each design group consisting of a carrier team and an orbiter team. A two-stage-to-orbit system is considered in the event that single-stage-to-orbit is deemed not feasible in the foreseeable future; the two-stage system would also be used as a complement to an already existing heavy lift vehicle. The design specifications given are to lift a 10,000-lb payload 27 ft long by 10 ft diameter, to low Earth orbit (300 n.m.) using an air breathing carrier configuration that will take off horizontally within 15,000 ft. The staging Mach number and altitude were to be determined by the design groups. One group designed a delta wing/body carrier with the orbiter nested within the fuselage of the carrier, and the other group produced a blended cranked-delta wing/body carrier with the orbiter in the more conventional piggyback configuration. Each carrier used liquid hydrogen-fueled turbofanramjet engines, with data provided by General Electric Aircraft Engine Group. While one orbiter used a full-scale Space Shuttle Main Engine (SSME), the other orbiter employed a half-scale SSME coupled with scramjet engines, with data again provided by General Electric. The two groups conceptual designs, along with the technical trade-offs, difficulties, and details that surfaced during the design process are presented.

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NASA NTRS1993

On the design of fault-tolerant robotic manipulator systems

Robotic systems are finding increasing use in space applications. Many of these devices are going to be operational on board the Space Station Freedom. Fault tolerance has been deemed necessary because of the criticality of the tasks and the inaccessibility of the systems to maintenance and repair. Design for fault tolerance in manipulator systems is an area within robotics that is without precedence in the literature. In this paper, we will attempt to lay down the foundations for such a technology. Design for fault tolerance demands new and special approaches to design, often at considerable variance from established design practices. These design aspects, together with reliability evaluation and modeling tools, are presented. Mechanical architectures that employ protective redundancies at many levels and have a modular architecture are then studied in detail. Once a mechanical architecture for fault tolerance has been derived, the chronological stages of operational fault tolerance are investigated. Failure detection, isolation, and estimation methods are surveyed, and such methods for robot sensors and actuators are derived. Failure recovery methods are also presented for each of the protective layers of redundancy. Failure recovery tactics often span all of the layers of a control hierarchy. Thus, a unified framework for decision-making and control, which orchestrates both the nominal redundancy management tasks and the failure management tasks, has been derived. The well-developed field of fault-tolerant computers is studied next, and some design principles relevant to the design of fault-tolerant robot controllers are abstracted. Conclusions are drawn, and a road map for the design of fault-tolerant manipulator systems is laid out with recommendations for a 10 DOF arm with dual actuators at each joint.

Tesar, Delbert↗

NASA NTRS1992

Aerodynamic design of turbomachinery blading in three-dimensional flow - An application to radial inflow turbines

A computational method, based on a theory for turbomachinery blading design in three-dimensional inviscid flow, is applied to a parametric design study of a radial inflow turbine wheel. As the method requires the specification of swirl distribution, a technique for its smooth generation within the blade region is proposed. Excellent agreements have been obtained between the computed results from this design method and those from direct Euler computations, demonstrating the correspondence and consistency between the two. The computed results indicate the sensitivity of the pressure distribution to a lean in the stacking axis and a minor alteration in the hub/shroud profiles. Analysis based on Navier-Stokes solver shows no breakdown of flow within the designed blade passage and agreement with that from design calculation; thus the flow in the designed turbine rotor closely approximates that of an inviscid one. These calculations illustrate the use of a design method coupled to an analysis tool for establishing guidelines and criteria for designing turbomachinery blading.

Yang, Y. L.↗

NASA NTRS1992

Efficient use of high performance computers for integrated controls and structures design

Simply transporting design codes from sequential-scalar computers to parallel-vector computers does not fully utilize the computational benefits offered by high performance computers. By performing integrated controls and structures design on an experimental truss platform with both sequential-scalar and parallel-vector design codes, conclusive results are presented to substantiate this claim. The efficiency of a Cholesky factorization scheme in conjunction with a variable-band row data structure is presented. In addition, the Lanczos eigensolution algorithm has been incorporated in the design code for both parallel and vector computations. Comparisons of computational efficiency between the initial design code and the parallel-vector design code are presented. It is shown that the Lanczos algorithm with the Cholesky factorization scheme is far superior to the sub-space iteration method of eigensolution when substantial numbers of eigenvectors are required for control design and/or performance optimization. Integrated design results show the need for continued efficiency studies in the area of element computations and matrix assembly.

Belvin, W. K.↗

NASA NTRS1988

Aircraft integrated design and analysis: A classroom experience

AAE 451 is the capstone course required of all senior undergraduates in the School of Aeronautics and Astronautics at Purdue University. During the past year the first steps of a long evolutionary process were taken to change the content and expectations of this course. These changes are the result of the availability of advanced computational capabilities and sophisticated electronic media availability at Purdue. This presentation will describe both the long range objectives and this year's experience using the High Speed Commercial Transport (HSCT) design, the AIAA Long Duration Aircraft design and a Remotely Piloted Vehicle (RPV) design proposal as project objectives. The central goal of these efforts was to provide a user-friendly, computer-software-based, environment to supplement traditional design course methodology. The Purdue University Computer Center (PUCC), the Engineering Computer Network (ECN), and stand-alone PC's were used for this development. This year's accomplishments centered primarily on aerodynamics software obtained from the NASA Langley Research Center and its integration into the classroom. Word processor capability for oral and written work and computer graphics were also blended into the course. A total of 10 HSCT designs were generated, ranging from twin-fuselage and forward-swept wing aircraft, to the more traditional delta and double-delta wing aircraft. Four Long Duration Aircraft designs were submitted, together with one RPV design tailored for photographic surveillance. Supporting these activities were three video satellite lectures beamed from NASA/Langley to Purdue. These lectures covered diverse areas such as an overview of HSCT design, supersonic-aircraft stability and control, and optimization of aircraft performance. Plans for next year's effort will be reviewed, including dedicated computer workstation utilization, remote satellite lectures, and university/industrial cooperative efforts.

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NASA NTRS1989

The design of a commercial space infrastructure

Space Services and Logistics, Inc. represents the complete engineering design of a technically and financially viable commercial space company. The final proposal offers an economically sound program of space vehicles and systems designed to substantially affect a variety of space markets and produce a vertically integrated structure within the next 20 years. Throughout this design process, particular stress has been placed on attaining the highest possible levels of safety and reliability. The final program financial design requires a considerable initial outlay, but promises a relatively quick return on invested capital, culminating in large annual profits by the end of the 20-year scope of the cost outlook. The overall design has been extensively researched and was primarily driven by the present and near-term projected market demands for services uniquely or competitively offered only by space-oriented operations. Heretofore, available capabilities, rather than these market demands, have determined the degree and type of commercial market access. Removing this limitation through extensive use of modularity and reconfigurability allows the company to gear itself to the market, while still remaining extremely competitive with existing systems. The markets identified as lucrative, and that have governed much of the design requirements, are: low-cost launch services to LEO over a wide range of payload masses and inclinations; upper stage payload delivery from LEO to GEO; manned space operations and human transport to and from orbit; EVA assembly and maintenance of large space structures; satellite servicing and repair by both humans and telerobotic operations; a line of customized satellites designed for extended life and capable of reconfiguration or technology upgrade on orbit; small-scale microgravity experimentation and manufacturing supported by spacecraft retrieval capabilities for experimental specimens and manufactured goods; and a full-range of payload integration, testing, design, and support services before launch and once in orbit.

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NASA NTRS1990

Inducing optimally directed non-routine designs

Non-routine designs are characterized by the creation of new variables and thus an expansion of the design space. These differ from routine designs in that the latter are restricted to a fixed set of variables and thus a pre-defined design space. In previous papers, the 1stPRINCE non-routine design methodology that expands the design space in such a way that optimal trends dictate the direction and form of this expansion is described. How inductive techniques can determine these optimal trends are examined. The induction techniques in 1stPRINCE utilize constraint information from monotonicity analysis to determine how to mutate the design space. The process observes the constraint information of mutated designs and induces trends from those constraints. Application of 1stPRINCE to a beam under flexural load leads to an optimally directed tapered beam. An interesting application of 1stPRINCE to determine the optimally directed shape of a spinning square block such that resistance to spinning is minimized leads to the discovery of a circular wheel.

Cagan, Jonathan↗

NASA NTRS1993

Computational Fluid Dynamics (CFD) applications in rocket propulsion analysis and design

Computational Fluid Dynamics (CFD) has been used in recent applications to affect subcomponent designs in liquid propulsion rocket engines. This paper elucidates three such applications for turbine stage, pump stage, and combustor chamber geometries. Details of these applications include the development of a high turning airfoil for a gas generator (GG) powered, liquid oxygen (LOX) turbopump, single-stage turbine using CFD as an integral part of the design process. CFD application to pump stage design has emphasized analysis of inducers, impellers, and diffuser/volute sections. Improvements in pump stage impeller discharge flow uniformity have been seen through CFD optimization on coarse grid models. In the area of combustor design, recent CFD analysis of a film cooled ablating combustion chamber has been used to quantify the interaction between film cooling rate, chamber wall contraction angle, and geometry and their effects of these quantities on local wall temperature. The results are currently guiding combustion chamber design and coolant flow rate for an upcoming subcomponent test. Critical aspects of successful integration of CFD into the design cycle includes a close-coupling of CFD and design organizations, quick turnaround of parametric analyses once a baseline CFD benchmark has been established, and the use of CFD methodology and approaches that address pertinent design issues. In this latter area, some problem details can be simplified while retaining key physical aspects to maintain analytical integrity.

Mcconnaughey, P. K.↗