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NASA NTRS2006

Automated Antenna Design with Evolutionary Algorithms

Current methods of designing and optimizing antennas by hand are time and labor intensive, and limit complexity. Evolutionary design techniques can overcome these limitations by searching the design space and automatically finding effective solutions. In recent years, evolutionary algorithms have shown great promise in finding practical solutions in large, poorly understood design spaces. In particular, spacecraft antenna design has proven tractable to evolutionary design techniques. Researchers have been investigating evolutionary antenna design and optimization since the early 1990s, and the field has grown in recent years as computer speed has increased and electromagnetic simulators have improved. Two requirements-compliant antennas, one for ST5 and another for TDRS-C, have been automatically designed by evolutionary algorithms. The ST5 antenna is slated to fly this year, and a TDRS-C phased array element has been fabricated and tested. Such automated evolutionary design is enabled by medium-to-high quality simulators and fast modern computers to evaluate computer-generated designs. Evolutionary algorithms automate cut-and-try engineering, substituting automated search though millions of potential designs for intelligent search by engineers through a much smaller number of designs. For evolutionary design, the engineer chooses the evolutionary technique, parameters and the basic form of the antenna, e.g., single wire for ST5 and crossed-element Yagi for TDRS-C. Evolutionary algorithms then search for optimal configurations in the space defined by the engineer. NASA's Space Technology 5 (ST5) mission will launch three small spacecraft to test innovative concepts and technologies. Advanced evolutionary algorithms were used to automatically design antennas for ST5. The combination of wide beamwidth for a circularly-polarized wave and wide impedance bandwidth made for a challenging antenna design problem. From past experience in designing wire antennas, we chose to constrain the evolutionary design to a monopole wire antenna. The results of the runs produced requirements-compliant antennas that were subsequently fabricated and tested. The evolved antenna has a number of advantages with regard to power consumption, fabrication time and complexity, and performance. Lower power requirements result from achieving high gain across a wider range of elevation angles, thus allowing a broader range of angles over which maximum data throughput can be achieved. Since the evolved antenna does not require a phasing circuit, less design and fabrication work is required. In terms of overall work, the evolved antenna required approximately three person-months to design and fabricate whereas the conventional antenna required about five. Furthermore, when the mission was modified and new orbital parameters selected, a redesign of the antenna to new requirements was required. The evolutionary system was rapidly modified and a new antenna evolved in a few weeks. The evolved antenna was shown to be compliant to the ST5 mission requirements. It has an unusual organic looking structure, one that expert antenna designers would not likely produce. This antenna has been tested, baselined and is scheduled to fly this year. In addition to the ST5 antenna, our laboratory has evolved an S-band phased array antenna element design that meets the requirements for NASA's TDRS-C communications satellite scheduled for launch early next decade. A combination of fairly broad bandwidth, high efficiency and circular polarization at high gain made for another challenging design problem. We chose to constrain the evolutionary design to a crossed-element Yagi antenna. The specification called for two types of elements, one for receive only and one for transmit/receive. We were able to evolve a single element design that meets both specifications thereby simplifying the antenna and reducing testing and integration costs. The highest performance antenna found using a getic algorithm and stochastic hill-climbing has been fabricated and tested. Laboratory results correspond well with simulation. Aerospace component design is an expensive and important step in space development. Evolutionary design can make a significant contribution wherever sufficiently fast, accurate and capable software simulators are available. We have demonstrated successful real-world design in the spacecraft antenna domain; and there is good reason to believe that these results could be replicated in other design spaces.

Hornby, Gregory S.↗

NASA NTRS2002

Mystery of Foil Air Bearings for Oil-free Turbomachinery Unlocked: Load Capacity Rule-of-thumb Allows Simple Estimation of Performance

The Oil-Free Turbomachinery team at the NASA Glenn Research Center has unlocked one of the mysteries surrounding foil air bearing performance. Foil air bearings are self-acting hydrodynamic bearings that use ambient air, or any fluid, as their lubricant. In operation, the motion of the shaft's surface drags fluid into the bearing by viscous action, creating a pressurized lubricant film. This lubricating film separates the stationary foil bearing surface from the moving shaft and supports load. Foil bearings have been around for decades and are widely employed in the air cycle machines used for cabin pressurization and cooling aboard commercial jetliners. The Oil-Free Turbomachinery team is fostering the maturation of this technology for integration into advanced Oil-Free aircraft engines. Elimination of the engine oil system can significantly reduce weight and cost and could enable revolutionary new engine designs. Foil bearings, however, have complex elastic support structures (spring packs) that make the prediction of bearing performance, such as load capacity, difficult if not impossible. Researchers at Glenn recently found a link between foil bearing design and load capacity performance. The results have led to a simple rule-of-thumb that relates a bearing's size, speed, and design to its load capacity. Early simple designs (Generation I) had simple elastic (spring) support elements, and performance was limited. More advanced bearings (Generation III) with elastic supports, in which the stiffness is varied locally to optimize gas film pressures, exhibit load capacities that are more than double those of the best previous designs. This is shown graphically in the figure. These more advanced bearings have enabled industry to introduce commercial Oil-Free gas-turbine-based electrical generators and are allowing the aeropropulsion industry to incorporate the technology into aircraft engines. The rule-of-thumb enables engine and bearing designers to easily size and select bearing technology for a new application and determine the level of complexity required in the bearings. This new understanding enables industry to assess the feasibility of new engine designs and provides critical guidance toward the future development of Oil-Free turbomachinery propulsion systems.

DellaCorte, Christopher↗

NASA NTRS1988

End-effector - joint conjugates for robotic assembly of large truss structures in space: A second generation

Current designs, a first generation intended for robotic assembly, have given priority to the ease and certainty of the assembly process under less than ideal conditions with a minimum of sensory feedback. As a consequence they are either heavy or expensive and all exhibit a relatively low packaging density. Low packaging density is caused by extensive scars applied to the node, increasing its envelope diameter by as much as 150 percent. Strut envelopes are violated to a lessor extent with diameters increased by 25 percent or more. This smaller percentage is still a significant problem owing to a much higher fraction of the packaged volume represented by struts. As structures in space become larger, packaging density becomes an important consideration. The objective is to develop end-effector-joint conjugates that do not violate the envelopes of a 2.5 inch diameter node or a 1.0 inch diameter strut.

Brewer, W. V.↗

NASA NTRS1997

Computational Tools and Facilities for the Next-Generation Analysis and Design Environment

This document contains presentations from the joint UVA/NASA Workshop on Computational Tools and Facilities for the Next-Generation Analysis and Design Environment held at the Virginia Consortium of Engineering and Science Universities in Hampton, Virginia on September 17-18, 1996. The presentations focused on the computational tools and facilities for analysis and design of engineering systems, including, real-time simulations, immersive systems, collaborative engineering environment, Web-based tools and interactive media for technical training. Workshop attendees represented NASA, commercial software developers, the aerospace industry, government labs, and academia. The workshop objectives were to assess the level of maturity of a number of computational tools and facilities and their potential for application to the next-generation integrated design environment.

Noor, Ahmed K.↗

NASA NTRS1993

The potential of genetic algorithms for conceptual design of rotor systems

The capabilities of genetic algorithms as a non-calculus based, global search method make them potentially useful in the conceptual design of rotor systems. Coupling reasonably simple analysis tools to the genetic algorithm was accomplished, and the resulting program was used to generate designs for rotor systems to match requirements similar to those of both an existing helicopter and a proposed helicopter design. This provides a comparison with the existing design and also provides insight into the potential of genetic algorithms in design of new rotors.

Crossley, William A.↗

NASA NTRS1984

Vortex generating flow passage design for increased film-cooling effectiveness and surface coverage

The fluid mechanics of the basic discrete hole film cooling process is described as an inclined jet in crossflow and a cusp shaped coolant flow channel contour that increases the efficiency of the film cooling process is hypothesized. The design concept requires the channel to generate a counter rotating vortex pair secondary flow within the jet stream by virture of flow passage geometry. The interaction of the vortex structures generated by both geometry and crossflow was examined in terms of film cooling effectiveness and surface coverage. Comparative data obtained with this vortex generating coolant passage showed up to factors of four increases in both effectiveness and surface coverage over that obtained with a standard round cross section flow passage. A streakline flow visualization technique was used to support the concept of the counter rotating vortex pair generating capability of the flow passage design.

Papell, S. S.↗

NASA NTRSDate not supplied

Acoustics and Performance of a Scaled Spacecraft Cabin Ventilation Fan

An axial fan was designed at NASA Glenn Research Center using tools developed for aircraft turbine engines. The fan unit design size, flow rate and pressure rise were chosen to be broadly in the range of the Orion cabin fan. A ground test prototype was built and tested, confirming design predictions. Pressure rise and flow rate measurements were conducted over a range of fan speeds while in-duct and radiated acoustic measurements were collected. Unsteady flow measurements were acquired between the rotor and stator. These methods are a hybrid of the techniques used for small fans and those used for aircraft engine component tests. A larger version of the fan was recently designed, based on the original fan, using aerodynamic scaling laws resulting in a design with approximately twice the flow rate and twice the pressure-rise compared to the original fan. The mechanical structure was optimized using generative design for low weight. The paper discusses this larger fan design including the scaling laws, the predicted performance and acoustics.

ventilation↗

NASA NTRS1974

Wind Tunnel Generation of Sinusoidal Lateral and Longitudinal Gusts by Circulation of Twin Parallel Airfoils

A gust generator capable of producing sinusoidal lateral and longitudinal gusts was developed for the purpose of studying the gust response of a model rotor-propeller in a wind tunnel. The gust generator utilized harmonic circulation control of twin parallel airfoils to achieve the harmonic lift variation required for gust generation. The gust generator design, construction, and testing is described. Typical test results are presented in the form of lateral and longitudinal gust perturbation velocities as a function of generator reduced frequency.

Ham, N. D.↗

NASA NTRS1997

A Comparison of Two Control Display Unit Concepts on Flight Management System Training

One of the biggest challenges for a pilot in the transition to a 'glass' cockpit is understanding the flight management system (FMS). Because of both the complex nature of the FMS and the pilot-FMS interface, a large portion of transition training is devoted to the FMS. The current study examined the impact of the primary pilot-FMS interface, the control display unit (CDU), on FMS training. Based on the hypothesis that the interface design could have a significant impact on training, an FMS simulation with two separate interfaces was developed. One interface was similar to a current-generation design, and the other was a multiwindows CDU based on graphical user interface techniques. For both application and evaluation reasons, constraints were applied to the graphical CDU design to maintain as much similarity as possible with the conventional CDU. This preliminary experiment was conducted to evaluate the interface effects on training. Sixteen pilots with no FMS experience were used in a between-subjects test. A time-compressed, airline-type FMS training environment was simulated. The subjects were trained to a fixed-time criterion, and performance was measured in a final, full-mission simulation context. This paper describes the technical approach, simulation implementation, and experimental results of this effort.

Abbott, Terence S.↗

NASA NTRS1995

The Evaluation of Two CDU Concepts and Their Effects on FMS Training

One of the biggest challenges for a pilot in the transition to a "glass" cockpit is understanding the Flight Management System (FMS). This is due to both the complex nature of the FMS and to the pilot-FMS interface. For these reasons, a large portion of transition training is devoted to the FMS. The intent of the current study was to examine the impact of the primary pilot-FMS interface, the Control Display Unit (CDU), on FMS training. The hypothesis of this study was that the interface design could have a significant impact on training. An FMS simulation was developed with two separate interfaces. One interface was similar to a current-generation design and the other was a multi-windows CDU based on graphical user interface techniques. For both application and evaluation reasons, constraints were applied to the graphical CDU design to maintain as much similarity as possible with the conventional CDU.

Abbott, Terence S.↗

NASA NTRS1984

A computer aided design procedure for generating gear teeth

A procedure for computer aided design (CAD) of gear teeth is presented. It is developed for generated teeth fabricated by a hob cutter or a shaper. It provides a means for analytically and numerically determining the tooth profile, given the cutter profile. An illustrative example with involute tooth profiles is given. Application with non-standard profiles and with bevel, spiral bevel, and hypoid gears is discussed.

Chang, S. H.↗

NASA NTRS1973

Developing structures technology for the day after tomorrow.

To prepare for new demands on aircraft structures, NASA has established a number of goals. These include automatic analysis and design, building confidence in advanced composites, improving the technology base for future supersonic and hypersonic vehicles, validating concepts for active controls, developing methods for predicting aircraft loads and aeroelasticity, and generating design methods for assuring structural integrity. Progress made in achieving these goals is discussed in detail.

Brooks, G. W.↗

NASA NTRS1979

Combined strength and aeroelastic wing synthesis via constraint approximation

A numerical optimization program using constraint approximations for preliminary sizing of wing structural design parameters to satisfy simultaneous strength and aeroelastic requirements is described. The effects of wing flexibility on loads and flutter are included. The iterative procedure approximates wing internal load distributions and flutter response in generating design constraints. Though a linear Taylor series approximation to the variation of flutter speed is made, constraints in general are formulated as nonlinear and solved in a minimum weight problem using a feasible directions search. The technique is demonstrated for the determination of the optimal ply orientations and for simultaneous sizing for strength and flutter with simple constraint approximations.

Mullen, J., Jr.↗

NASA NTRS1979

Advanced oxygen-hydrocarbon rocket engine study

A consistent engine system data base was generated for defining advantages and disadvantages, system performance and operating limits, engine parametric data, and technology requirements for candidate high pressure LO2/HC engine systems. Optimum LO2/HC engine power cycles were synthetized and representative conceptual engine design generated for a specified advanced surface to orbit transportation system.

Obrien, C. J.↗

NASA NTRSDate not supplied

Making & Breaking the Rules for DED Design

Design for Additive Manufacturing (DfAM) is widely used to describe design activities and guidelines employed in the creation of Additively Manufactured (AM) parts. Basic design rules for widely adopted processes like Powder Bed Fusion (PBF) are relatively understood including material performance, part size constraints, self-supporting angles, overhangs, wall thicknesses, and feature resolution. Complexity is often inherent with PBF using organically inspired solutions through generative design and topology optimization software to create designs that often cannot be realized via traditional manufacturing processes. The design rules for Directed Energy Deposition (DED) are less well known, and, in some cases, the lack of understanding is likely inhibiting broader application of the various DED processes. This presentation covers key design rules for DED fusion processes and elucidates opportunities like multi-material deposition and build approaches ranging from basic features to complex large-scale parts. Complementary to the opportunistic characteristics of DfAM for DED, Manufacture for AM (MfAM) encompasses the restrictive aspects of the manufacturing lifecycle with limitations due to bead width and wall thickness, self-supporting angles, surface texture, microstructural evolution, and residual stresses. AM enabled part design must always consider the entire value chain starting with incoming feedstock (e.g. plate, wire, or powder) and progressing through the printing process, post-processing (e.g. machining, inspection), and final system assembly. Key considerations, like the tradeoffs between feature resolution and build rate, for process and part selection and economic assessments will be discussed as DED is often traded against other AM processes. After highlighting typical DED design rules, we will also show how some of those rules can be broken via use cases and part designs that span the full spectrum of DED processes with examples of various DED part designs.

Additive Manufacturing↗

NASA NTRS1995

Ball bearing vibrations amplitude modeling and test comparisons

Bearings generate disturbances that, when combined with structural gains of a momentum wheel, contribute to induced vibration in the wheel. The frequencies generated by a ball bearing are defined by the bearing's geometry and defects. The amplitudes at these frequencies are dependent upon the actual geometry variations from perfection; therefore, a geometrically perfect bearing will produce no amplitudes at the kinematic frequencies that the design generates. Because perfect geometry can only be approached, emitted vibrations do occur. The most significant vibration is at the spin frequency and can be balanced out in the build process. Other frequencies' amplitudes, however, cannot be balanced out. Momentum wheels are usually the single largest source of vibrations in a spacecraft and can contribute to pointing inaccuracies if emitted vibrations ring the structure or are in the high-gain bandwidth of a sensitive pointing control loop. It is therefore important to be able to provide an a priori knowledge of possible amplitudes that are singular in source or are a result of interacting defects that do not reveal themselves in normal frequency prediction equations. This paper will describe the computer model that provides for the incorporation of bearing geometry errors and then develops an estimation of actual amplitudes and frequencies. Test results were correlated with the model. A momentum wheel was producing an unacceptable 74 Hz amplitude. The model was used to simulate geometry errors and proved successful in identifying a cause that was verified when the parts were inspected.

Hightower, Richard A., III↗

NASA NTRSDate not supplied

Concept Design a 1.4 MW Inverter for Rotor Loss Minimization in a Partially Superconducting Motor

Partially superconducting machines with cryocooler-cooled rotors are a potential near term technology that can achieve the motor performance needed by future fixed wing electric aircraft. For this type of machine, minimizing cryogenic heat load is one of the keys for enabling high machine performance. Rotor eddy current loss is often the most difficult cryogenic heat load to mitigate due to current ripple from the motor drive. This paper presents the concept design for a 20 kW/kg, 99.5 percent efficient motor drive that has sufficiently low current ripple to enable high performance partially superconducting machines by minimizing eddy current loss in the rotor. The motor drive concept design uses a resonant, interleaved, and multilevel topology to achieve these high-performance metrics with little current ripple. Rotor magnetic loss analysis using NASA’s 1.4 MW High Efficiency Megawatt Motor (HEMM) is used in the design process to down select the motor drive topology and show that the final design generates less than 5 W of magnetic loss in the rotor.

Concept design↗

NASA NTRS1999

X-33/RLV Program Aerospike Engines

Substantial progress was made during the past year in support of the X-33/RLV program. X-33 activity was directed towards completing the remaining design work and building hardware to support test activities. RLV work focused on the nozzle ramp and powerpack technology tasks and on supporting vehicle configuration studies. On X-33, the design activity was completed to the detail level and the remainder of the drawings were released. Component fabrication and engine assembly activity was initiated, and the first two powerpacks and the GSE and STE needed to support powerpack testing were completed. Components fabrication is on track to support the first engine assembly schedule. Testing activity included powerpack testing and component development tests consisting of thrust cell single cell testing, CWI system spider testing, and EMA valve flow and vibration testing. Work performed for RLV was divided between engine system and technology development tasks. Engine system activity focused on developing the engine system configuration and supporting vehicle configuration studies. Also, engine requirements were developed, and engine performance analyses were conducted. In addition, processes were developed for implementing reliability, mass properties, and cost controls during design. Technology development efforts were divided between powerpack and nozzle ramp technology tasks. Powerpack technology activities were directed towards the development of a prototype powerpack and a ceramic turbine technology demonstrator (CTTD) test article which will allow testing of ceramic turbines and a close-coupled gas generator design. Nozzle technology efforts were focused on the selection of a composite nozzle supplier and on the fabrication and test of composite nozzle coupons.

Source record↗