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NASA NTRS2004

Aerodynamic Optimization of Rocket Control Surface Geometry Using Cartesian Methods and CAD Geometry

Aerodynamic design is an iterative process involving geometry manipulation and complex computational analysis subject to physical constraints and aerodynamic objectives. A design cycle consists of first establishing the performance of a baseline design, which is usually created with low-fidelity engineering tools, and then progressively optimizing the design to maximize its performance. Optimization techniques have evolved from relying exclusively on designer intuition and insight in traditional trial and error methods, to sophisticated local and global search methods. Recent attempts at automating the search through a large design space with formal optimization methods include both database driven and direct evaluation schemes. Databases are being used in conjunction with surrogate and neural network models as a basis on which to run optimization algorithms. Optimization algorithms are also being driven by the direct evaluation of objectives and constraints using high-fidelity simulations. Surrogate methods use data points obtained from simulations, and possibly gradients evaluated at the data points, to create mathematical approximations of a database. Neural network models work in a similar fashion, using a number of high-fidelity database calculations as training iterations to create a database model. Optimal designs are obtained by coupling an optimization algorithm to the database model. Evaluation of the current best design then gives either a new local optima and/or increases the fidelity of the approximation model for the next iteration. Surrogate methods have also been developed that iterate on the selection of data points to decrease the uncertainty of the approximation model prior to searching for an optimal design. The database approximation models for each of these cases, however, become computationally expensive with increase in dimensionality. Thus the method of using optimization algorithms to search a database model becomes problematic as the number of design variables is increased.

Nelson, Andrea↗

NASA NTRS2011

Relationship Between Optimal Gain and Coherence Zone in Flight Simulation

In motion simulation the inertial information generated by the motion platform is most of the times different from the visual information in the simulator displays. This occurs due to the physical limits of the motion platform. However, for small motions that are within the physical limits of the motion platform, one-to-one motion, i.e. visual information equal to inertial information, is possible. It has been shown in previous studies that one-to-one motion is often judged as too strong, causing researchers to lower the inertial amplitude. When trying to measure the optimal inertial gain for a visual amplitude, we found a zone of optimal gains instead of a single value. Such result seems related with the coherence zones that have been measured in flight simulation studies. However, the optimal gain results were never directly related with the coherence zones. In this study we investigated whether the optimal gain measurements are the same as the coherence zone measurements. We also try to infer if the results obtained from the two measurements can be used to differentiate between simulators with different configurations. An experiment was conducted at the NASA Langley Research Center which used both the Cockpit Motion Facility and the Visual Motion Simulator. The results show that the inertial gains obtained with the optimal gain are different than the ones obtained with the coherence zone measurements. The optimal gain is within the coherence zone.The point of mean optimal gain was lower and further away from the one-to-one line than the point of mean coherence. The zone width obtained for the coherence zone measurements was dependent on the visual amplitude and frequency. For the optimal gain, the zone width remained constant when the visual amplitude and frequency were varied. We found no effect of the simulator configuration in both the coherence zone and optimal gain measurements.

Gracio, Bruno Jorge Correia↗

NASA NTRS2011

Cross-Polar Aircraft Trajectory Optimization and the Potential Climate Impact

Cross-Polar routes offer new opportunities for air travel markets. Transpolar flights reduce travel times, fuel burns, and associated environmental emissions by flying direct paths between many North American and Asian cities. This study evaluates the potential benefits of flying wind-optimal polar routes and assessed their potential impact on climate change. An optimization algorithm is developed for transpolar flights to generate wind-optimal trajectories that minimize climate impact of aircraft, in terms of global warming potentials (relative to warming by one kg of CO2) of several types of emissions, while avoiding regions of airspace that facilitate persistent contrail formation. Estimations of global warming potential are incorporated into the objective function of the optimization algorithm to assess the climate impact of aircraft emissions discharged at a given location and altitude. The regions of airspace with very low ambient temperature and areas favorable to persistent contrail formation are modeled as undesirable regions that aircraft should avoid and are formulated as soft state constraints. The fuel burn and climate impact of cross-polar air traffic flying various types of trajectory including flight plan, great circle, wind-optimal, and contrail-avoidance are computed for 15 origin-destination pairs between major international airports in the U.S. and Asia. Wind-optimal routes reduce average fuel burn of flight plan routes by 4.4% on December 4, 2010 and 8.0% on August 7, 2010, respectively. The tradeoff between persistent contrail formation and additional global warming potential of aircraft emissions is investigated with and without altitude optimization. Without altitude optimization, the reduction in contrail travel times is gradual with increase in total fuel consumption. When altitude is optimized, a one percent increase in additional global warming potential, a climate impact equivalent to that of 4070kg and 4220kg CO2 emission, reduces 135 and 105 minutes persistent contrail formation per flight during a day with medium and high contrail formation, respectively.

Ng, Hok K.↗

NASA NTRS2011

Cross-Polar Aircraft Trajectory Optimization and Potential Climate Impact

Cross-Polar routes offer new opportunities for air travel markets. Transpolar flights reduce travel times, fuel burns, and associated environmental emissions by flying direct paths between many North American and Asian cities. This study evaluates the potential benefits of flying wind-optimal polar routes and assessed their potential impact on climate change. An optimization algorithm is developed for transpolar flights to generate wind-optimal trajectories that minimize climate impact of aircraft, in terms of global warming potentials (relative to warming by one kg of CO2) of several types of emissions, while avoiding regions of airspace that facilitate persistent contrail formation. Estimations of global warming potential are incorporated into the objective function of the optimization algorithm to assess the climate impact of aircraft emissions discharged at a given location and altitude. The regions of airspace with very low ambient temperature and areas favorable to persistent contrail formation are modeled as undesirable regions that aircraft should avoid and are formulated as soft state constraints. The fuel burn and climate impact of cross-polar air traffic flying various types of trajectory including flightplan, great circle, wind-optimal, and contrail-avoidance are computed for 15 origin-destination pairs between major international airports in the U.S. and Asia. Wind-optimal routes reduce average fuel burn of flight plan routes by 4.4% on December 4, 2010 and 8.0% on August 7, 2010, respectively. The tradeoff between persistent contrail formation and additional global warming potential of aircraft emissions is investigated with and without altitude optimization. Without altitude optimization, the reduction in contrail travel times is gradual with increase in total fuel consumption. When altitude is optimized, a one percent increase in additional global warming potential, a climate impact equivalent to that of 4070kg and 4220kg CO2 emission, reduces 135 and 105 minutes persistent contrail formation per flight during a day with medium and high contrail formation, respectively.

Sridhar, Banavar↗

NASA NTRS2015

An Expert System-Driven Method for Parametric Trajectory Optimization During Conceptual Design

During the early phases of engineering design, the costs committed are high, costs incurred are low, and the design freedom is high. It is well documented that decisions made in these early design phases drive the entire design's life cycle cost. In a traditional paradigm, key design decisions are made when little is known about the design. As the design matures, design changes become more difficult in both cost and schedule to enact. The current capability-based paradigm, which has emerged because of the constrained economic environment, calls for the infusion of knowledge usually acquired during later design phases into earlier design phases, i.e. bringing knowledge acquired during preliminary and detailed design into pre-conceptual and conceptual design. An area of critical importance to launch vehicle design is the optimization of its ascent trajectory, as the optimal trajectory will be able to take full advantage of the launch vehicle's capability to deliver a maximum amount of payload into orbit. Hence, the optimal ascent trajectory plays an important role in the vehicle's affordability posture yet little of the information required to successfully optimize a trajectory is known early in the design phase. Thus, the current paradigm of optimizing ascent trajectories involves generating point solutions for every change in a vehicle's design parameters. This is often a very tedious, manual, and time-consuming task for the analysts. Moreover, the trajectory design space is highly non-linear and multi-modal due to the interaction of various constraints. When these obstacles are coupled with the Program to Optimize Simulated Trajectories (POST), an industry standard program to optimize ascent trajectories that is difficult to use, expert trajectory analysts are required to effectively optimize a vehicle's ascent trajectory. Over the course of this paper, the authors discuss a methodology developed at NASA Marshall's Advanced Concepts Office to address these issues. The methodology is two-fold: first, capture the heuristics developed by human analysts over their many years of experience; and secondly, leverage the power of modern computing to evaluate multiple trajectories simultaneously and therefore enable the exploration of the trajectory's design space early during the pre- conceptual and conceptual phases of design. This methodology is coupled with design of experiments in order to train surrogate models, which enables trajectory design space visualization and parametric optimal ascent trajectory information to be available when early design decisions are being made.

Dees, Patrick D.↗

NASA NTRSDate not supplied

Propulsive trajectory optimization to minimize surface contamination

MOTIVATION: We present an optimization technique for propulsive vehicles that autonomously minimizes contamination during surface approach and landing. In addition to short-range hoppers, the optimization technique is also fully applicable to traditional orbit-to-surface landers. This study addresses scenarios where surface alterations from propulsion events are counterproductive or hazardous to the mission objectives. This is of immediate interest for landers (whether human or robotic), that may rely on pristine soils collected in the immediate vicinity of landing sites to accomplish science investigations, mining, or ISRU surface operations. Such missions are averse to various surface-plume interactions such as thermal scoring, physical agitation, and contamination. The capability can be applied with minimal impact to the baseline mission concept. METHODS: Optimization algorithms have been developed to calculate descent trajectories and maneuvers, thrust magnitude, and attitude for various mission cases. These parameters are determined as an optimal solution when minimizing either fuel consumption, contamination deposited at the landing site, or some weighted combination of both. Among constraints imposed on the solution, we examined pitch rate, vertical takeoff and vertical landing (VTVL) requirements, size of the contamination zone, and minimum ground clearance during flight. This tool provides unique, non-intuitive solutions and can be a valuable resource for mission planners. RESULTS: A variety of agile trajectory solutions were obtained, each yielding different reductions in landing site contamination and corresponding to only modest increases in fuel consumption. Several optimal trajectories were obtained by varying the contamination weight in the fitness function. As expected, when the contamination weight is zero, the trajectory appears close to parabolic since the optimization scheme only attempts to minimize for fuel utilization, yielding essentially, the expected ballistic trajectory. Notably for contamination weights greater than zero, trajectory inflections are observed in the descent phase, which manifests as hovering or additional, mini “pseudo hops” before the final touchdown. A trajectory inflection is characterized by arresting the majority of the spacecraft vertical velocity component at a coordinate outside of the landing target, and without violating ground clearance constraints. FUTURE WORK: Our optimization technique is ready for laboratory or field demonstrations to validate the sophisticated maneuvering solutions obtained for fuel optimization and surface preservation. An appropriate testbed would validate the optimal guidance algorithms, the navigation system, and sensor suite by emulating vehicle flight in closed loop robotic tests. Critically, these algorithms could then be ported to flight software for implementation.

surface contamination↗

NASA NTRSDate not supplied

Sensitivity of Optimal Midcourse Correction Scheduling for Robust Cislunar Trajectory Design

A new approach to optimal trajectory design is the determination of optimal trajectories that are robust to initial trajectory dispersions, navigation errors, maneuver execution errors, and environment modeling errors. This paper investigates the sensitivity of cislunar robust optimal trajectory design to launch date, duration of navigation measurement passes, and navigation measurement frequency. For a given cislunar trajectory from translunar injection (TLI) to lunar orbit insertion (LOI), the optimal locations of midcourse corrections, also known as trajectory correction maneuvers (TCM) are determined by minimizing the final 3-σ ∆v subject to a final 3-σ position dispersion constraint for a given launch date, specified measurement pass duration prior to each maneuver, and measurement frequency. Optical navigation (OpNav) is assumed, and OpNav field-of-view (FOV) and lighting constraints are employed. These constraints turn out to be important elements of the problem. The sensitivity of the optimal TCM locations are then investigated by varying the launch date, duration of OpNav measurement passes, and the OpNav measurement frequency, and then re-optimizing the locations of the TCMs. Given the problem parameters provided herein, results show that while the optimal TCM locations with respect to TLI vary greatly from one launch date to another, their locations with respect to LOI are nearly invariant over a 2-month launch window. Results also show that in all cases the optimal location of the last TCM is found to be at the point where the OpNav lunar FOV constraint is first violated. For all other TCMs, OpNav measurement pass duration and measurement frequency can have a moderate to large affect on the optimal TCM locations.

Linear Covariance Analysis↗

NASA NTRS2023

Automated Fiber Placement Through Thickness Defect Stacking Optimization

In its 2022 commercial market outlook, Boeing forecasted an 80% increase in the global fleet through 2041 compared to 2019 pre-pandemic levels. This sharp rise in demand will drive pressure onto airframe manufacturers to ramp up production and find more efficient ways to design and manufacture airplanes. Complicating this challenge is the industry’s recent transformation from traditional metal-based airframes towards hybrid composite-metal aircraft. While composites have been used in aviation for decades, aircraft manufacturers are still struggling to design and manufacture quality parts at a high rate. Automated Fiber Placement (AFP) is one of the main manufacturing techniques used to produce large-scale composite parts. After a design has been created, a manufacturing strategy has to be developed based on the working material, part geometry, and machine capabilities. This process planning stage is essential to the AFP workflow and currently requires a high level of manual input from an experienced process planner. In an effort to automate and optimize this stage, the Computer Aided Process Planning (CAPP) module was developed. CAPP assists process planners in identifying optimal starting point location and layup strategy for each ply of a laminate. This Ply-Level Optimization (PLO) phase operates on the quantification of ply quality through predictable geometry-based defects such as gaps, overlaps, angle deviation, and steering. As you move from PLO to Laminate-Level Optimization (LLO) the design space grows exponentially, emphasizing the need for automated optimization. The work presented in this thesis expands CAPP’s functionality by comparing the planned fiber paths through the thickness of the laminate to mitigate stacked area defects and achieve an optimal laminate-level manufacturing strategy. Within CAPP, predicted gap and overlap defects are imported from Vericut Composites Programming (VCP) and then discretized to streamline the through-thickness comparison. Two objective functions are used to score different combinations of ply layup strategies based on defect stacking both globally and locally. Four combinatorial optimization algorithms were coupled with these objective functions to investigate the laminate-level manufacturing strategy design space and converge on the optimal plan. These algorithms were evaluated based on accuracy and efficiency through virtual testing on a complex tool surface. A separate LLO approach was developed to achieve near-optimal laminates in significantly less time. The end result is a software package which greatly reduces the required input from process planners, shortening the design-build cycle time and improving part quality.

AFP↗

NASA NTRS2014

Optimizing Medical Kits for Spaceflight

The Integrated Medical Model (IMM) is a probabilistic model that estimates medical event occurrences and mission outcomes for different mission profiles. IMM simulation outcomes describing the impact of medical events on the mission may be used to optimize the allocation of resources in medical kits. Efficient allocation of medical resources, subject to certain mass and volume constraints, is crucial to ensuring the best outcomes of in-flight medical events. We implement a new approach to this medical kit optimization problem. METHODS We frame medical kit optimization as a modified knapsack problem and implement an algorithm utilizing a dynamic programming technique. Using this algorithm, optimized medical kits were generated for 3 different mission scenarios with the goal of minimizing the probability of evacuation and maximizing the Crew Health Index (CHI) for each mission subject to mass and volume constraints. Simulation outcomes using these kits were also compared to outcomes using kits optimized..RESULTS The optimized medical kits generated by the algorithm described here resulted in predicted mission outcomes more closely approached the unlimited-resource scenario for Crew Health Index (CHI) than the implementation in under all optimization priorities. Furthermore, the approach described here improves upon in reducing evacuation when the optimization priority is minimizing the probability of evacuation. CONCLUSIONS This algorithm provides an efficient, effective means to objectively allocate medical resources for spaceflight missions using the Integrated Medical Model.

Optimization↗

NASA NTRS1977

An optimality criterion for sizing members of heated structures with temperature constraints

A thermal optimality criterion is presented for sizing members of heated structures with multiple temperature constraints. The optimality criterion is similar to an existing optimality criterion for design of mechanically loaded structures with displacement constraints. Effectiveness of the thermal optimality criterion is assessed by applying it to one- and two-dimensional thermal problems where temperatures can be controlled by varying the material distribution in the structure. Results obtained from the optimality criterion agree within 2 percent with results from a closed-form solution and with results from a mathematical programming technique. The thermal optimality criterion augments existing optimality criteria for strength and stiffness related constraints and offers the possibility of extension of optimality techniques to sizing structures with combined thermal and mechanical loading.

Rao, G. V.↗

NASA NTRS1983

Optimization methods applied to hybrid vehicle design

The use of optimization methods as an effective design tool in the design of hybrid vehicle propulsion systems is demonstrated. Optimization techniques were used to select values for three design parameters (battery weight, heat engine power rating and power split between the two on-board energy sources) such that various measures of vehicle performance (acquisition cost, life cycle cost and petroleum consumption) were optimized. The apporach produced designs which were often significant improvements over hybrid designs already reported on in the literature. The principal conclusions are as follows. First, it was found that the strategy used to split the required power between the two on-board energy sources can have a significant effect on life cycle cost and petroleum consumption. Second, the optimization program should be constructed so that performance measures and design variables can be easily changed. Third, the vehicle simulation program has a significant effect on the computer run time of the overall optimization program; run time can be significantly reduced by proper design of the types of trips the vehicle takes in a one year period. Fourth, care must be taken in designing the cost and constraint expressions which are used in the optimization so that they are relatively smooth functions of the design variables. Fifth, proper handling of constraints on battery weight and heat engine rating, variables which must be large enough to meet power demands, is particularly important for the success of an optimization study. Finally, the principal conclusion is that optimization methods provide a practical tool for carrying out the design of a hybrid vehicle propulsion system.

Donoghue, J. F.↗

NASA NTRS1985

A sequential linear optimization approach for controller design

A linear optimization approach with a simple real arithmetic algorithm is presented for reliable controller design and vibration suppression of flexible structures. Using first order sensitivity of the system eigenvalues with respect to the design parameters in conjunction with a continuation procedure, the method converts a nonlinear optimization problem into a maximization problem with linear inequality constraints. The method of linear programming is then applied to solve the converted linear optimization problem. The general efficiency of the linear programming approach allows the method to handle structural optimization problems with a large number of inequality constraints on the design vector. The method is demonstrated using a truss beam finite element model for the optimal sizing and placement of active/passive-structural members for damping augmentation. Results using both the sequential linear optimization approach and nonlinear optimization are presented and compared. The insensitivity to initial conditions of the linear optimization approach is also demonstrated.

Horta, L. G.↗

NASA NTRS1984

Optimization in the systems engineering process

The objective is to look at optimization as it applies to the design process at a large aircraft company. The design process at Lockheed-Georgia is described. Some examples of the impact that optimization has had on that process are given, and then some areas that must be considered if optimization is to be successful and supportive in the total design process are indicated. Optimization must continue to be sold and this selling is best done by consistent good performance. For this good performance to occur, the future approaches must be clearly thought out so that the optimization methods solve the problems that actually occur during design. The visibility of the design process must be maintained as further developments are proposed. Careful attention must be given to the management of data in the optimization process, both for technical reasons and for administrative purposes. Finally, to satisfy program needs, provisions must be included to supply data to support program decisions, and to communicate with design processes outside of the optimization process. If designers fail to adequately consider all of these needs, the future acceptance of optimization will be impeded.

Lemmerman, L. A.↗

NASA NTRS1988

Structural optimization of rotor blades with integrated dynamics and aerodynamics

The problem of structural optimization of helicopter rotor blades with integrated dynamic and aerodynamic design considerations is addressed. Results of recent optimization work on rotor blades for minimum weight with constraints on multiple coupled natural flap-lag frequencies, blade autorotational inertia and centrifugal stress has been reviewed. A strategy has been defined for the ongoing activities in the integrated dynamic/aerodynamic optimization of rotor blades. As a first step, the integrated dynamic/airload optimization problem has been formulated. To calculate system sensitivity derivatives necessary for the optimization recently developed, Global Sensitivity Equations (GSE) are being investigated. A need for multiple objective functions for the integrated optimization problem has been demonstrated and various techniques for solving the multiple objective function optimization are being investigated. The method called the Global Criteria Approach has been applied to a test problem with the blade in vacuum and the blade weight and the centrifugal stress as the multiple objectives. The results indicate that the method is quite effective in solving optimization problems with conflicting objective functions.

Chattopadhyay, Aditi↗

NASA NTRS1989

Integrated aerodynamic/dynamic optimization of helicopter rotor blades

An integrated aerodynamic/dynamic optimization procedure is used to minimize blade weight and 4 per rev vertical hub shear for a rotor blade in forward flight. The coupling of aerodynamics and dynamics is accomplished through the inclusion of airloads which vary with the design variables during the optimization process. Both single and multiple objective functions are used in the optimization formulation. The Global Criteria Approach is used to formulate the multiple objective optimization and results are compared with those obtained by using single objective function formulations. Constraints are imposed on natural frequencies, autorotational inertia, and centrifugal stress. The program CAMRAD is used for the blade aerodynamic and dynamic analyses, and the program CONMIN is used for the optimization. Since the spanwise and the azimuthal variations of loading are responsible for most rotor vibration and noise, the vertical airload distributions on the blade, before and after optimization, are compared. The total power required by the rotor to produce the same amount of thrust for a given area is also calculated before and after optimization. Results indicate that integrated optimization can significantly reduce the blade weight, the hub shear and the amplitude of the vertical airload distributions on the blade and the total power required by the rotor.

Chattopadhyay, Aditi↗

NASA NTRS1989

Structural optimization of rotor blades with integrated dynamics and aerodynamics

Chattopadhyay, Aditi↗

NASA NTRS1989

The Sizing and Optimization Language (SOL): A computer language to improve the user/optimizer interface

The nonlinear mathematical programming method (formal optimization) has had many applications in engineering design. A figure illustrates the use of optimization techniques in the design process. The design process begins with the design problem, such as the classic example of the two-bar truss designed for minimum weight as seen in the leftmost part of the figure. If formal optimization is to be applied, the design problem must be recast in the form of an optimization problem consisting of an objective function, design variables, and constraint function relations. The middle part of the figure shows the two-bar truss design posed as an optimization problem. The total truss weight is the objective function, the tube diameter and truss height are design variables, with stress and Euler buckling considered as constraint function relations. Lastly, the designer develops or obtains analysis software containing a mathematical model of the object being optimized, and then interfaces the analysis routine with existing optimization software such as CONMIN, ADS, or NPSOL. This final state of software development can be both tedious and error-prone. The Sizing and Optimization Language (SOL), a special-purpose computer language whose goal is to make the software implementation phase of optimum design easier and less error-prone, is presented.

Lucas, S. H.↗

NASA NTRS1989

Recent experience in simultaneous control-structure optimization

To show the feasibility of simultaneous optimization as design procedure, low order problems were used in conjunction with simple control formulations. The numerical results indicate that simultaneous optimization is not only feasible, but also advantageous. Such advantages come at the expense of introducing complexities beyond those encountered in structure optimization alone, or control optimization alone. Examples include: larger design parameter space, optimization may combine continuous and combinatoric variables, and the combined objective function may be nonconvex. Future extensions to include large order problems, more complex objective functions and constraints, and more sophisticated control formulations will require further research to ensure that the additional complexities do not outweigh the advantages of simultaneous optimization. Some areas requiring more efficient tools than currently available include: multiobjective criteria and nonconvex optimization. Efficient techniques to deal with optimization over combinatoric and continuous variables, and with truncation issues for structure and control parameters of both the model space as well as the design space need to be developed.

Salama, M.↗