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An information driven strategy to support multidisciplinary design

The design of complex engineering systems such as aircraft, automobiles, and computers is primarily a cooperative multidisciplinary design process involving interactions between several design agents. The common thread underlying this multidisciplinary design activity is the information exchange between the various groups and disciplines. The integrating component in such environments is the common data and the dependencies that exist between such data. This may be contrasted to classical multidisciplinary analyses problems where there is coupling between distinct design parameters. For example, they may be expressed as mathematically coupled relationships between aerodynamic and structural interactions in aircraft structures, between thermal and structural interactions in nuclear plants, and between control considerations and structural interactions in flexible robots. These relationships provide analytical based frameworks leading to optimization problem formulations. However, in multidisciplinary design problems, information based interactions become more critical. Many times, the relationships between different design parameters are not amenable to analytical characterization. Under such circumstances, information based interactions will provide the best integration paradigm, i.e., there is a need to model the data entities and their dependencies between design parameters originating from different design agents. The modeling of such data interactions and dependencies forms the basis for integrating the various design agents.

Rangan, Ravi M.↗

Performance evaluation of the Engineering Analysis and Data Systems (EADS) 2

The Engineering Analysis and Data System (EADS)II (1) was installed in March 1993 to provide high performance computing for science and engineering at Marshall Space Flight Center (MSFC). EADS II increased the computing capabilities over the existing EADS facility in the areas of throughput and mass storage. EADS II includes a Vector Processor Compute System (VPCS), a Virtual Memory Compute System (CFS), a Common Output System (COS), as well as Image Processing Station, Mini Super Computers, and Intelligent Workstations. These facilities are interconnected by a sophisticated network system. This work considers only the performance of the VPCS and the CFS. The VPCS is a Cray YMP. The CFS is implemented on an RS 6000 using the UniTree Mass Storage System. To better meet the science and engineering computing requirements, EADS II must be monitored, its performance analyzed, and appropriate modifications for performance improvement made. Implementing this approach requires tool(s) to assist in performance monitoring and analysis. In Spring 1994, PerfStat 2.0 was purchased to meet these needs for the VPCS and the CFS. PerfStat(2) is a set of tools that can be used to analyze both historical and real-time performance data. Its flexible design allows significant user customization. The user identifies what data is collected, how it is classified, and how it is displayed for evaluation. Both graphical and tabular displays are supported. The capability of the PerfStat tool was evaluated, appropriate modifications to EADS II to optimize throughput and enhance productivity were suggested and implemented, and the effects of these modifications on the systems performance were observed. In this paper, the PerfStat tool is described, then its use with EADS II is outlined briefly. Next, the evaluation of the VPCS, as well as the modifications made to the system are described. Finally, conclusions are drawn and recommendations for future worked are outlined.

Debrunner, Linda S.↗

Application of CFD to the analysis and design of high-speed inlets

Over the past seven years, efforts under the present Grant have been aimed at being able to apply modern Computational Fluid Dynamics to the design of high-speed engine inlets. In this report, a review of previous design capabilities (prior to the advent of functioning CFD) was presented and the example of the NASA 'Mach 5 inlet' design was given as the premier example of the historical approach to inlet design. The philosophy used in the Mach 5 inlet design was carried forward in the present study, in which CFD was used to design a new Mach 10 inlet. An example of an inlet redesign was also shown. These latter efforts were carried out using today's state-of-the-art, full computational fluid dynamics codes applied in an iterative man-in-the-loop technique. The potential usefulness of an automated machine design capability using an optimizer code was also discussed.

Rose, William C.↗

Range Process Simulation Tool

Range Process Simulation Tool (RPST) is a computer program that assists managers in rapidly predicting and quantitatively assessing the operational effects of proposed technological additions to, and/or upgrades of, complex facilities and engineering systems such as the Eastern Test Range. Originally designed for application to space transportation systems, RPST is also suitable for assessing effects of proposed changes in industrial facilities and large organizations. RPST follows a model-based approach that includes finite-capacity schedule analysis and discrete-event process simulation. A component-based, scalable, open architecture makes RPST easily and rapidly tailorable for diverse applications. Specific RPST functions include: (1) definition of analysis objectives and performance metrics; (2) selection of process templates from a processtemplate library; (3) configuration of process models for detailed simulation and schedule analysis; (4) design of operations- analysis experiments; (5) schedule and simulation-based process analysis; and (6) optimization of performance by use of genetic algorithms and simulated annealing. The main benefits afforded by RPST are provision of information that can be used to reduce costs of operation and maintenance, and the capability for affordable, accurate, and reliable prediction and exploration of the consequences of many alternative proposed decisions.

Phillips, Dave↗

Development and Hot-fire Testing of Additively Manufactured Copper Combustion Chambers for Liquid Rocket Engine Applications

NASA and industry partners are working towards fabrication process development to reduce costs and schedules associated with manufacturing liquid rocket engine components with the goal of reducing overall mission costs. One such technique being evaluated is powder-bed fusion or selective laser melting (SLM), commonly referred to as additive manufacturing (AM). The NASA Low Cost Upper Stage Propulsion (LCUSP) program was designed to develop processes and material characterization for GRCop-84 (a NASA Glenn Research Center-developed copper, chrome, niobium alloy) commensurate with powder-bed AM, evaluate bimetallic deposition, and complete testing of a full scale combustion chamber. As part of this development, the process has been transferred to industry partners to enable a long-term supply chain of monolithic copper combustion chambers. To advance the processes further and allow for optimization with multiple materials, NASA is also investigating the feasibility of bimetallic AM chambers. In addition to the LCUSP program, NASA has completed a series of development programs and hot-fire tests to demonstrate SLM GRCop-84 and other AM techniques. NASA's efforts include a 4K lbf thrust liquid oxygen/methane (LOX/CH4) combustion chamber and subscale thrust chambers for 1.2K lbf LOX/hydrogen (H2) applications that have been designed and fabricated with SLM GRCop-84. The same technologies for these lower thrust applications are being applied to 25-35K lbf main combustion chamber (MCC) designs. This paper describes the design, development, manufacturing and testing of these numerous combustion chambers, and the associated lessons learned throughout their design and development processes.

Gradl, Paul R.↗

Scalability in SLA lattice through lattice orientation and hybrid frame and plate architectures

Lightweighting has been a key goal for engineers and designers, with lattice structures widely explored as the building blocks for structural components. Cellular structure-inspired lattice truss frame designs made of struts, have been extensively studied. All plate-based lattice designs have superior mechanical performance. Limits in scalability occur from formation of closed pockets limiting uv curing in processes like stereolithography (SLA). We examine hybrid frame and plate body-centered cubic-simply cubic (BCC-SC) lattices under compression. Unit cells and scaled up lattice exhibit an increase in yield stress and modulus with the addition of plates. The loading direction on the hybrid frame and plate unit cells affected the magnitude of improvement. Simulations and measurements indicated that the optimal lightweight lattice was determined to be when two plates were placed opposite each other with plates buttressing the struts, inhibiting buckling of the struts aligned with the loading direction. This lattice resulted in 63% improvement in specific modulus, a 137% improvement in specific yield point, and a 360% improvement in specific energy absorption (SEA) and the scaled up 4 × 4 × 4 scaled-up structures, showed a 107%, 148%, and 297% in specific modulus, specific yield point, and SEA, respectively A combined stretching-bending behavior was identified in optimal orientations reflecting the delayed buckling mechanism paired to a rising stress-strain curve past the elastic yield indicating bending resistance. The mass moment of inertia was found to be a key parameter correlating optimum orientation for the same number of plates added to the BCC-SC frame.

Mahan Ghosh↗

Evaluating a Web-Based Interface for Internet Telemedicine

The objective is to introduce the usability engineering methodology, heuristic evaluation, to the design and development of a web-based telemedicine system. Using a set of usability criteria, or heuristics, one evaluator examined the Spacebridge to Russia web-site for usability problems. Thirty-four usability problems were found in this preliminary study and all were assigned a severity rating. The value of heuristic analysis in the iterative design of a system is shown because the problems can be fixed before deployment of a system and the problems are of a different nature than those found by actual users of the system. It was therefore determined that there is potential value of heuristic evaluation paired with user testing as a strategy for optimal system performance design.

Lathan, Corinna E.↗

Looking to the Future: A Call to Action for Advanced GNC Algorithm Verification and Validation

Future space systems will rely on autonomous Guidance, Navigation, and Control (GNC) functions to efficiently manage safe and precise self-directed operations in uncertain complex environments. Fundamentally, the GNC system plays a key role in mission performance and safety because it computes the ideal trajectory (Guidance), determines the actual trajectory (Navigation), and executes the ideal trajectory (Control) of a vehicle’s position and attitude. Our current GNC systems are highly automated and already have a high degree of complexity. As missions become more ambitious, GNC systems for launch vehicles and space platforms (e.g., spacecraft, probes, and landers) will require higher levels of performance and autonomous operation than previously encountered, for example, this includes GNC for optimizing aerodynamic and/or propulsion performance during planetary entry. This GNC Verification and Validation (V&V) paper highlights concerns with what undoubtedly will be a trend towards increased complexity as fully autonomous GNC systems are developed for future space missions. Clearly, complex GNC systems pose challenges in the prelaunch V&V phase, which is a relatively expensive part of a mission’s life cycle. Essentially the V&V phase is focused on checking that the system effectively meets all the design and operational requirements for the mission. The authors of this paper (i.e., the Inter-Agency Working Group of GNC subject matter experts) focused on this fundamental question over the past few years: Will the GNC engineering community of practice be sufficiently prepared to perform the necessary V&V on evolving GNC architectures that are driven by very demanding requirements for autonomy, resiliency, reconfigurability, adaptability, and mission cost-benefit balance? It is the viewpoint of our Inter-Agency team that the GNC V&V approaches and processes needed to address the next generation of complex GNC systems, which likely will employ various forms of modern GNC technology, are not currently established to the level the community will need in the future. While researchers and practitioners have made some progress in developing new GNC V&V methods for modern GNC systems, a good deal of work remains to be done to codify such methods in a comprehensive and systematic manner. Thus, the Inter-Agency team’s partner organizations [the National Aeronautics and Space Administration (NASA), the European Space Agency (ESA), the National Centre for Space Studies (CNES), the German Aerospace Center (DLR), the French Aerospace Lab (ONERA), and ISAE-SUPAERO] have conducted preliminary investigations into advancing GNC V&V techniques, which resulted in the identification of the need for education, new V&V tools, and benchmark problems for the GNC community. The necessary proactive steps to be taken to meet the challenges and fill the gaps in GNC V&V are summarized in this paper. The first steps include identifying advanced analysis tools, developing a GNC V&V roadmap, and expanding education and training programs for GNC practitioners. This paper is a call to action and proposes a comprehensive set of recommended actions for all our stakeholders: space agencies, researchers, and industry.

Samir Bennani↗

A COTS-Based Attitude Dependent Contact Scheduling System

The mission architecture of the Gamma-ray Large Area Space Telescope (GLAST) requires a sophisticated ground system component for scheduling the downlink of science data. Contacts between the ````````````````` satellite and the Tracking and Data Relay Satellite System (TDRSS) are restricted by the limited field-of-view of the science data downlink antenna. In addition, contacts must be scheduled when permitted by the satellite s complex and non-repeating attitude profile. Complicating the matter further, the long lead-time required to schedule TDRSS services, combined with the short duration of the downlink contact opportunities, mandates accurate GLAST orbit and attitude modeling. These circumstances require the development of a scheduling system that is capable of predictively and accurately modeling not only the orbital position of GLAST but also its attitude. This paper details the methods used in the design of a Commercial Off The Shelf (COTS)-based attitude-dependent. TDRSS contact Scheduling system that meets the unique scheduling requirements of the GLAST mission, and it suggests a COTS-based scheduling approach to support future missions. The scheduling system applies filtering and smoothing algorithms to telemetered GPS data to produce high-accuracy predictive GLAST orbit ephemerides. Next, bus pointing commands from the GLAST Science Support Center are used to model the complexities of the two dynamic science gathering attitude modes. Attitude-dependent view periods are then generated between GLAST and each of the supporting TDRSs. Numerous scheduling constraints are then applied to account for various mission specific resource limitations. Next, an optimization engine is used to produce an optimized TDRSS contact schedule request which is sent to TDRSS scheduling for confirmation. Lastly, the confirmed TDRSS contact schedule is rectified with an updated ephemeris and adjusted bus pointing commands to produce a final science downlink contact schedule.

DeGumbia, Jonathan D.↗

Portable inference engine: An extended CLIPS for real-time production systems

The present C-Language Integrated Production System (CLIPS) architecture has not been optimized to deal with the constraints of real-time production systems. Matching in CLIPS is based on the Rete Net algorithm, whose assumption of working memory stability might fail to be satisfied in a system subject to real-time dataflow. Further, the CLIPS forward-chaining control mechanism with a predefined conflict resultion strategy may not effectively focus the system's attention on situation-dependent current priorties, or appropriately address different kinds of knowledge which might appear in a given application. Portable Inference Engine (PIE) is a production system architecture based on CLIPS which attempts to create a more general tool while addressing the problems of real-time expert systems. Features of the PIE design include a modular knowledge base, a modified Rete Net algorithm, a bi-directional control strategy, and multiple user-defined conflict resolution strategies. Problems associated with real-time applications are analyzed and an explanation is given for how the PIE architecture addresses these problems.

Le, Thach↗

Effect of model uncertainty on failure detection - The threshold selector

The performance of all failure detection, isolation, and accomodation (DIA) algorithms is influenced by the presence of model uncertainty. A unique framework is presented to incorporate a knowledge of modeling error in the analysis and design of failure detection systems. The tools being used are very similar to those in robust control theory. A concept is introduced called the threshold selector, which is a nonlinear inequality whose solution defines the set of detectable sensor failure signals. The threshold selector represents an innovative tool for analysis and synthesis of DIA algorithms. It identifies the optimal threshold to be used in innovations-based DIA algorithms. The optimal threshold is shown to be a function of the bound on modeling errors, the noise properties, the speed of DIA filters, and the classes of reference and failure signals. The size of the smallest detectable failure is also determined. The results are applied to a multivariable turbofan jet engine example, which demonstrates improvements compared to previous studies.

Emami-Naeini, Abbas↗

Predesign of diamond turned refractive/diffractive elements for IR objectives

Diffractive lenses have arrived. Literally hundreds of papers have been published and technology impact reports have been written about the exciting addition of a new tool for the lens designer. Sophisticated computer programs have been developed to aid in the optimization of these diffractive phase profiles for a wide variety of applications. Now, several fabrication methods are being pursued to produce these diffractive elements economically. The best known process is the etching of a multi-level relief grating, known as binary optics. This process uses sets of computer generated lithographic masks. Another, more recently developed method is Dry Photopolymer Embossing (DPE). This replication process uses master holograms. And now, diamond turning is being applied for the machining of these elements. Diamond turning is especially well suited for infrared optics. As any process has advantages and limitations, so has diamond turning. These advantages and limitations are discussed and general guidelines are presented to aid the designer and systems engineer in the project predesign stage.

Riedl, Max J.↗

Overview of the Orion Vibroacoustic Test Capability at NASA Glenn Research Center

In order to support the environmental test needs for our new Orion and Constellation program, NASA is developing unique world-class test facilities. To optimize this testing of spaceflight hardware while minimizing transportation issues, a one-stop, under one roof test capability is being developed at the Space Power Facility at the NASA Glenn Research Center's Plum Brook Station. This facility will provide the capability to perform the following environmental testing: (1) reverberation acoustic testing, (2) mechanical base-shake sine testing, (3) modal testing, (4) thermal-vacuum testing, and (5) EMI/EMC (electromagnetic interference and compatibility) testing. An overview of this test capability will be provided in this presentation, with special focus on the two new vibroacoustic test facilities currently being designed and built, the Reverberant Acoustic Test Facility (RATF) and the Mechanical Vibration Facility (MVF). Testing of the engineering developmental hardware and qualification hardware of the Orion (Crew Exploration Vehicle) will commence shortly after the facilities are commissioned.

Hughes, William O.↗

Maturation of Additive Manufactured Aerospace Alloys and Development of Mechanical and Thermophysical Properties for Space Applications

The National Aeronautics and Space Administration (NASA) has been involved in the development and maturation of metal additive manufacturing (AM) for space applications since the late 2000’s. Several efforts have focused on the understanding of AM processes through design optimization, component fabrication, material characterization, testing, standards development, and infusion into propulsion development for flight applications. NASA and partners have matured commonly used aerospace alloys from various alloy families (Nickel, Steel, Iron, Aluminum, and Titanium) and AM processes. An extensive effort has been ongoing between NASA, industry partners, and academia to complete detailed AM process and heat treatment characterization, in addition to generating temperature-dependent mechanical and thermophysical properties. This presentation highlights the characterization and property results using laser powder bed fusion (L-PBF) and laser powder directed energy deposition (LP-DED) processes among various alloys. In addition to commonly used alloys, there is a need for ongoing AM optimized alloys using integrated computational materials engineering (ICME) and process development for high performance applications. The applications targeted are launch vehicles, liquid rocket engines, advanced propulsion systems, advanced power systems, and in-space propulsion with high heat fluxes, high pressure, and that utilize propellants such as hydrogen, which can degrade alloys. This presentation will also discuss some of the ongoing novel alloy development and maturation using AM for use in these harsh environments, such as GRCop-42, GRCop-84, NASA HR-1, and C-103. The results from these processes have demonstrated that AM can enable rapid development and new AM optimized alloys can yield higher performance. These alloys have undergone modeling, fundamental metallurgical evaluations, heat treatment studies, and microstructure characterization and mechanical testing campaigns. This, combined with direct application-specific component fabrication and hot-fire testing, can enable the increase of the Technology Readiness Level (TRL) through high duty-cycle testing. This presentation provides a background and overview of these various common and AM-enabled alloys and processing developments including the initial effort related to metallurgical, mechanical, and thermophysical property studies. It also covers the latest advancement in the parallel component development, hot-fire testing, and future developments for these alloys.

Additive Manufacturing↗

Design of Oil-Lubricated Machine for Life and Reliability

In the post-World War II era, the major technology drivers for improving the life, reliability, and performance of rolling-element bearings and gears have been the jet engine and the helicopter. By the late 1950s, most of the materials used for bearings and gears in the aerospace industry had been introduced into use. By the early 1960s, the life of most steels was increased over that experienced in the early 1940s, primarily by the introduction of vacuum degassing and vacuum melting processes in the late 1950s. The development of elastohydrodynamic (EHD) theory showed that most rolling bearings and gears have a thin film separating the contacting bodies during motion and it is that film which affects their lives. Computer programs modeling bearing and gear dynamics that incorporate probabilistic life prediction methods and EHD theory enable optimization of rotating machinery based on life and reliability. With improved manufacturing and processing, the potential improvement in bearing and gear life can be as much as 80 times that attainable in the early 1950s. The work presented summarizes the use of laboratory fatigue data for bearings and gears coupled with probabilistic life prediction and EHD theories to predict the life and reliability of a commercial turboprop gearbox. The resulting predictions are compared with field data.

Zaretsky, Erwin V.↗

Active stability augmentation of large space structures: A stochastic control problem

A problem in SCOLE is that of slewing an offset antenna on a long flexible beam-like truss attached to the space shuttle, with rather stringent pointing accuracy requirements. The relevant methodology aspects in robust feedback-control design for stability augmentation of the beam using on-board sensors is examined. It is framed as a stochastic control problem, boundary control of a distributed parameter system described by partial differential equations. While the framework is mathematical, the emphasis is still on an engineering solution. An abstract mathematical formulation is developed as a nonlinear wave equation in a Hilbert space. That the system is controllable is shown and a feedback control law that is robust in the sense that it does not require quantitative knowledge of system parameters is developed. The stochastic control problem that arises in instrumenting this law using appropriate sensors is treated. Using an engineering first approximation which is valid for small damping, formulas for optimal choice of the control gain are developed.

Balakrishnan, A. V.↗

CIAM/NASA Mach 6.5 Scramjet Flight and Ground Test

The Russian Central Institute of Aviation Motors (CIAM) performed a flight test of a CIAM-designed, hydrogen-cooled/fueled dual-mode scramjet engine over a Mach number range of approximately 3.5 to 6.4 on February 12, 1998, at the Sary Shagan test range in Kazakhstan. This rocket-boosted, captive-carry test of the axisymmetric engine reached the highest Mach number of any scramjet engine flight test to date. The flight test and the accompanying ground test program, conducted in a CIAM test facility near Moscow, were performed under a NASA contract administered by the Dryden Flight Research Center with technical assistance from the Langley Research Center. Analysis of the flight and ground data by both CIAM and NASA resulted in the following preliminary conclusions. An unexpected control sensor reading caused non-optimal fueling of the engine, and flowpath modifications added to the engine inlet during manufacture caused markedly reduced inlet performance. Both of these factors appear to have contributed to the dual-mode scramjet engine operating primarily in a subsonic combustion mode. At the maximum Mach number test point, combustion caused transition from supersonic flow at the fuel injector station to primarily subsonic flow in the combustor. Ground test data were obtained at similar conditions to the flight test, allowing for a meaningful comparison between the ground and flight data. The results of this comparison indicate that the differences in engine performance are small.

Voland, R. T.↗

An Object-oriented Computer Code for Aircraft Engine Weight Estimation

Reliable engine-weight estimation at the conceptual design stage is critical to the development of new aircraft engines. It helps to identify the best engine concept amongst several candidates. At NASA Glenn (GRC), the Weight Analysis of Turbine Engines (WATE) computer code, originally developed by Boeing Aircraft, has been used to estimate the engine weight of various conceptual engine designs. The code, written in FORTRAN, was originally developed for NASA in 1979. Since then, substantial improvements have been made to the code to improve the weight calculations for most of the engine components. Most recently, to improve the maintainability and extensibility of WATE, the FORTRAN code has been converted into an object-oriented version. The conversion was done within the NASA s NPSS (Numerical Propulsion System Simulation) framework. This enables WATE to interact seamlessly with the thermodynamic cycle model which provides component flow data such as airflows, temperatures, and pressures, etc. that are required for sizing the components and weight calculations. The tighter integration between the NPSS and WATE would greatly enhance system-level analysis and optimization capabilities. It also would facilitate the enhancement of the WATE code for next-generation aircraft and space propulsion systems. In this paper, the architecture of the object-oriented WATE code (or WATE++) is described. Both the FORTRAN and object-oriented versions of the code are employed to compute the dimensions and weight of a 300- passenger aircraft engine (GE90 class). Both versions of the code produce essentially identical results as should be the case. Keywords: NASA, aircraft engine, weight, object-oriented

Tong, Michael T.↗