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NASTRAN and COPES/CONMIN were used in the early-stage design optimization of a propeller and shaft. The work was undertaken, in part, to assess the performance of these programs for such a task. While the optimization was successful, some drawbacks to the approach surfaced and are discussed.
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.
The design, development, and optimization of the thin film filters used on the Extreme Ultraviolet Explorer (EUVE) Satellite to define the EUV wavelength bandpasses of the individual instruments was a complicated task. The bandpasses had to be optimized for the astrophysical goals of the EUVE mission and constrained by the strong geocoronal EUV background emission. Materials with optical constants that met these requirements had to be found and tested. In many cases these materials were not compatible or were not strong enough to survive the intense vibrations of a rocket launch. Other effects, such as photoelectron 'halo' produced in the filters, were not discovered until flight qualification. The final set of flight filters included: lexan/boron, aluminum/carbon, titanium/antimony/aluminum, and tin/silicon monoxide. This paper discusses the lessons learned in the development of these filters, including the optimization process, material interactions and problems, calibration techniques, vibration susceptibility, thermal tests, and photoelectron emission. We feel the experiences gained over the last 10 years creating the filter sets for EUVE will be invaluable for future missions that use thin film filters.
The General Aviation Element of the Aviation Safety Program's Synthetic Vision Systems (SVS) Project is developing technology to eliminate low visibility induced General Aviation (GA) accidents. SVS displays present computer generated 3-dimensional imagery of the surrounding terrain on the Primary Flight Display (PFD) to greatly enhance pilot's situation awareness (SA), reducing or eliminating Controlled Flight into Terrain, as well as Low-Visibility Loss of Control accidents. SVS-conducted research is facilitating development of display concepts that provide the pilot with an unobstructed view of the outside terrain, regardless of weather conditions and time of day. A critical component of SVS displays is the appropriate presentation of terrain to the pilot. An experimental study is being conducted at NASA Langley Research Center (LaRC) to explore and quantify the relationship between the realism of the terrain presentation and resulting enhancements of pilot SA and performance. Composed of complementary simulation and flight test efforts, Terrain Portrayal for Head-Down Displays (TP-HDD) experiments will help researchers evaluate critical terrain portrayal concepts. The experimental effort is to provide data to enable design trades that optimize SVS applications, as well as develop requirements and recommendations to facilitate the certification process. In this part of the experiment a fixed based flight simulator was equipped with various types of Head Down flight displays, ranging from conventional round dials (typical of most GA aircraft) to glass cockpit style PFD's. The variations of the PFD included an assortment of texturing and Digital Elevation Model (DEM) resolution combinations. A test matrix of 10 terrain display configurations (in addition to the baseline displays) were evaluated by 27 pilots of various backgrounds and experience levels. Qualitative (questionnaires) and quantitative (pilot performance and physiological) data were collected during the experimental runs. This paper focuses on the experimental set-up and final physiological results of the TP-HDD simulation experiment. The physiological measures of skin temperature, heart rate, and muscle response, show a decreased engagement (while using the synthetic vision displays as compared to the baseline conventional display) of the sympathetic and somatic nervous system responses which, in turn, indicates a reduced level of mental workload. This decreased level of workload is expected to enable improvement in the pilot's situation and terrain awareness.
Spacecraft configurations, life support systems, attitude control, and optimization of spacecraft design and instrumentation for orbiting primate spacecraft
Optimization for zero gravity experiment on solution growth of gallium arsenide and design of experiment package for melt growth of indium antimonide crystals
An optimization method for flush-orifice air data system design has been developed using the Genetic Algorithm approach. The optimization of the orifice array minimizes the effect of normally distributed random noise in the pressure readings on the calculation of air data parameters, namely, angle of attack, sideslip angle and freestream dynamic pressure. The optimization method is applied to the design of Pressure Distribution/Air Data System experiment (PD/ADS) proposed for inclusion in the Aeroassist Flight Experiment (AFE). Results obtained by the Genetic Algorithm method are compared to the results obtained by conventional gradient search method.
A need exists for understanding precisely how particles move and interact in a fluid in the absence of gravity. Such understanding is required, for example, for modeling and predicting crystal growth in space where crystals grow from solution around nucleation sites as well as for any study of particles or bubbles in liquids or in experiments where particles are used as tracers for mapping microconvection. We have produced an exact solution to the general equation of motion of particles at extremely low Reynolds number in microgravity that covers a wide range of interesting conditions. We have also developed diagnostic tools and experimental techniques to test the validity of the general equation . This program, which started in May, 1998, will produce the flight definition for an experiment in a microgravity environment of space to validate the theoretical model. We will design an experiment with the help of the theoretical model that is optimized for testing the model, measuring g, g-jitter, and other microgravity phenomena. This paper describes the goals, rational, and approach for the flight definition program. The first objective of this research is to understand the physics of particle interactions with fluids and other particles in low Reynolds number flows in microgravity. Secondary objectives are to (1) observe and quantify g-jitter effects and microconvection on particles in fluids, (2) validate an exact solution to the general equation of motion of a particle in a fluid, and (3) to characterize the ability of isolation tables to isolate experiments containing particle in liquids. The objectives will be achieved by recording a large number of holograms of particle fields in microgravity under controlled conditions, extracting the precise three-dimensional position of all of the particles as a function of time and examining the effects of all parameters on the motion of the particles. The feasibility for achieving these results has already been established in the ongoing ground-based NRA, which led to the "virtual spaceflight chamber" concept.
The movement of a particle in a fluid is one of the most fundamental processes in physics and plays an important role in materials science. For example, the physics of crystal growth from a nucleation site in solution can be dominated by movement of the solution over the crystal surface. Gravity usually dominates the equations of motion, but in microgravity other terms can dominate, making the equation much more complex. Until recently, the equations were solved only by numerical methods and/or by neglecting terms. During this study, we discovered an exact solution to the equations, which shows that the usually neglected terms become extremely important in microgravity. We also developed diagnostic recording methods using holography to save all of the particle field data, allowing the experiment to essentially be transferred from space back to earth in what we call the virtual apparatus . We will record holograms of particle distributions in motion in microgravity and bring them back to earth for analysis, allowing the study of the full three-dimensional motion of sets of particles, allowing us to test the new analytical solutions. The experiment will also provide accurate measurements of the quasi-steady acceleration of the space platform and other interesting microgravity and g-jitter effects. This program will produce the flight definition for an experiment in the microgravity environment of space to validate the theoretical model. We will design an experiment with the help of the theoretical model that is optimized for testing the model, measuring g, g-jitter, and other microgravity phenomena.
In support of the Blended-Wing-Body aircraft concept, a new flow control hybrid vane/jet design has been developed for use in a boundary-layer-ingesting (BLI) offset inlet in transonic flows. This inlet flow control is designed to minimize the engine fan-face distortion levels and the first five Fourier harmonic half amplitudes while maximizing the inlet pressure recovery. This concept represents a potentially enabling technology for quieter and more environmentally friendly transport aircraft. An optimum vane design was found by minimizing the engine fan-face distortion, DC60, and the first five Fourier harmonic half amplitudes, while maximizing the total pressure recovery. The optimal vane design was then used in a BLI inlet wind tunnel experiment at NASA Langley's 0.3-meter transonic cryogenic tunnel. The experimental results demonstrated an 80-percent decrease in DPCPavg, the reduction in the circumferential distortion levels, at an inlet mass flow rate corresponding to the middle of the operational range at the cruise condition. Even though the vanes were designed at a single inlet mass flow rate, they performed very well over the entire inlet mass flow range tested in the wind tunnel experiment with the addition of a small amount of jet flow control. While the circumferential distortion was decreased, the radial distortion on the outer rings at the aerodynamic interface plane (AIP) increased. This was a result of the large boundary layer being distributed from the bottom of the AIP in the baseline case to the outer edges of the AIP when using the vortex generator (VG) vane flow control. Experimental results, as already mentioned, showed an 80-percent reduction of DPCPavg, the circumferential distortion level at the engine fan-face. The hybrid approach leverages strengths of vane and jet flow control devices, increasing inlet performance over a broader operational range with significant reduction in mass flow requirements. Minimal distortion level requirements are met using vanes alone, avoiding engine stall and increasing robustness of this hybrid inlet flow control approach. This design applies to aerospace applications needing flush-mounted boundary-layer-ingesting inlets.
NASA HR-1 is a Fe-Ni-Cr alloy that is used for high pressure hydrogen applications such as rocket engines, energy, and oil and gas. This investigation was focused on conducting a design of experiment program aimed at mapping the parameter process window for NASA HR-1 using the laser blown powder directed energy deposition (LP-DED) process. A two phased design of experiments (DOE), the first phase of the experiment was focused on optimizing single bead tracks while the second phase of the experiment was focused on optimizing bead overlap hatching in a multi pass bead build up. During the first phase of the deposition parameters, namely laser power, travel speed, and powder feed rate were varied. A down selection from the single bead parameter set was made and hatching experiments were conducted that focused on the overlap distance. In this paper the approach for conducting the DOE and results are discussed. The results focused on measurement of bead geometry, the as-built microstructural evolution, and porosity within the samples. The team at MSFC saw a variety of results across the process map created during the first phase of experimentation and were able to down select a parameter that created an optimal bead shape with a minimal amount of build porosity. It was determined that laser power and robot travel speed were the most sensitive parameters. The results from this investigation will inform future laser powder directed energy deposition parameter developments.
The Space Life Sciences division (SLSD) concentrates on optimizing a crew member's health. Developments are translated into innovative engineering solutions, research growth, and community awareness. This internship incorporates all those areas by targeting various projects. The main project focuses on integrating clinical and biomedical engineering principles to design, develop, and test new medical kits scheduled for launch in the Spring of 2011. Additionally, items will be tagged with Radio Frequency Interference Devices (RFID) to keep track of the inventory. The tags will then be tested to optimize Radio Frequency feed and feed placement. Research growth will occur with ground based experiments designed to measure calcium encrusted deposits in the International Space Station (ISS). The tests will assess the urine calcium levels with Portable Clinical Blood Analyzer (PCBA) technology. If effective then a model for urine calcium will be developed and expanded to microgravity environments. To support collaboration amongst the subdivisions of SLSD the architecture of the Crew Healthcare Systems (CHeCS) SharePoint site has been redesigned for maximum efficiency. Community collaboration has also been established with the University of Southern California, Dept. of Aeronautical Engineering and the Food and Drug Administration (FDA). Hardware disbursements will transpire within these communities to support planetary surface exploration and to serve as an educational tool demonstrating how ground based medicine influenced the technological development of space hardware.
The work that has been done in the last decade or so in the application of optimization techniques to vehicle design is discussed. Much of the work reviewed deals with the design of body or suspension (chassis) components for reduced weight. Also reviewed are studies dealing with system optimization problems for improved functional performance, such as ride or handling. In reviewing the work on the use of optimization techniques, one notes the transition from the rare mention of the methods in the 70's to an increased effort in the early 80's. Efficient and convenient optimization and analysis tools still need to be developed so that they can be regularly applied in the early design stage of the vehicle development cycle to be most effective. Based on the reported applications, an attempt is made to assess the potential for automotive application of optimization techniques. The major issue involved remains the creation of quantifiable means of analysis to be used in vehicle design. The conventional process of vehicle design still contains much experience-based input because it has not yet proven possible to quantify all important constraints. This restraint on the part of the analysis will continue to be a major limiting factor in application of optimization to vehicle design.
The quality engineering methods of Dr. Genichi Taguchi, employing design of experiments, are important statistical tools for designing high quality systems at reduced cost. The Taguchi method was utilized to study several simultaneous parameter level variations of a lunar aerobrake structure to arrive at the lightest weight configuration. Finite element analysis was used to analyze the unique experimental aerobrake configurations selected by Taguchi method. Important design parameters affecting weight and global buckling were identified and the lowest weight design configuration was selected.
Aerospace vehicle structures must be optimized for mass to maximize the mission payload. During the conceptual design phase, structures must be optimized to accurately predict the mass of the design. Analysis methods that are used in sizing members should allow for the selection of a variety of metallic and composite materials and user-defined geometry constraints. Rapid vehicle structural analysis is often necessary to improve the fidelity and the results that are obtained during the preliminary design. Recent experiences are highlighted that utilize the Collier Research Corporation's Hypersizer toolset to optimize structural concepts.
An oxidizer-swirled coaxial element injector is being investigated for application in the Space Transportation Main Engine (STME). Single element cold flow experiments were conducted to provide characterization of the STME injector element for future analysis, design, and optimization. All tests were conducted to quiescent, ambient backpressure conditions. Spray angle, circumferential spray uniformity, dropsize, and dropsize distribution were measured in water-only and water/nitrogen flows. Rupe mixing efficiency was measured using water/sucrose solution flows with a large grid patternator for simple comparative evaluation of mixing. Factorial designs of experiment were used for statistical evaluation of injector geometrical design features and propellant flow conditions on mixing and atomization. Increasing the free swirl angle of the liquid oxidizer had the greatest influence on increasing the mixing efficiency. The addition of gas assistance had the most significant effect on reducing oxidizer droplet size parameters and increasing droplet size distribution. Increasing the oxidizer injection velocity had the greatest influence for reducing oxidizer droplet size parameters and increasing size distribution for non-gas assisted flows. Single element and multi-element subscale hot fire testing are recommended to verify optimized designs before committing to the STME design.
Several current rocket engine concepts such as the bell-annular tri-propellant engine, and the linear aerospike being proposed for the X-33 require unconventional three dimensional rocket nozzles which must conform to rectangular or sector shaped envelopes to meet integration constraints. These types of nozzles exist outside the current experience database, therefore, the application of efficient design methods for these propulsion concepts is critical to the success of launch vehicle programs. The objective of this work is to optimize several different nozzle configurations, including two- and three-dimensional geometries. Methodology includes coupling computational fluid dynamic (CFD) analysis to genetic algorithms and Taguchi methods as well as implementation of a streamline tracing technique. Results of applications are shown for several geometeries including: three dimensional thruster nozzles with round or super elliptic throats and rectangualar exits, two- and three-dimensional thrusters installed within a bell nozzle, and three dimensional thrusters with round throats and sector shaped exits. Due to the novel designs considered for this study, there is little experience which can be used to guide the effort and limit the design space. With a nearly infinite parameter space to explore, simple parametric design studies cannot possibly search the entire design space within the time frame required to impact the design cycle. For this reason, robust and efficient optimization methods are required to explore and exploit the design space to achieve high performance engine designs. Five case studies which examine the application of various techniques in the engineering environment are presented in this paper.
A peak-seeking control algorithm for real-time trim optimization for reduced fuel consumption has been developed by researchers at the National Aeronautics and Space Administration (NASA) Dryden Flight Research Center to address the goals of the NASA Environmentally Responsible Aviation project to reduce fuel burn and emissions. The peak-seeking control algorithm is based on a steepest-descent algorithm using a time-varying Kalman filter to estimate the gradient of a performance function of fuel flow versus control surface positions. In real-time operation, deflections of symmetric ailerons, trailing-edge flaps, and leading-edge flaps of an F/A-18 airplane are used for optimization of fuel flow. Results from six research flights are presented herein. The optimization algorithm found a trim configuration that required approximately 3 percent less fuel flow than the baseline trim at the same flight condition. This presentation also focuses on the design of the flight experiment and the practical challenges of conducting the experiment.