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NASA NTRSDate not supplied

Integration of Design Data Into Automated Fiber Placement Process Planning Metrics

With the ever-expanding aviation industry, a need is arising for more rapid production of composite aircraft to meet increasing demand. State-of-the-art aircraft such as the Boeing 787showcase 50% composite material usage by weight, highlighting this emerging industry-wide adoption of the material system. Currently, many of the large structures associated with these aircraft are manufactured additively via Automated Fiber Placement (AFP). The AFP process shows great potential for efficient manufacturing, however unavoidable defects still occur because of tool surface geometry, placement errors, or poor process planning, resulting in decreased quality and throughput. Due to such effects, it is critical to incorporate design for manufacturing (DFM) principles to achieve the optimal manufacturing plan and resulting structure. This work will develop a methodology for incorporating design information into process planning metrics in an automated fashion to achieve an optimal set of process inputs.The analysis incorporates HyperX, Computer Aided Process Planning (CAPP) and Vericut Composite Programming (VCP). Safety margins from HyperX are imported into CAPP where AFP defects are mapped to the values. The resulting margins are then incorporated into the CAPP manufacturability algorithms, creating a design informed process planning analysis

Automated Fiber Placement↗

NASA NTRS2009

Investigating Liquid CO2 as a Coolant for a MTSA Heat Exchanger Design

Metabolic heat regenerated Temperature Swing Adsorption (MTSA) technology is being developed for thermal and carbon dioxide (CO 2) control for a future Portable Life Support System (PLSS), as well as water recycling. CO 2 removal and rejection is accomplished by driving a sorbent through a temperature swing of approximately 210 K to 280 K . The sorbent is cooled to these sub-freezing temperatures by a Sublimating Heat Exchanger (SHX) with liquid coolant expanded to sublimation temperatures. Water is the baseline coolant available on the moon, and if used, provides a competitive solution to the current baseline PLSS schematic. Liquid CO2 (LCO2) is another non-cryogenic coolant readily available from Martian resources which can be produced and stored using relatively low power and minimal infrastructure. LCO 2 expands from high pressure liquid (~5800 kPa) to Mars ambient (0.8 kPa) to produce a gas / solid mixture at temperatures as low as 156 K. Analysis and experimental work are presented to investigate factors that drive the design of a heat exchanger to effectively use this sink. Emphasis is given to enabling efficient use of the CO 2 cooling potential and mitigation of heat exchanger clogging due to solid formation. Minimizing mass and size as well as coolant delivery are also considered. The analysis and experimental work is specifically performed in an MTSA-like application to enable higher fidelity modeling for future optimization of a SHX design. In doing so, the work also demonstrates principles and concepts so that the design can be further optimized later in integrated applications (including Lunar application where water might be a choice of coolant).

Paul, Heather L.↗

NASA NTRS1973

Aircraft maneuver optimization of reduced-order approximation

Review of recent work in recasting the energy type of approximation to aircraft flight in terms of singular perturbation theory and in extending this theory to three-dimensional maneuvers. Singular perturbations for differential equations arising in optimal control are first examined for a system of fairly general form but low order. The attitude dynamics for optimal flight of a rocket in vacuum is then studied as an introductory, and fairly transparent, example. The question of the choice of variables is then discussed. Finally, optimal aircraft flight in various reduced-order approximations is investigated. In particular, the problem of three-dimensional aircraft flight is formulated for singular perturbation treatment, and possibilities for decoupling into several lower-order problems are illustrated. The use of reduced-order approximation facilitates numerical computations by reducing the number of multiplier initial values that must be determined simultaneously and by improving the conditioning of the differential equations.

Kelley, H. J.↗

NASA NTRS1995

Application of response surface techniques to helicopter rotor blade optimization procedure

In multidisciplinary optimization problems, response surface techniques can be used to replace the complex analyses that define the objective function and/or constraints with simple functions, typically polynomials. In this work a response surface is applied to the design optimization of a helicopter rotor blade. In previous work, this problem has been formulated with a multilevel approach. Here, the response surface takes advantage of this decomposition and is used to replace the lower level, a structural optimization of the blade. Problems that were encountered and important considerations in applying the response surface are discussed. Preliminary results are also presented that illustrate the benefits of using the response surface.

Henderson, Joseph Lynn↗

NASA NTRSDate not supplied

Advanced Supersonic Parachute Inflation Research Experiment 2 (ASPIRE2) Flight Mechanics and Parachute Performance

The Advanced Supersonic Parachute Inflation Re-search Experiment-2 (ASPIRE2) program consists of a sounding rocket flight test to be launched at Wallops Flight Facility (WFF) in 2025. This effort seeks to qualify the supersonic parachute for the Sample Retrieval Lander (SRL) under the Mars Sample Return (MSR) program, building off the successes of its predecessor program, ASPIRE, which launched in both 2017 and 2018. The conops for the ASPIRE2 mission are shown in Figure 1 relative to its predecessor. While the ASPIRE pro-gram qualified a 21.5 m diameter disk-gap band parachute deployed at Mach 1.7, the SRL parachute will be increased to 24 m in diameter and target a Mach 2.1 parachute deployment condition, the largest diameter supersonic parachute deployed at the highest Mach number to date. These requirements are driven by the increased landing mass of the sample retrieval lander, which is roughly a 50% increase over that of the Mars2020 entry vehicle. These changes necessitate ASPIRE2 to certify the parachute performance under similar deployment conditions. This work will cover the 6-DoF para-chute model implementation and flight mechanics performance for the ASPIRE2 campaign and discuss how these results will impact the design of the test article. The ASPIRE2 trajectory is simulated using a multi-body flight dynamics tool, Program to Optimize Simulated Trajectories II (POST2). This work will summarize both the flight mechanics and parachute modeling (from payload separation until splashdown) and performance for this mission. Various design trades will be assessed such as para-chute tuning parameters as well as vehicle center of gravity location.

Evan Roelke↗

NASA NTRS1997

Design, Modeling and Performance Optimization of a Novel Rotary Piezoelectric Motor

This work has demonstrated a proof of concept for a torsional inchworm type motor. The prototype motor has shown that piezoelectric stack actuators can be used for rotary inchworm motor. The discrete linear motion of piezoelectric stacks can be converted into rotary stepping motion. The stacks with its high force and displacement output are suitable actuators for use in piezoelectric motor. The designed motor is capable of delivering high torque and speed. Critical issues involving the design and operation of piezoelectric motors were studied. The tolerance between the contact shoes and the rotor has proved to be very critical to the performance of the motor. Based on the prototype motor, a waveform optimization scheme was proposed and implemented to improve the performance of the motor. The motor was successfully modeled in MATLAB. The model closely represents the behavior of the prototype motor. Using the motor model, the input waveforms were successfully optimized to improve the performance of the motor in term of speed, torque, power and precision. These optimized waveforms drastically improve the speed of the motor at different frequencies and loading conditions experimentally. The optimized waveforms also increase the level of precision of the motor. The use of the optimized waveform is a break-away from the traditional use of sinusoidal and square waves as the driving signals. This waveform optimization scheme can be applied to any inchworm motors to improve their performance. The prototype motor in this dissertation as a proof of concept was designed to be robust and large. Future motor can be designed much smaller and more efficient with lessons learned from the prototype motor.

Duong, Khanh A.↗

NASA NTRS1990

Large scale nonlinear numerical optimal control for finite element models of flexible structures

This paper discusses the development of large scale numerical optimal control algorithms for nonlinear systems and their application to finite element models of structures. This work is based on our expansion of the optimal control algorithm (DDP) in the following steps: improvement of convergence for initial policies in non-convex regions, development of a numerically accurate penalty function method approach for constrained DDP problems, and parallel processing on supercomputers. The expanded constrained DDP algorithm was applied to the control of a four-bay, two dimensional truss with 12 soft members, which generates geometric nonlinearities. Using an explicit finite element model to describe the structural system requires 32 state variables and 10,000 time steps. Our numerical results indicate that for constrained or unconstrained structural problems with nonlinear dynamics, the results obtained by our expanded constrained DDP are significantly better than those obtained using linear-quadratic feedback control.

Shoemaker, Christine A.↗

NASA NTRS2010

ACT Payload Shroud Structural Concept Analysis and Optimization

Aerospace structural applications demand a weight efficient design to perform in a cost effective manner. This is particularly true for launch vehicle structures, where weight is the dominant design driver. The design process typically requires many iterations to ensure that a satisfactory minimum weight has been obtained. Although metallic structures can be weight efficient, composite structures can provide additional weight savings due to their lower density and additional design flexibility. This work presents structural analysis and weight optimization of a composite payload shroud for NASA s Ares V heavy lift vehicle. Two concepts, which were previously determined to be efficient for such a structure are evaluated: a hat stiffened/corrugated panel and a fiber reinforced foam sandwich panel. A composite structural optimization code, HyperSizer, is used to optimize the panel geometry, composite material ply orientations, and sandwich core material. HyperSizer enables an efficient evaluation of thousands of potential designs versus multiple strength and stability-based failure criteria across multiple load cases. HyperSizer sizing process uses a global finite element model to obtain element forces, which are statistically processed to arrive at panel-level design-to loads. These loads are then used to analyze each candidate panel design. A near optimum design is selected as the one with the lowest weight that also provides all positive margins of safety. The stiffness of each newly sized panel or beam component is taken into account in the subsequent finite element analysis. Iteration of analysis/optimization is performed to ensure a converged design. Sizing results for the hat stiffened panel concept and the fiber reinforced foam sandwich concept are presented.

Zalewski, Bart B.↗

NASA NTRS1998

Weather Avoidance Using Route Optimization as a Decision Aid: An AWIN Topical Study

The aviation community is faced with reducing the fatal aircraft accident rate by 80 percent within 10 years. This must be achieved even with ever increasing, traffic and a changing National Airspace System. This is not just an altruistic goal, but a real necessity, if our growing level of commerce is to continue. Honeywell Technology Center's topical study, "Weather Avoidance Using Route Optimization as a Decision Aid", addresses these pressing needs. The goal of this program is to use route optimization and user interface technologies to develop a prototype decision aid for dispatchers and pilots. This decision aid will suggest possible diversions through single or multiple weather hazards and present weather information with a human-centered design. At the conclusion of the program, we will have a laptop prototype decision aid that will be used to demonstrate concepts to industry for integration into commercialized products for dispatchers and/or pilots. With weather a factor in 30% of aircraft accidents, our program will prevent accidents by strategically avoiding weather hazards in flight. By supplying more relevant weather information in a human-centered format along with the tools to generate flight plans around weather, aircraft exposure to weather hazards can be reduced. Our program directly addresses the NASA's five year investment areas of Strategic Weather Information and Weather Operations (simulation/hazard characterization and crew/dispatch/ATChazard monitoring, display, and decision support) (NASA Aeronautics Safety Investment Strategy: Weather Investment Recommendations, April 15, 1997). This program is comprised of two phases, Phase I concluded December 31, 1998. This first phase defined weather data requirements, lateral routing algorithms, an conceptual displays for a user-centered design. Phase II runs from January 1999 through September 1999. The second phase integrates vertical routing into the lateral optimizer and combines the user interface into a prototype software testbed. Phase II concludes with a dispatcher and pilot evaluation of the route optimizer decision aid. This document describes work completed in Phase I in contract with NASA Langley August 1998 - December 1998. This report includes: (1) Discuss how weather hazards were identified in partnership with experts, and how weather hazards were prioritized; (2) Static representations of display layouts for integrated planning function (3) Cost function for the 2D route optimizer; (4) Discussion of the method for obtaining, access to raw data of, and the results of the flight deck user information requirements definition; (5) Itemized display format requirements identified for representing weather hazards in a route planning aid.

Source record↗

NASA NTRS1995

The use of optimal polarizations for studying the microphysics of precipitation: Nonattenuating wavelengths

The objective of this work is to explore relationships between the microphysical properties of precipitation and optimal polarizations. The dependence of three optimal polarization parameters (asymmetry ratio A, optimal tilt tau(sub op), and optimal ellipticity epsilon(sub op) on the reflectivity-weighted mean drop shape, mean canting angle, and standard deviation of a Gaussian canting angle distribution is studied. This is accomplished by using computer simulations that provide the rms scattering matrix for an ensemble of canted drops with a prescribed two-parameter canting angle distribution. Also examined are the effects of propagation on the polarization parameters for nonattenuating wavelengths. The asymmetry ratio A is simply the ratio of the maximal to minimal total backscattered energy (ratio of the largest and smallest eigenvalue of the Graves power matrix G is identically equal to S dagger S). Similar to Z(sub DR), this ratio decreases with increasing mean axial ratio, but unlike Z(sub DR), it is not affected by canting (for a single drop). The dependence of A on the reflectivity-weighted mean drop shape is examined, and a power-law relationship similar to that which exists for Z(sub DR) is established. The asymmetry ratio A can be regarded as a generalization of Z(sub DR) because it requires only a measurement of linear depolarization ratio (in addition to Z(sub DR)), is independent of the propagation phase, and is less sensitive to canting. In a similar manner, the dependence of optimal ellipticity and tilt on the microphysical parameters is studied. In particular, it appears that the rms tilt of the optimal polarization ellipse is proportional to the variance of the canting angle distribution. Several other promising relationships between optimal polarizations and the microphysical variables of an ensemble of hydrometeors are also discussed.

Kwiatkowski, John M.↗

NASA NTRS2004

Performance and Reliability Optimization for Aerospace Systems subject to Uncertainty and Degradation

This report summarizes work performed by the Space Systems Laboratory (SSL) for NASA Langley Research Center in the field of performance optimization for systems subject to uncertainty. The objective of the research is to develop design methods and tools to the aerospace vehicle design process which take into account lifecycle uncertainties. It recognizes that uncertainty between the predictions of integrated models and data collected from the system in its operational environment is unavoidable. Given the presence of uncertainty, the goal of this work is to develop means of identifying critical sources of uncertainty, and to combine these with the analytical tools used with integrated modeling. In this manner, system uncertainty analysis becomes part of the design process, and can motivate redesign. The specific program objectives were: 1. To incorporate uncertainty modeling, propagation and analysis into the integrated (controls, structures, payloads, disturbances, etc.) design process to derive the error bars associated with performance predictions. 2. To apply modern optimization tools to guide in the expenditure of funds in a way that most cost-effectively improves the lifecycle productivity of the system by enhancing the subsystem reliability and redundancy. The results from the second program objective are described. This report describes the work and results for the first objective: uncertainty modeling, propagation, and synthesis with integrated modeling.

Miller, David W.↗

NASA NTRS1993

Trajectory optimization for the National Aerospace Plane

The objective of this second phase research is to investigate the optimal ascent trajectory for the National Aerospace Plane (NASP) from runway take-off to orbital insertion and address the unique problems associated with the hypersonic flight trajectory optimization. The trajectory optimization problem for an aerospace plane is a highly challenging problem because of the complexity involved. Previous work has been successful in obtaining sub-optimal trajectories by using energy-state approximation and time-scale decomposition techniques. But it is known that the energy-state approximation is not valid in certain portions of the trajectory. This research aims at employing full dynamics of the aerospace plane and emphasizing direct trajectory optimization methods. The major accomplishments of this research include the first-time development of an inverse dynamics approach in trajectory optimization which enables us to generate optimal trajectories for the aerospace plane efficiently and reliably, and general analytical solutions to constrained hypersonic trajectories that has wide application in trajectory optimization as well as in guidance and flight dynamics. Optimal trajectories in abort landing and ascent augmented with rocket propulsion and thrust vectoring control were also investigated. Motivated by this study, a new global trajectory optimization tool using continuous simulated annealing and a nonlinear predictive feedback guidance law have been under investigation and some promising results have been obtained, which may well lead to more significant development and application in the near future.

Lu, Ping↗

NASA NTRS2015

Evaluation of Carbon Composite Overwrap Pressure Vessels Fabricated Using Ionic Liquid Epoxies Project

The intent of the work proposed here is to ascertain the viability of ionic liquid (IL) epoxy based carbon fiber composites for use as storage tanks at cryogenic temperatures. This IL epoxy has been specifically developed to address composite cryogenic tank challenges associated with achieving NASA's in-space propulsion and exploration goals. Our initial work showed that an unadulterated ionic liquid (IL) carbon-fiber composite exhibited improved properties over an optimized commercial product at cryogenic temperatures. Subsequent investigative work has significantly improved the IL epoxy and our first carbon-fiber Composite Overwrap Pressure Vessel (COPV) was successfully fabricated. Here additional COPVs, using a further improved IL epoxy, will be fabricated and pressure tested at cryogenic temperatures with the results rigorously analyzed. Investigation of the IL composite for lower pressure liner-less cryogenic tank applications will also be initiated. It is expected that the current Technology Readiness Level (TRL) will be raised from about TRL 3 to TRL 5 where unambiguous predictions for subsequent development/testing can be made.

Grugel, Richard↗

NASA NTRS2013

Analysis-Driven Design Optimization of a SMA-Based Slat-Cove Filler for Aeroacoustic Noise Reduction

Airframe noise is a significant component of environmental noise in the vicinity of airports. The noise associated with the leading-edge slat of typical transport aircraft is a prominent source of airframe noise. Previous work suggests that a slat-cove filler (SCF) may be an effective noise treatment. Hence, development and optimization of a practical slat-cove-filler structure is a priority. The objectives of this work are to optimize the design of a functioning SCF which incorporates superelastic shape memory alloy (SMA) materials as flexures that permit the deformations involved in the configuration change. The goal of the optimization is to minimize the actuation force needed to retract the slat-SCF assembly while satisfying constraints on the maximum SMA stress and on the SCF deflection under static aerodynamic pressure loads, while also satisfying the condition that the SCF self-deploy during slat extension. A finite element analysis model based on a physical bench-top model is created in Abaqus such that automated iterative analysis of the design could be performed. In order to achieve an optimized design, several design variables associated with the current SCF configuration are considered, such as the thicknesses of SMA flexures and the dimensions of various components, SMA and conventional. Designs of experiment (DOE) are performed to investigate structural response to an aerodynamic pressure load and to slat retraction and deployment. DOE results are then used to inform the optimization process, which determines a design minimizing actuator forces while satisfying the required constraints.

Scholten, William↗

NASA NTRS1984

Overview: Applications of numerical optimization methods to helicopter design problems

There are a number of helicopter design problems that are well suited to applications of numerical design optimization techniques. Adequate implementation of this technology will provide high pay-offs. There are a number of numerical optimization programs available, and there are many excellent response/performance analysis programs developed or being developed. But integration of these programs in a form that is usable in the design phase should be recognized as important. It is also necessary to attract the attention of engineers engaged in the development of analysis capabilities and to make them aware that analysis capabilities are much more powerful if integrated into design oriented codes. Frequently, the shortcoming of analysis capabilities are revealed by coupling them with an optimization code. Most of the published work has addressed problems in preliminary system design, rotor system/blade design or airframe design. Very few published results were found in acoustics, aerodynamics and control system design. Currently major efforts are focused on vibration reduction, and aerodynamics/acoustics applications appear to be growing fast. The development of a computer program system to integrate the multiple disciplines required in helicopter design with numerical optimization technique is needed. Activities in Britain, Germany and Poland are identified, but no published results from France, Italy, the USSR or Japan were found.

Miura, H.↗

NASA NTRS1983

Optimization of aircraft seat cushion fire blocking layers

This report describes work completed by the National Aeronautics and Space Administration - for the Federal Aviation Administration Technical Center. The purpose of this work was to examine the potential of fire blocking mechanisms for aircraft seat cushions in order to provide an optimized seat configuration with adequate fire protection and minimum weight. Aluminized thermally stable fabrics were found to provide adequate fire protection when used in conjunction with urethane foams, while maintaining minimum weight and cost penalty.

Kourtides, D. A.↗

NASA NTRS1995

Methodologies to determine forces on bones and muscles of body segments during exercise, employing compact sensors suitable for use in crowded space vehicles

Work under this grant was carried out by the author and by a graduate research assistant. An instrumented bicycle ergometer was implemented focusing on the stated objective: to estimate the forces exerted by each muscle of the feet, calf, and thigh of an individual while bicycling. The sensors used were light and compact. These were probes to measure muscle EMG activity, miniature accelerometers, miniature load sensors, and small encoders to measure angular positions of the pedal. A methodology was developed and implemented to completely describe the kinematics of the limbs using data from the sensors. This work has been published as a Master's Thesis by the Graduate student supported by the grant. The instrumented ergometer along with the sensors and instrumentation were tested during a KC-135 Zero-Gravity flight in July, 1994. A complete description of the system and the tests performed have been published as a report submitted to NASA Johnson Space Center. The data collected during the KC-135 flight is currently being processed so that a kinematic description of the bicycling experiment will be soon determined. A methodology to estimate the muscle forces has been formulated based on previous work. The methodology involves the use of optimization concepts so that the individual muscle forces that represent variables in dynamic equations of motion may be estimated. Optimization of a criteria (goal) function such as minimization of energy will be used along with constraint equations defined by rigid body equations of motion. Use of optimization principles is necessary, because the equations of motion alone constitute an indeterminate system of equations with respect to the large amount of muscle forces which constitute the variables in these equations. The number of variables is reduced somewhat by using forces measured by the load cells installed on the pedal. These load cells measure pressure and shear forces on the foot. The author and his collaborators at NASA and at the University of Alabama, Tuscaloosa, are continuing the work of reducing the experimental data from the KC-135 flight, and the implementation of the optimization methods to estimate muscle forces. As soon as results from these efforts are available, they will be published in reputable journals. Results of this work will impact studies addressing bone density loss and development of countermeasures to minimize bone loss in zero gravity conditions. By analyzing muscle forces on Earth and in Space during exercise, scientists could eventually formulate new exercises and machines to help maintain bone density. On Earth, this work will impact studies concerning arthritis, and will provide the means to study possible exercise countermeasures to minimize arthritis problems.

Figueroa, Fernando↗

NASA NTRS2024

Revisiting Optimal Guidance Solution for Vertical Landing and Take-Off

The vertical landing and take-off are crucial phases of a rocket-powered spacecraft's powered descent and ascent trajectories, during which its motion is confined to a single (vertical) axis. It is well-known that the minimum-propellant guidance solutions for vertical landing and take-off in a vacuum, consist of only one coast and one full-thrust arc and no singular arc exists in these problems. However, an exact solution for the vertical descent problem is not found in the literature. In the present work, exact guidance solutions for the optimal vertical landing and take-off are presented that are valid for arbitrary boundary conditions. The time-based and switching function-based guidance law implementations are discussed and their performance is compared using lunar descent and ascent simulations.

powered descent↗