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Development of Response Surface Models for Rapid Analysis & Multidisciplinary Optimization of Launch Vehicle Design Concepts

Multdisciplinary design optimization (MDO) is an important step in the design and evaluation of launch vehicles, since it has a significant impact on performance and lifecycle cost. The objective in MDO is to search the design space to determine the values of design parameters that optimize the performance characteristics subject to system constraints. Vehicle Analysis Branch (VAB) at NASA Langley Research Center has computerized analysis tools in many of the disciplines required for the design and analysis of launch vehicles. Vehicle performance characteristics can be determined by the use of these computerized analysis tools. The next step is to optimize the system performance characteristics subject to multidisciplinary constraints. However, most of the complex sizing and performance evaluation codes used for launch vehicle design are stand-alone tools, operated by disciplinary experts. They are, in general, difficult to integrate and use directly for MDO. An alternative has been to utilize response surface methodology (RSM) to obtain polynomial models that approximate the functional relationships between performance characteristics and design variables. These approximation models, called response surface models, are then used to integrate the disciplines using mathematical programming methods for efficient system level design analysis, MDO and fast sensitivity simulations. A second-order response surface model of the form given has been commonly used in RSM since in many cases it can provide an adequate approximation especially if the region of interest is sufficiently limited.

Unal, Resit

Development of Response Surface Models for Rapid Analysis and Multidisciplinary Optimization of Launch Vehicle Design Concepts

Multidisciplinary design optimization (MDO) is an important step in the design and evaluation of launch vehicles, since it has a significant impact on performance and lifecycle cost. The objective in MDO is to search the design space to determine the values of design parameters that optimize the performance characteristics subject to system constraints. Vehicle Analysis Branch (VAB) at NASA Langley Research Center has computerized analysis tools in many of the disciplines required for the design and analysis of launch vehicles. Vehicle performance characteristics can be determined by the use of these computerized analysis tools. The next step is to optimize the system performance characteristics subject to multidisciplinary constraints. However, most of the complex sizing and performance evaluation codes used for launch vehicle design are stand-alone tools, operated by disciplinary experts. They are, in general, difficult to integrate and use directly for MDO.

Unal, Resit

Global Cost and Weight Evaluation of Fuselage Side Panel Design Concepts

This report documents preliminary design trades conducted under NASA contracts NAS1 18889 (Advanced Technology Composite Aircraft Structures, ATCAS) and NAS1-19349 (Task 3, Pathfinder Shell Design) for a subsonic wide body commercial aircraft fuselage side panel section utilizing composite materials. Included in this effort were (1) development of two complete design concepts, (2) generation of cost and weight estimates, (3) identification of technical issues and potential design enhancements, and (4) selection of a single design to be further developed. The first design concept featured an open-section stringer stiffened skin configuration while the second was based on honeycomb core sandwich construction. The trade study cost and weight results were generated from comprehensive assessment of each structural component comprising the fuselage side panel section from detail fabrication through airplane final assembly. Results were obtained in three phases: (1) for the baseline designs, (2) after global optimization of the designs, and (3) the results anticipated after detailed design optimization. A critical assessment of both designs was performed to determine the risk associated with each concept, that is the relative probability of achieving the cost and weight projections. Seven critical technical issues were identified as the first step towards side panel detailed design optimization.

Polland, D. R.

A new airfoil design concept

The present airfoil design concept is based on utilizing unconventional geometry characteristics near the airfoil trailing edge which include a finite trailing edge thickness, strongly divergent trailing edge upper and lower surfaces, and high surface curvature on the lower surface at or near the lower surface trailing edge. This paper presents computational analyses of airfoils and a wing utilizing the concept, airfoil validation wind tunnel test results of several configurations, and wing-validation wind tunnel test results for a complete wing design. In addition to validating the concept, the airfoil and wing testing provided additional detailed data to better understand the aerodynamic advantage of such an unconventional trailing edge configuration. It is demonstrated that the concept represents a significant step in airfoil technology beyond that achieved with the Supercritical Airfoil. This concept provides the aerodynamicist an additional degree of design freedom and flexibility previously unrecognized.

Henne, P. A.

Novel Composites for Wing and Fuselage Applications: Novel Wing Design Concepts - Task 1

Design trade studies were conducted to arrive at advanced wing designs that integrated new material forms with innovative structural concepts and cost-effective fabrication methods. A representative spar was selected for design, fabrication, and test to validate the predicted performance. Textile processes, such as knitting, weaving and stitching, were used to produce fiber preforms that were later fabricated into composite span through epoxy Resin Transfer Molding (RTM), Resin Film Infusion (RFI), and consolidation of commingled thermoplastic and graphite tows. The target design ultimate strain level for these innovative structural design concepts was 6000 mu in. per in. The spars were subjected to four-point beam bending to validate their structural performance. The various material form /processing combination Y-spars were rated for their structural efficiency and acquisition cost. The acquisition cost elements were material, tooling, and labor.

Suarez, J. A.

A survey of aerobraking orbital transfer vehicle design concepts

The five existing design concepts of the aerobraking orbital transfer vehicle (namely, the raked sphere-cone designs, conical lifting-brake, raked elliptic-cone, lifting-body, and ballute) are reviewed and critiqued. Historical backgrounds, and the geometrical, aerothermal, and operational features of these designs are reviewed first. Then, the technological requirements for the vehicle (namely, navigation, aerodynamic stability and control, afterbody flow impingement, nonequilibrium radiation, convective heat-transfer rates, mission abort and multiple atmospheric passes, transportation and construction, and the payload-to-vehicle weight requirements) are delineated by summarizing the recent advancements made on these issues. Each of the five designs are critiqued and rated on these issues. The highest and the lowest ratings are given to the raked sphere-cone and the ballute design, respectively.

Park, Chul

An Evolutionary Computation System Design Concept for Developing Controlled Closed Ecosystems: An Intelligent Systems Approach to Foster Gravitational Ecosystem Research for Developing Sustainable Communities in Space and on Earth

An adjustably-autonomous intelligent systems approach for developing Closed Ecosystems (CESs) is presented, which includes a design concept and preliminary design details for the Controlled Closed-Ecosystem Development System (CCEDS) and the Orbiting Modular Artificial-Gravity Spacecraft (OMAGS). The paper is divided into three sections: CESs, the CCEDS Design Concept, and Orbiting Fractional-Gravity Closed Ecosystems OMAGS design concept. The first section briefly describes Closed EcoSystems (CESs), complex adaptive systems, biomes, microbial microbiomes, and their relevance for the study of astrobiology. This section also discusses initial efforts in the development of Closed Environment Life Support Systems (CELSSs) for sustainable communities in space and on Earth. This section concludes with a discussion of the bioregenerative life support system challenge of and the corresponding consequences due to the inverse relationship of the very small human biomass/non-human biomass ratio overall on the Earth with respect to the extremely large human biomass/non-human-biomass ratio found in cities and the International Space Station. The second section describes the CCEDS design concept, which consists of a population of controlled colonies of CES Modules (CESMs), each an integrated CES, continually generating data for an intelligent system that operates the CESs and their CESMs. A variety of CESM types and their use are briefly described. The CCEDS intelligent system uses an evolutionary computation algorithm described in this section to develop and optimize these CESs to increase their viability duration and the size of the animals they support with the ultimate goal to support populations of humans, both on Earth and in space. The CCEDS architecture, its five control subsystems, and its five evolutionary computation levels are also discussed. The section concludes with a discussion of several CCEDS design strategies. The third section summarizes the OMAGS design concept for a spacecraft with a payload consisting of CESs in an orbiting spacecraft centrifuge that operates for at least 5 years. The spacecraft concept is described including its 150cm-radius centrifuge with a 2 ton & 3,000 liter bioscience payload capacity for 24 CESMs. The centrifuge design has four physical levels for its CESMs, each level subject to a different fractional gravity level. This section presents the spacecraft benefits of being designed and operated such that the spacecraft and payload centrifuge wheel counter-rotate resulting in net zero angular momentum and zero gyroscopic forces. Artificial-gravity generation by centripetal acceleration is also discussed. This section concludes by showing the external specifications of the CESMs and their layout in the centrifuge, followed by discussing the multi-payload module rationale. In tandem, the CCEDS and OMAGS systems can be used to foster gravitational ecosystem research for developing sustainable communities in space and on Earth.

Dorais, Gregory A.

Concept Design for a 5 MW Partially Superconducting Generator

This paper presents a concept design for the 5 MW generators on NASA’s SUSAN hybrid electric flight concept. The performance targets for this machine are 25 kW/kg and 99% efficiency. The concept design is a partially superconducting machine that builds on NASA’s past work on its High Efficiency Megawatt Motor (HEMM). A partially superconducting machine design tool is used to create a preliminary concept design capable of achieving the target specifications for the SUSAN generator. Higher fidelity design and analysis is applied to the preliminary design. After high fidelity analysis the machine is predicted to achieve 22.3 kW/kg and 99.1% efficiency. Lessons learned from this concept design will be incorporated in the next iteration of the machine.

Thomas Tallerico

Concept Design of a 5 MW Partially Superconducting Generator

This paper presents a concept design for the 5 MW generators on NASA’s SUSAN electric flight demonstrator concept vehicle. The performance targets for this machine are 25 kW/kg and 99% efficiency. The concept design is a partially superconducting machine that builds on NASA’s past work on its High Efficiency Megawatt Motor(HEMM). A partially superconducting machine design tool is used to create a preliminary concept design capable of achieving the target specifications for the SUSAN generator. Higher fidelity design and analysis is applied to the preliminary design. After high fidelity analysis the machine is predicted to achieve 22.3 kW/kg and 99.1% efficiency. Lessons learned from this concept design will be incorporated in the next iteration of the machine.

Thomas Tallerico

The natural flow wing-design concept

A wing-design study was conducted on a 65 degree swept leading-edge delta wing in which the wing geometry was modified to take advantage of the naturally occurring flow that forms over a slender wing in a supersonic flow field. Three-dimensional nonlinear analysis methods were used in the study which was divided into three parts: preliminary design, initial design, and final design. In the preliminary design, the wing planform, the design conditions, and the near-conical wing-design concept were derived, and a baseline standard wing (conventional airfoil distribution) and a baseline near-conical wing were chosen. During the initial analysis, a full-potential flow solver was employed to determine the aerodynamic characteristics of the baseline standard delta wing and to investigate modifications to the airfoil thickness, leading-edge radius, airfoil maximum-thickness position, and wing upper to lower surface asymmetry on the baseline near-conical wing. The final design employed an Euler solver to analyze the best wing configurations found in the initial design and to extend the study of wing asymmetry to develop a more refined wing. Benefits resulting from each modification are discussed, and a final 'natural flow' wing geometry was designed that provides an improvement in aerodynamic performance compared with that of a baseline conventional uncambered wing, linear-theory cambered wing, and near-conical wing.

Wood, Richard M.

Transit Habitat Government-Reference Conceptual Design Reaction Control System Propulsion Concept Design Data Book

The function of Transit Habitat (TH) Reaction Control System (RCS) propulsion is to provide free-flying spacecraft capabilities and to augment Gateway stack control when docked on Gateway. The requirements of multiple propellant replenishments and extensive life operation have significant impacts on selection of the propulsion system concept and components for the RCS. The intent of this document is to provide insight into the government-reference conceptual design of a propulsion system for TH element. A pressure-fed hypergolic bi-propellant system is the assumed propulsion approach for the RCS. Its architectural concept is being traded within the NASA Moon to Mars architecture. A pressure-regulated system is examined. The propellants under consideration are Monomethyl Hydrazine (MMH) and Mixed Oxides of Nitrogen with 3% Nitric Oxide (MON3). A peer review was conducted to assess the flow schematic design and propulsion component selection, compliant with a set of assumed requirements. Redundant components to satisfy one-fault tolerance for function and two-fault tolerance against catastrophic events are incorporated in the propulsion concept design. Instrumentation laid out on the schematic would be used to gather data to monitor the health of the propulsion system and to support quantity gauging of the propulsion system fluids. Venting propellant ullage gas overboard during the refilling operations poses a significant concern to the external surfaces of the TH. A liquid/gas separator would be required to eliminate, or at least reduce, the amount of liquid propellant expelled in the vent gas mixture. The technology readiness level of the phase separator for the TH must be advanced. Metal diaphragm and non-positive-expulsion PMD propellant tank systems were traded against each other, with the PMD architecture being selected. A blowdown concept is also considered for the TH RCS propulsion. Its fluid schematic is derived from the pressure-regulated schematic with removal of assemblies involving the helium pressurization and ullage venting. Its system wet mass is 10% heavier than the pressure-regulated due to thruster performance loss and larger propellant tanks. There is no firm constraint on the propulsion system mass at this phase of the design. The blowdown concept can offer reduction in component count and operation, that would lead to a more reliable propulsion system. The blowdown concept would also benefit avionics, thermal, power, and structures on the TH. Assessing these benefits will be carried as a future work. Drawbacks of thrust and minimum impulse bit (MIB) variations due to the blowdown operation would be acceptable to Guidance, Navigation, and Control (GNC). Although the blowdown concept has been selected as a current baseline, further evaluation of the concept will be the subject of future work to ensure that the blowdown propulsion operation is appropriate for the HT RCS propulsion. This document also highlights key trade studies and design decisions, including pros and cons of the selected concept. Other appropriate options for components are pointed out for future assessments. Additional background information and documents for further review are referenced in this report.

spacecraft propulsion

Enroute flight planning: Evaluating design concepts for the development of cooperative problem-solving concepts

The goals of this research were to develop design concepts to support the task of enroute flight planning. And within this context, to explore and evaluate general design concepts and principles to guide the development of cooperative problem solving systems. A detailed model is to be developed of the cognitive processes involved in flight planning. Included in this model will be the identification of individual differences of subjects. Of particular interest will be differences between pilots and dispatchers. The effect will be studied of the effect on performance of tools that support planning at different levels of abstraction. In order to conduct this research, the Flight Planning Testbed (FPT) was developed, a fully functional testbed environment for studying advanced design concepts for tools to aid in flight planning.

Smith, Philip J.

Design concepts for low-cost composite turbofan engine frame

Design concepts for low cost, lightweight composite engine frames were applied to the design requirements for the frame of a commercial, high bypass engine. Four alternative composite frame design concepts identified which consisted of generic type components and subcomponents that could be adapted to use in different locations in the engine and the different engine sizes. A variety of materials and manufacturing methods were projected with a goal for the lowest number of parts at the lowest possible cost. After a preliminary evaluation of all four frame concepts, two designs were selected for an extended design and evaluation which narrowed the final selection down to one frame that was significantly lower in cost and slighty lighter than the other frame. An implementation plan for this lowest cost frame is projected for future development and includes prospects for reducing its weight with proposed unproven, innovative fabrication techniques.

Mitchell, S. C.

Mars Surface Habitat Concept Design

An initial Mars Surface Habitat (MSH) concept design study was conducted as part of the National Aeronautics and Space Administration (NASA) Habitation Systems Development Office’s effort to inform NASA crewed Mars architecture decisions. The study assessed the unique challenges, risks, and benefits of a surface habitation element within the Mars architecture trade space. The goal of the study was to identify unique functional capabilities necessary to support a crewed mission on the Martian surface, the unique challenges and risks associated with such an architecture, and the areas of further analysis required to make such a mission possible. Continuing NASA’s development and execution of the Moon to Mars lunar surface missions, attention will continue progressing toward the initial crewed Mars mission. To prepare for this, NASA’s Exploration Systems Development Mission Directorate (ESDMD) has established a strategic analysis cycle (SAC) where an architectural trade space is identified and evaluated. Given that the Mars architecture and mission profile are still in this trade space, the architecture and mission considered for this study is SAC21. In addition, reference conceptual designs are being refined for the Mars Transit Habitat (TH) and MSH systems which will enable crew to safely travel to and inhabit the surface of Mars. The NASA Mars architectures trade space includes the use of a Pressurized Rover (PR) to address both crew habitation and mobility needs. This study assesses the use of a dedicated habitat via the MSH and an unpressurized terrain vehicle for crew mobility and exploration in lieu of the PR. Determining the optimum mission architecture will require continued analysis by ESDMD teams and this study is intended to support of such a study. The MSH concept design team aims to explore this area of the Mars habitation trade space, and in doing so, inform and highlight the considerations associated with a MSH in the surface architecture. It is not the intention of this study to make specific habitation or architecture decisions, but instead to provide a habitation element concept compatible with the Mars architecture trade space.

Mars Surface Habitat

Mars Surface Habitat (MSH) Concept Design

An initial Mars Surface Habitat (MSH) concept design study was conducted as part of the National Aeronautics and Space Administration (NASA) Habitation Systems Development Office’s effort to inform NASA crewed Mars architecture decisions. The study assessed the unique challenges, risks, and benefits of a surface habitation element within the Mars architecture trade space. The goal of the study was to identify unique functional capabilities necessary to support a crewed mission on the Martian surface, the unique challenges and risks associated with such an architecture, and the areas of further analysis required to make such a mission possible. Continuing NASA’s development and execution of the Moon to Mars lunar surface missions, attention will continue progressing toward the initial crewed Mars mission. To prepare for this, NASA’s Exploration Systems Development Mission Directorate (ESDMD) has established a strategic analysis cycle (SAC) where an architectural trade space is identified and evaluated. Given that the Mars architecture and mission profile are still in this trade space, the architecture and mission considered for this study is SAC21. In addition, reference conceptual designs are being refined for the Mars Transit Habitat (TH) and MSH systems which will enable crew to safely travel to and inhabit the surface of Mars. The NASA Mars architectures trade space includes the use of a Pressurized Rover (PR) to address both crew habitation and mobility needs. This study assesses the use of a dedicated habitat via the MSH and an unpressurized terrain vehicle for crew mobility and exploration in lieu of the PR. Determining the optimum mission architecture will require continued analysis by ESDMD teams and this study is intended to support of such a study. The MSH concept design team aims to explore this area of the Mars habitation trade space, and in doing so, inform and highlight the considerations associated with a MSH in the surface architecture. It is not the intention of this study to make specific habitation or architecture decisions, but instead to provide a habitation element concept compatible with the Mars architecture trade space.

Ryan Hughes

Concept Design of a 5 MW Axial Flux Partially Superconducting Electric Machine

Single aisle class and larger electric and hybrid electric airplanes require high performance electric machines with power levels greater than 1 MW. Partially superconducting machines with superconducting rotors cooled by cryocoolers and no-cryogenic stators are one possible solution for meeting the machine performance requirements at these power levels. In this paper, a conceptual design for a double-stator single-rotor axial-flux partially superconducting machine is presented. A design tool for the topology is presented and used to generate an initial concept design. High fidelity analysis of the concept design is used to access the feasibility of the concept design to meet its target performance metrics and find areas of refinement for the next iteration of the design tool and the design.

Thomas Tallerico

The aerocapture vehicle mission design concept

Aerocapture is a mission design concept which uses an aerodynamically controlled atmospheric entry to capture payloads into orbit as opposed to a completely propulsive orbit insertion. Results are presented which demonstrate great performance gains and good accuracy using aerocapture. These results deal only with projected Mars missions; therefore, the aerocapture vehicle system design requirements deal only with Mars. It will be evident, however, that this concept can be readily applied to other atmosphere-bearing celestial bodies.

Cruz, M. I.