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User's Guide for the Commercial Modular Aero-Propulsion System Simulation (C-MAPSS)

This report is a Users Guide for the NASA-developed Commercial Modular Aero-Propulsion System Simulation (C-MAPSS) software, which is a transient simulation of a large commercial turbofan engine (up to 90,000-lb thrust) with a realistic engine control system. The software supports easy access to health, control, and engine parameters through a graphical user interface (GUI). C-MAPSS provides the user with a graphical turbofan engine simulation environment in which advanced algorithms can be implemented and tested. C-MAPSS can run user-specified transient simulations, and it can generate state-space linear models of the nonlinear engine model at an operating point. The code has a number of GUI screens that allow point-and-click operation, and have editable fields for user-specified input. The software includes an atmospheric model which allows simulation of engine operation at altitudes from sea level to 40,000 ft, Mach numbers from 0 to 0.90, and ambient temperatures from -60 to 103 F. The package also includes a power-management system that allows the engine to be operated over a wide range of thrust levels throughout the full range of flight conditions.

Frederick, Dean K.↗

User's Guide for the Commercial Modular Aero-Propulsion System Simulation (C-MAPSS): Version 2

This report is a Users Guide for version 2 of the NASA-developed Commercial Modular Aero-Propulsion System Simulation (C-MAPSS) software, which is a transient simulation of a large commercial turbofan engine (up to 90,000-lb thrust) with a realistic engine control system. The software supports easy access to health, control, and engine parameters through a graphical user interface (GUI). C-MAPSS v.2 has some enhancements over the original, including three actuators rather than one, the addition of actuator and sensor dynamics, and an improved controller, while retaining or improving on the convenience and user-friendliness of the original. C-MAPSS v.2 provides the user with a graphical turbofan engine simulation environment in which advanced algorithms can be implemented and tested. C-MAPSS can run user-specified transient simulations, and it can generate state-space linear models of the nonlinear engine model at an operating point. The code has a number of GUI screens that allow point-and-click operation, and have editable fields for user-specified input. The software includes an atmospheric model which allows simulation of engine operation at altitudes from sea level to 40,000 ft, Mach numbers from 0 to 0.90, and ambient temperatures from -60 to 103 F. The package also includes a power-management system that allows the engine to be operated over a wide range of thrust levels throughout the full range of flight conditions.

Liu, Yuan↗

Ultra High Temperature (UHT) SiC Fiber (Phase 2)

Silicon-carbide fiber-reinforced silicon-carbide ceramic matrix composites (SiCSiC CMC) are emerginglightweight re-usable structural materials not only for hot section components in gas turbine engines, but also for controlsurfaces and leading edges of reusable hypersonic vehicles as well as for nuclear propulsion and reactor components. Ithas been shown that when these CMC are employed in engine hot-section components, the higher the upper usetemperature (UUT) of the SiC fiber, the more performance benefits are accrued, such as higher operating temperatures,reduced component cooling air, reduced fuel consumption, and reduced emissions. The first generation of SiCSiC CMC with a temperature capability of 2200-2400F are on the verge of being introduced into the hot-section components ofcommercial and military gas turbine engines.Today the SiC fiber type currently recognized as the worlds best in terms ofthermo-mechanical performance is the Sylramic-iBN fiber. This fiber was previously developed by the PI at NASA GRC using patented processes to improve the high-cost commercial Sylramic fiber, which in turn was derived from anotherlow-cost low-performance commercial fiber. Although the Sylramic-iBN fiber shows state-of-the art creep and rupture resistance for use temperatures above 2550oF, NASA has shown by fundamental creep studies and model developmentthat its microstructure and creep resistance could theoretically be significantly improved to produce an Ultra HighTemperature (UHT) SiC fiber.This Phase II Seedling Fund effort has been focused on the key objective of effectively repeating the similar processes used for producing the Sylramic-iBN fiber using a design of experiments approach to first understand the cause of the less than optimum Sylramic-iBN microstructure and then attempting to develop processconditions that eliminate or minimize these key microstructural issues. In so doing, it is predicted that that theseadvanced process could result in an UHT SiC fiber with 20 times more creep resistance than the Sylramic-iBN fiber,which in turn would allow SiCSiC CMC to operate up to 2700oF and above, thereby further enhancing the performancebenefits of SiCSiC components in aero-propulsion engines. It was also envisioned that the fiber processes developedduring Phase II efforts would not only reduce production costs for the UHT fiber by using low-cost precursor fibers andcombined processes, but also allow the UHT fibers to be directly produced in preforms of the precursor fibers, possibly atthe facilities of the CMC fabricator.

SiC Ceramic Fiber↗

Integrated design and manufacturing for the high speed civil transport (a combined aerodynamics/propulsion optimization study)

This report documents the efforts of a Georgia Tech High Speed Civil Transport (HSCT) aerospace student design team in completing a design methodology demonstration under NASA's Advanced Design Program (ADP). Aerodynamic and propulsion analyses are integrated into the synthesis code FLOPS in order to improve its prediction accuracy. Executing the integrated product and process development (IPPD) methodology proposed at the Aerospace Systems Design Laboratory (ASDL), an improved sizing process is described followed by a combined aero-propulsion optimization, where the objective function, average yield per revenue passenger mile ($/RPM), is constrained by flight stability, noise, approach speed, and field length restrictions. Primary goals include successful demonstration of the application of the response surface methodolgy (RSM) to parameter design, introduction to higher fidelity disciplinary analysis than normally feasible at the conceptual and early preliminary level, and investigations of relationships between aerodynamic and propulsion design parameters and their effect on the objective function, $/RPM. A unique approach to aircraft synthesis is developed in which statistical methods, specifically design of experiments and the RSM, are used to more efficiently search the design space for optimum configurations. In particular, two uses of these techniques are demonstrated. First, response model equations are formed which represent complex analysis in the form of a regression polynomial. Next, a second regression equation is constructed, not for modeling purposes, but instead for the purpose of optimization at the system level. Such an optimization problem with the given tools normally would be difficult due to the need for hard connections between the various complex codes involved. The statistical methodology presents an alternative and is demonstrated via an example of aerodynamic modeling and planform optimization for a HSCT.

Baecher, Juergen↗

Aero-Propulsion Technology (APT) Task V Low Noise ADP Engine Definition Study

A study was conducted to identify and evaluate noise reduction technologies for advanced ducted prop propulsion systems that would allow increased capacity operation and result in an economically competitive commercial transport. The study investigated the aero/acoustic/structural advancements in fan and nacelle technology required to match or exceed the fuel burned and economic benefits of a constrained diameter large Advanced Ducted Propeller (ADP) compared to an unconstrained ADP propulsion system with a noise goal of 5 to 10 EPNDB reduction relative to FAR 36 Stage 3 at each of the three measuring stations namely, takeoff (cutback), approach and sideline. A second generation ADP was selected to operate within the maximum nacelle diameter constrain of 160 deg to allow installation under the wing. The impact of fan and nacelle technologies of the second generation ADP on fuel burn and direct operating costs for a typical 3000 nm mission was evaluated through use of a large, twin engine commercial airplane simulation model. The major emphasis of this study focused on fan blade aero/acoustic and structural technology evaluations and advanced nacelle designs. Results of this study have identified the testing required to verify the interactive performance of these components, along with noise characteristics, by wind tunnel testing utilizing and advanced interaction rig.

Holcombe, V.↗

Overview of the Turbine Based Combined Cycle Discipline

The NASA Fundamental Aeronautics Hypersonics project is focused on technologies for combined cycle, airbreathing propulsions systems to enable reusable launch systems for access to space. Turbine Based Combined Cycle (TBCC) propulsion systems offer specific impulse (Isp) improvements over rocket-based propulsion systems in the subsonic takeoff and return mission segments and offer improved safety. The potential to realize more aircraft-like operations with expanded launch site capability and reduced system maintenance are additional benefits. The most critical TBCC enabling technologies as identified in the National Aeronautics Institute (NAI) study were: 1) mode transition from the low speed propulsion system to the high speed propulsion system, 2) high Mach turbine engine development, 3) transonic aero-propulsion performance, 4) low-Mach-number dual-mode scramjet operation, 5) innovative 3-D flowpath concepts and 6) innovative turbine based combined cycle integration. To address several of these key TBCC challenges, NASA s Hypersonics project (TBCC Discipline) initiated an experimental mode transition task that includes an analytic research endeavor to assess the state-of-the-art of propulsion system performance and design codes. This initiative includes inlet fluid and turbine performance codes and engineering-level algorithms. This effort has been focused on the Combined Cycle Engine Large-Scale Inlet Mode Transition Experiment (CCE LIMX) which is a fully integrated TBCC propulsion system with flow path sizing consistent with previous NASA and DoD proposed Hypersonic experimental flight test plans. This experiment is being tested in the NASA-GRC 10 x 10 Supersonic Wind Tunnel (SWT) Facility. The goal of this activity is to address key hypersonic combined-cycle-engine issues: (1) dual integrated inlet operability and performance issues unstart constraints, distortion constraints, bleed requirements, controls, and operability margins, (2) mode-transition constraints imposed by the turbine and the ramjet/scramjet flow paths (imposed variable geometry requirements), (3) turbine engine transients (and associated time scales) during transition, (4) high-altitude turbine engine re-light, and (5) the operating constraints of a Mach 3-7 combustor (specific to the TBCC). The model will be tested in several test phases to develop a unique TBCC database to assess and validate design and analysis tools and address operability, integration, and interaction issues for this class of advanced propulsion systems. The test article and all support equipment is complete and available at the facility. The test article installation and facility build-up in preparation for the inlet performance and operability characterization is near completion and testing is planned to commence in FY11.

Thomas, Scott R.↗

Propulsion Control Technology Development Needs to Address NASA Aeronautics Research Mission Goals for Thrusts 3a and 4

The Commercial Aero-Propulsion Control Working Group (CAPCWG), consisting of propulsion control technology leads from The Boeing Company, GE Aviation, Honeywell, Pratt & Whitney, Rolls-Royce, and NASA (National Aeronautics and Space Administration) Glenn Research Center, has been working together over the past year to identify propulsion control technology areas of common interest that we believe are critical to achieving the challenging NASA Aeronautics Research goals for Thrust 3a: Ultra-Efficient Commercial Vehicles - Subsonic Transports, and Thrust 4: Transition to Alternative Propulsion and Energy. This paper describes the various propulsion control technology development areas identified by CAPCWG as most critical for NASA to invest in. For Thrust 3a these are: i) Integrated On-Board Model Based Engine Control and Health Management; ii) Flexible and Modular Networked Control Hardware and Software Architecture; iii) Intelligent Air/Fuel Control for Low Emissions Combustion; and iv) Active Clearance Control. For Thrust 4a, the focus is on Hybrid Electric Propulsion (HEP) for single aisle commercial aircraft. The specific technology development areas include: i) Integrated Power and Propulsion System Dynamic Modeling for Control; ii) Control Architectures for HEP; iii) HEP Control Verification and Validation; and iv) Engine/Airplane Control Integration. For each of the technology areas, the discussion includes: problem to be solved and how it relates to NASA goals, and the challenges to be addressed in reducing risk.

Propulsion Control↗

High-Order Methods in NASA’s Next Generation of Computational Fluid Dynamics Tools

The missions of the National Aeronautics and Space Administration (NASA) routinely produce unique requirements and challenges for development and application of Computational Fluid Dynamics (CFD) methods. NASA presently embodies four distinct Mission Directorates: Aeronautics Research, Exploration Systems, Science, and Space Operations. These missions generate requirements for systems that operate in a wide variety of environments. They range from the high-speed flight of aerodynamically optimized vehicles operating in the earth’s atmosphere to spacecraft designed for missions that don’t favor aerodynamic optimization, some operating in the atmosphere of planets and planetary moons such as Mars and Venus or Saturn’s moon Titan. Systems supporting these vehicles, such as rocket and jet propulsion, reaction control systems, fluid and thermal transfer systems, etc. can also generate their own unique set of flow phenomena that challenge today’s CFD methodology. Through the NASA Engineering and Safety Center (NESC), NASA annually conducts state-of-the-discipline assessments in fifteen distinct engineering disciplines. These assessments are performed by the NASA Technical Fellows that lead Technical Discipline Teams (TDT) of recognized experts in these fifteen areas. In the Aerosciences discipline, three topics have been identified as the top challenges for the discipline: aero-plume interaction prediction, unsteady separated flows, and aerothermodynamic prediction. These challenge areas are defined by the Agency’s high-risk projects and problems on which the NESC is requested to perform independent testing, analysis, and assessments. When viewed as a whole, these tests, analyses, and assessments provide a clear view of the recurring technical challenges facing Agency engineers and researchers and can be used to guide future research and technology development. The present state-of-the-art in the application of CFD at NASA is the use of Reynolds-Averaged Navier- Stokes (RANS) solvers, primarily executed in a steady-state mode of operation. In isolated cases, Unsteady RANS (URANS) solvers have been employed when steady RANS solutions produce poorly converging or oscillating results or in cases, such as aeroelastic analysis, which require unsteady aerodynamic simulation. For most traditional external and internal aerodynamic flows, structured overset grids or unstructured grids are employed to minimize geometric modeling and grid generation times. Grid adaptation, primarily as a series of coarse-grain intermediate processing steps is also seeing use on particularly complex flow problems and configurations. In the case of aerothermodynamic flows, engineers have been forced to continue to employ structured grid techniques as the present unstructured grid methodology has proven inadequate in the prediction of surface heating. In the area of aero-plume interaction modeling, two-gas, frozen chemistry simulation is generally the state-of-the- art, with some production solvers capable of predicting flows with only a single gas component. Prediction of flows falling into the afore-mentioned top Aerosciences technical challenges have severely stressed the present state-of-the-art in CFD prediction and for some problems, such as unsteady separated flows and aero-plume interaction cases, engineers have begun employing Large Eddy Simulation (LES) and Hybrid RANS/LES techniques. In some isolated aero-propulsion interaction cases, chemically reacting flow simulations have been applied. These methods are highly evolutionary and engineers have little experience in their application, so they cannot be heavily relied upon in today’s application environment. Therefore, this leads one to muse over which numerical technologies will be included in the CFD tools that will be employed 30 years in the future. This presentation will describe specific technical problems that have stressed NASA’s traditional CFD methods to their breaking point and will link these issues to the Agency’s top Aerosciences technical challenges. The discussion will then shift to the characteristics of future CFD solvers that will be required to attack these challenges and how these characteristics differ from the present state-of-the- art. High-order methods certainly appear to have a place in the development of future CFD tools and some of the physical characteristics of our most challenging problems suggest that high-order methods are the only way to effectively solve them. But there are some relatively severe implementation issues that face these methods, particularly in the area of general applicability and robust operation as an engineering tool. Desired characteristics of next-generation CFD solvers will be discussed and the author’s view of which emerging numerical technologies might be employed to address these attributes will also be presented

David M Schuster↗

Design of a Distributed Propulsion Concept Using an Adjoint-Based Approach and Blade Element Theory to Minimize Power

The adjoint-based design capability in FUN3D is extended to allow efficient gradient-based optimization and design of concepts with highly integrated and distributed aero-propulsive systems. Previous work by the authors demonstrated the derivation and application of design sensitivities of flow power and vehicle forces with respect to design variables associated with actuator disk size, loading, and installation on the aircraft. In this work, calculations of propulsive power, shaft power, and propeller efficiency using blade element-based disk loading, along with sensitivity derivatives needed to perform adjoint-based design, have been implemented. This includes the derivation of additional design sensitivities for actuator disk variables with respect to the radial distributions of blade pitch angle and chord length. The blade element-based loading implementation allows us to tailor the actuator disk loading to provide greater design authority and calculate the torque imparted on the flow for the modeling of swirl effects. The design capability is demonstrated by the optimization of NASA's parallel hybrid electric PEGASUS aircraft concept. The optimization objective is the minimization of shaft power at the aerodynamic interface planes for the wing-mounted and tail-cone boundary layer ingestion propulsors, subject to vehicle performance and propulsive constraints.

Irian Ordaz↗

Investigation of Longitudinal Aero-Propulsive Interactions of a Small Quadrotor Unmanned Aircraft System

Aerodynamic propulsive and airframe interactions significantly influence the forces and moments of multirotor vehicles. This paper presents recent results studying the influence of these effects on a small quadrotor vehicle in hover and forward flight. Aerodynamic interaction model development was explored utilizing system identification tools and incorporated into a previously developed NASA quadrotor flight dynamic simulation. The aerodynamic interaction model improved accuracy of the simulation in comparison to free-flight and static wind tunnel results. Comparisons between models of different fidelity were completed to demonstrate the effects of aerodynamic interaction on model accuracy and provide recommendations for modelling requirements.

George Altamirano↗

Hybrid-Electric Aero-Propulsion Controls Testbed Results

NASA is supporting the development of Electrified Aircraft Propulsion (EAP) technology due to its potential to reduce aircraft fuel burn, emissions, and noise as well as improving safety and performance. One focus of this research is the electrification of conventional turbomachinery propulsion systems, which offers ways to improve the performance and operability of turbine-engine powered aircraft through the addition of electro-mechanical systems. These hybrid-electric turbine engines provide additional actuation and energy management control opportunities for improving stability and transient response behavior. This paper summarizes the results of a Hardware-in-the-Loop (HIL) test performed at the NASA Electric Aircraft Testbed (NEAT) during the summer of 2022. The test demonstrates the feasibility and performance of an advanced energy management control strategy by integrating a simulated turbofan engine with scaled electro-mechanical hardware. A full-scale real-time reference model of a geared turbofan was run alongside a scaled electro-mechanical system representing the electrified turbofan components operating at a megawatt-scale power level. The model was interfaced with the hardware through a novel closed-loop control and scaling algorithm that emulated the dynamic speed and torque response of the turbofan shafts. The control strategy was implemented on the electrical machines connected to the emulated turbomachinery shafts. The results from the testbed are compared against simulations that predict the testbed and geared turbofan model operation. The energy management control strategy successfully changed the operating point of the engine model and improved its stability during throttle transients. These results also demonstrate the success of the novel closed loop control and scaling approach for emulating turbomachinery and elevate the Technology Readiness Level (TRL) of the energy management control strategy.

Aeronautics↗

Hybrid-Electric Aero-Propulsion Controls Testbed Results with Energy Storage

Electrified aircraft propulsion (EAP) research is a priority of the National Aeronautics and Space Administration (NASA) for its potential to increase propulsion system efficiency, performance, and operability at the subsystem and vehicle levels while decreasing emissions. These EAP systems demand more advanced control algorithms due to increased complexity. NASA has developed a reconfigurable, hardware-in-the-loop rig to verify control algorithm performance using a sub-scale electro-mechanical system. A novel capability of this rig is the ability to test full scale EAP control algorithms on a sub-scale representation of the electro-mechanical system without turbomachinery/rotors. A novel feature is the use of a physical energy storage device within the electro-mechanical system. A dual spool, parallel hybrid-electric turbofan architecture and energy management control system is tested with the goal of verifying the ability to obtain turbomachinery model operability benefits while controlling sub-scale electro-mechanical hardware. Pre-test predictions of the turbofan model, control, and rig performance were obtained through simulation using a software model of the rig. Theoretical results showing the true performance of the turbofan model were obtained through a software simulation using full-scale mechanical shaft models. The paper compares theoretical, predicted, and actual test results from the turbofan model, energy management control and rig perspectives. The results show that the presence of sub-scale electro-mechanical hardware did not inhibit the energy management algorithm from achieving turbomachinery operability benefits.

hybrid↗

Hybrid-Electric Aero-Propulsion Controls Testbed Results with Energy Storage

Electrified aircraft propulsion (EAP) research is a priority of the National Aeronautics and Space Administration (NASA) for its potential to increase propulsion system efficiency, performance, and operability at the subsystem and vehicle levels while decreasing emissions. These EAP systems demand more advanced control algorithms due to increased complexity. NASA has developed a reconfigurable, hardware-in-the-loop rig to verify control algorithm performance using a sub-scale electro-mechanical system. A novel capability of this rig is the ability to test full scale EAP control algorithms on a sub-scale representation of the electro-mechanical system without turbomachinery/rotors. A novel feature is the use of a physical energy storage device within the electro-mechanical system. A dual spool, parallel hybrid-electric turbofan architecture and energy management control system is tested with the goal of verifying the ability to obtain turbomachinery model operability benefits while controlling sub-scale electro-mechanical hardware. Pre-test predictions of the turbofan model, control, and rig performance were obtained through simulation using a software model of the rig. Theoretical results showing the true performance of the turbofan model were obtained through a software simulation using full-scale mechanical shaft models. The paper compares theoretical, predicted, and actual test results from the turbofan model, energy management control and rig perspectives. The results show that the presence of sub-scale electro-mechanical hardware did not inhibit the energy management algorithm from achieving turbomachinery operability benefits.

hybrid↗

Hybrid-Electric Aero-Propulsion Controls Testbed Results

NASA is supporting the development of Electrified Aircraft Propulsion (EAP) technology due to its potential to reduce aircraft fuel burn, emissions, and noise as well as improving safety and performance. One focus of this research is the electrification of conventional turbomachinery propulsion systems, which offers ways to improve the performance and operability of turbine-engine powered aircraft through the addition of electro-mechanical systems. These hybrid-electric turbine engines provide additional actuation and energy management control opportunities for improving stability and transient response behavior. This paper summarizes the results of a Hardware-in-the-Loop (HIL) test performed at the NASA Electric Aircraft Testbed (NEAT) during the summer of 2022. The test demonstrates the feasibility and performance of an advanced energy management control strategy by integrating a simulated turbofan engine with scaled electro-mechanical hardware. A full-scale real-time reference model of a geared turbofan was run alongside a scaled electro-mechanical system representing the electrified turbofan components operating at a megawatt-scale power level. The model was interfaced with the hardware through a novel closed-loop control and scaling algorithm that emulated the dynamic speed and torque response of the turbofan shafts. The control strategy was implemented on the electrical machines connected to the emulated turbomachinery shafts. The results from the testbed are compared against simulations that predict the testbed and geared turbofan model operation. The energy management control strategy successfully changed the operating point of the engine model and improved its stability during throttle transients. These results also demonstrate the success of the novel closed loop control and scaling approach for emulating turbomachinery and elevate the Technology Readiness Level (TRL) of the energy management control strategy.

Aeronautics↗