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Analyzing rocket engines is one of Marshall Space Flight Center's specialties. When Marshall engineers lacked a software program flexible enough to meet their needs for analyzing rocket engine fluid flow, they overcame the challenge by inventing the Generalized Fluid System Simulation Program (GFSSP), which was named the co-winner of the NASA Software of the Year award in 2001. This paper describes the GFSSP in a wide variety of applications
This paper documents the work done on the bearing assessment program over the past two and a half years. The objective of the program is to develop a nondestructive evaluation system for the space shuttle main engine high pressure oxidizer turbopumps which would be used to detect anomalies in installed bearings without component disassembly. Databases of various signatures are obtained by slowly turning the pump shafts before and after an engine firing. These signatures are then analyzed and compared to the original signatures to more accurately predict bearing wear.
In June 1992, Georgia Tech's School of Aerospace Engineering was awarded a NASA University Space Research Association (USRA) Advanced Design Program (ADP) to address 'Integrated Design and Manufacturing for the High Speed Civil Transport (HSCT)' in its graduate aerospace systems design courses. This report summarizes the results of the five courses incorporated into the Georgia Tech's USRA ADP program. It covers AE8113: Introduction to Concurrent Engineering, AE4360: Introduction to CAE/CAD, AE4353: Design for Life Cycle Cost, AE6351: Aerospace Systems Design One, and AE6352: Aerospace Systems Design Two. AE8113: Introduction to Concurrent Engineering was an introductory course addressing the basic principles of concurrent engineering (CE) or integrated product development (IPD). The design of a total system was not the objective of this course. The goal was to understand and define the 'up-front' customer requirements, their decomposition, and determine the value objectives for a complex product, such as the high speed civil transport (HSCT). A generic CE methodology developed at Georgia Tech was used for this purpose. AE4353: Design for Life Cycle Cost addressed the basic economic issues for an HSCT using a robust design technique, Taguchi's parameter design optimization method (PDOM). An HSCT economic sensitivity assessment was conducted using a Taguchi PDOM approach to address the robustness of the basic HSCT design. AE4360: Introduction to CAE/CAD permitted students to develop and utilize CAE/CAD/CAM knowledge and skills using CATIA and CADAM as the basic geometric tools. AE6351: Aerospace Systems Design One focused on the conceptual design refinement of a baseline HSCT configuration as defined by Boeing, Douglas, and NASA in their system studies. It required the use of NASA's synthesis codes FLOPS and ACSYNT. A criterion called the productivity index (P.I.) was used to evaluate disciplinary sensitivities and provide refinements of the baseline HSCT configuration. AE6352: Aerospace Systems Design Two was a continuation of Aerospace Systems Design One in which wing concepts were researched and analyzed in more detail. FLOPS and ACSYNT were again used at the system level while other off-the-shelf computer codes were used for more detailed wing disciplinary analysis and optimization. The culmination of all efforts and submission of this report conclude the first year's efforts of Georgia Tech's NASA USRA ADP. It will hopefully provide the foundation for next year's efforts concerning continuous improvement of integrated design and manufacturing for the HSCT.
The Modular Rocket Engine Control Software (MRECS) Program is a technology demonstration effort designed to advance the state-of-the-art in launch vehicle propulsion systems. Its emphasis is on developing and demonstrating a modular software architecture for advanced engine control systems that will result in lower software maintenance (operations) costs. It effectively accommodates software requirement changes that occur due to hardware technology upgrades and engine development testing. Ground rules directed by MSFC were to optimize modularity and implement the software in the Ada programming language. MRECS system software and the software development environment utilize Commercial-Off-the-Shelf (COTS) products. This paper presents the objectives, benefits, and status of the program. The software architecture, design, and development environment are described. MRECS tasks are defined and timing relationships given. Major accomplishments are listed. MRECS offers benefits to a wide variety of advanced technology programs in the areas of modular software architecture, reuse software, and reduced software reverification time related to software changes. MRECS was recently modified to support a Space Shuttle Main Engine (SSME) hot-fire test. Cold Flow and Flight Readiness Testing were completed before the test was cancelled. Currently, the program is focused on supporting NASA MSFC in accomplishing development testing of the Fastrac Engine, part of NASA's Low Cost Technologies (LCT) Program. MRECS will be used for all engine development testing.
Progress in the development and future requirements of the Variable Stream Control Engine (VSCE) are presented. The two most critical components of this advanced system for future supersonic transports, the high performance duct burner for thrust augmentation, and the low jet coannular nozzle were studied. Nozzle model tests substantiated the jet noise benefit associated with the unique velocity profile possible with a coannular nozzle system on a VSCE. Additional nozzle model performance tests have established high thrust efficiency levels only at takeoff and supersonic cruise for this nozzle system. An experimental program involving both isolated component and complete engine tests has been conducted for the high performance, low emissions duct burner with good results and large scale testing of these two components is being conducted using a F100 engine as the testbed for simulating the VSCE. Future work includes application of computer programs for supersonic flow fields to coannular nozzle geometries, further experimental testing with the duct burner segment rig, and the use of the Variable Cycle Engine (VCE) Testbed Program for evaluating the VSCE duct burner and coannular nozzle technologies.
The STS-60 Space Shuttle Program Mission Report summarizes the Payload activities as well as the Orbiter, External Tank (ET), Solid Rocket Booster (SRB), Redesigned Solid Rocket Motor (RSRM), and the Space Shuttle main engine (SSME) systems performance during the sixtieth flight of the Space Shuttle Program and eighteenth flight of the Orbiter vehicle Discovery (OV-103). In addition to the Orbiter, the flight vehicle consisted of an ET designated at ET-61 (Block 10); three SSME's which were designated as serial numbers 2012, 2034, and 2032 in positions 1, 2, and 3, respectively; and two SRB's which were designated BI-062. The RSRM's that were installed in each SRB were designated as 360L035A (lightweight) for the left SRB, and 360Q035B (quarterweight) for the right SRB. This STS-60 Space Shuttle Program Mission Report fulfills the Space Shuttle Program requirement as documented in NSTS 07700, Volume VIII, Appendix E. That document requires that each major organizational element supporting the Program report the results of its hardware evaluation and mission performance plus identify all related in-flight anomalies. The primary objectives of the STS-60 mission were to deploy and retrieve the Wake Shield Facility-1 (WSF-1), and to activate the Spacehab-2 payload and perform on-orbit experiments. Secondary objectives of this flight were to activate and command the Capillary Pumped Loop/Orbital Debris Radar Calibration Spheres/Breman Satellite Experiment/Getaway Special (GAS) Bridge Assembly (CAPL/ODERACS/BREMSAT/GBA) payload, the Auroral Photography Experiment-B (APE-B), and the Shuttle Amateur Radio Experiment-II (SAREX-II).
The STS-70 Space Shuttle Program Mission Report summarizes the Payload activities as well as the Orbiter, External Tank (ET), Solid Rocket Booster (SRB), Reusable Solid Rocket Motor (RSRM), and the Space Shuttle main engine (SSME) systems performance during the seventieth flight of the Space Shuttle Program, the forty-fifth flight since the return-to-flight, and the twenty-first flight of the Orbiter Discovery (OV-103). In addition to the Orbiter, the flight vehicle consisted of an ET that was designated ET-71; three SSMEs that were designated as serial numbers 2036, 2019, and 2017 in positions 1, 2, and 3, respectively; and two SRBs that were designated 81-073. The RSRMs, designated RSRM-44, were installed in each SRB and were designated as 36OL044A for the left SRB, and 36OL044B for the right SRB. The primary objective of this flight was to deploy the Tracking and Data Relay Satellite-G/Inertial Upper Stage (TDRS-G/IUS). The secondary objectives were to fulfill the requirements of the Physiological and Anatomical Rodent Experiment/National Institutes of Health-Rodents (PARE/NIH-R); Bioreactor Demonstration System (BDS); Commercial Protein Crystal Growth (CPCG) experiment; Space Tissue Loss/National Institutes of Health - Cells (STL/NIH-C) experiment; Biological Research in Canisters (BRIC) experiment; Shuttle Amateur Radio Experiment-2 (SAREX-2); Visual Function Tester-4 (VFT-4); Hand-Held, Earth-Oriented, Real-Time, Cooperative, User-Friendly Location-Targeting and Environmental System (HERCULES); Microencapsulation in Space-B (MIS-B) experiment; Window Experiment (WINDEX); Radiation Monitoring Equipment-3 (RME-3); and the Military Applications of Ship Tracks (MAST) payload.
The STS-80 Space Shuttle Program Mission Report summarizes the Payload activities as well as the Orbiter, External Tank (ET), Solid Rocket Booster (SRB), Reusable Solid Rocket Motor (RSRM), and the Space Shuttle main engine (SSME) systems performance during the eightieth flight of the Space Shuttle Program, the fifty-fifth flight since the return-to-flight, and the twenty-first flight of the Orbiter Columbia (OV-102).
The sprayed ceramic gas turbine outer air seal system was tested in two JT9D engines to substantiate the abradability and durability of the seals. Of particular significance was that one of the tests, a 150 hour 1000 cycle endurance program at nominal JT9D operating conditions, was completed with minimal effect on the seals and received Federal Aviation Administration cognizance with respect to potential field service use by the airlines. The other engine test completed 1825 endurance cycles at severe operating conditions and no burn through or other serious defects in the structural integrity of a seal segment was observed. These test results combined with other Pratt and Whitney Aircraft engine tests substantiate the potential of the ceramic outer air seal system to attain the durability goal of 50000 hour engine operating capability. Both engine tests subjected the seals to intentional blade rubs and demonstrated good abradability with volume wear ratios greater than 100, far exceeding the design goal of 10. The improved volume wear ratio will allow the turbine tip clearance to be reduced, thereby resulting in an estimated thrust specific fuel consumption improvement of 0.3 percent.
The Space Systems Integration and Operations Research Applications (SIORA) Program was initiated in late 1986 as a cooperative applications research effort between Stanford University, NASA Kennedy Space Center, and Lockheed Space Operations Company. One of the major initial SIORA tasks was the application of automation and robotics technology to all aspects of the Shuttle tile processing and inspection system. This effort has adopted a systems engineering approach consisting of an integrated set of rapid prototyping testbeds in which a government/university/industry team of users, technologists, and engineers test and evaluate new concepts and technologies within the operational world of Shuttle. These integrated testbeds include speech recognition and synthesis, laser imaging inspection systems, distributed Ada programming environments, distributed relational database architectures, distributed computer network architectures, multimedia workbenches, and human factors considerations.
Cryogenic propellants are readily heated when used. This poses a problem for rocket engine efficiency and effective boot-strapping of the engine, as seen in the "hot" LOX (Liquid Oxygen) problem on the S-1 stage of the Saturn vehicle. In order to remedy this issue, cryogenic fluids were found to be sub-cooled by injection of a warm non-condensing gas. Experimental results show that the mechanism behind the sub-cooling is evaporative cooling. It has been shown that a sub-cooled temperature difference of approximately 13 deg F below saturation temperature [1]. The phenomenon of sub-cooling of cryogenic propellants by a non-condensing gas is not readily available with the General Fluid System Simulation Program (GFSSP) [2]. GFSSP is a thermal-fluid program used to analyze a wide variety of systems that are directly impacted by thermodynamics and fluid mechanics. In order to model this phenomenon, additional capabilities had to be added to GFSSP in the form of a FORTRAN coded sub-routine to calculate the temperature of the sub-cooled fluid. Once this was accomplished, the sub-routine was implemented to a GFSSP model that was created to replicate an experiment that was conducted to validate the GFSSP results.
A full scale engine test of the NASA/General Electric Company (GE) Energy Efficient Engine (E3) was conducted to demonstrate the E3 engine concept and evaluate its performance. The test program, performed at the GE outdoor engine test facilities in Peebles, OH, included a detailed evaluation of the total pressure and temperature profiles at the exit of the mixed flow exhaust system to determine its mixing effectiveness. Subscale model tests of the same mixed flow exhaust system had been previously conducted at FluiDyne Engineering Corporation in Minneapolis, Minnesota as part of the GE E3 mixer aerodynamic technology development program. The scale model and full scale engine nozzle exit survey data and the calculated mixing effectiveness are compared and discussed. Results indicate the full scale engine mixing effectiveness to be five percent higher than the scale model as a result of a geometric difference and higher turbulence levels in the engne exhaust flowfield.
Systems engineering (SE) discipline has revolutionized the way engineers and managers think about solving issues related to design of complex systems: With continued development of state-of-the-art technologies, systems are becoming more complex and therefore, a systematic approach is essential to control and manage their integrated design and development. This complexity is driven from integration issues. In this case, subsystems must interact with one another in order to achieve integration objectives, and also achieve the overall system's required performance. Systems engineering process addresses these issues at multiple levels. It is a technology and management process dedicated to controlling all aspects of system life cycle to assure integration at all levels. The Advanced Integration Matrix (AIM) project serves as the systems engineering and integration function for the Human Support Technology (HST) program. AIM provides means for integrated test facilities and personnel for performance trade studies, analyses, integrated models, test results, and validated requirements of the integration of HST. The goal of AIM is to address systems-level integration issues for exploration missions. It will use an incremental systems integration approach to yield technologies, baselines for further development, and possible breakthrough concepts in the areas of technological and organizational interfaces, total information flow, system wide controls, technical synergism, mission operations protocols and procedures, and human-machine interfaces.
The Energy Efficient Engine (E3) combustor effort was conducted as part of the overall NASA/GE E3 Program. This effort included the selection of an advanced double-annular combustion system design. The primary intent of this effort was to evolve a design that meets the stringent emissions and life goals of the E3, as well as all of the usual performance requirements of combustion systems for modern turbofan engines. Numerous detailed design studies were conducted to define the features of the combustion system design. Development test hardware was fabricated, and an extensive testing effort was undertaken to evaluate the combustion system subcomponents in order to verify and refine the design. Technology derived from this effort was incorporated into the engine combustion hardware design. The advanced engine combustion system was then evaluated in component testing to verify the design intent. What evolved from this effort was an advanced combustion system capable of satisfying all of the combustion system design objectives and requirements of the E3.
In this study, we proposed an Advanced Health Management System (AHMS) functional architecture and conducted a technology assessment for liquid propellant rocket engine lifecycle health management. The purpose of the AHMS is to improve reusable rocket engine safety and to reduce between-flight maintenance. During the study, past and current reusable rocket engine health management-related projects were reviewed, data structures and health management processes of current rocket engine programs were assessed, and in-depth interviews with rocket engine lifecycle and system experts were conducted. A generic AHMS functional architecture, with primary focus on real-time health monitoring, was developed. Fourteen categories of technology tasks and development needs for implementation of the AHMS were identified, based on the functional architecture and our assessment of current rocket engine programs. Five key technology areas were recommended for immediate development, which (1) would provide immediate benefits to current engine programs, and (2) could be implemented with minimal impact on the current Space Shuttle Main Engine (SSME) and Reusable Launch Vehicle (RLV) engine controllers.
Artificial intelligence application requirements demand powerful representation capabilities as well as efficiency for real-time domains. Many tools exist, the most prevalent being expert systems tools such as ART, KEE, OPS5, and CLIPS. Other tools just emerging from the research environment are truth maintenance systems for representing non-monotonic knowledge, constraint systems, object oriented programming, and qualitative reasoning. Unfortunately, as many knowledge engineers have experienced, simply applying a tool to an application requires a large amount of effort to bend the application to fit. Much work goes into supporting work to make the tool integrate effectively. A Knowledge Management Design System (KNOMAD), is described which is a collection of tools built in layers. The layered architecture provides two major benefits; the ability to flexibly apply only those tools that are necessary for an application, and the ability to keep overhead, and thus inefficiency, to a minimum. KNOMAD is designed to manage many knowledge bases in a distributed environment providing maximum flexibility and expressivity to the knowledge engineer while also providing support for efficiency.
The Modular Rocket Engine Control Software (MRECS) Program is a technology demonstration effort designed to advance the state-of-the-art in launch vehicle propulsion systems. Its emphasis is on developing and demonstrating a modular software architecture for a generic, advanced engine control system that will result in lower software maintenance (operations) costs. It effectively accommodates software requirements changes that occur due to hardware. technology upgrades and engine development testing. Ground rules directed by MSFC were to optimize modularity and implement the software in the Ada programming language. MRECS system software and the software development environment utilize Commercial-Off-the-Shelf (COTS) products. This paper presents the objectives and benefits of the program. The software architecture, design, and development environment are described. MRECS tasks are defined and timing relationships given. Major accomplishment are listed. MRECS offers benefits to a wide variety of advanced technology programs in the areas of modular software, architecture, reuse software, and reduced software reverification time related to software changes. Currently, the program is focused on supporting MSFC in accomplishing a Space Shuttle Main Engine (SSME) hot-fire test at Stennis Space Center and the Low Cost Boost Technology (LCBT) Program.
This report summarizes the results of a multi-year training grant for the development and implementation of a Multidisciplinary Design and Analysis (MDA) Fellowship Program at Georgia Tech. The Program funded the creation of graduate MS and PhD degree programs in aerospace systems design, analysis and integration. It also provided prestigious Fellowships with associated Industry Internships for outstanding engineering students. The graduate program has become the foundation for a vigorous and productive research effort and has produced: 20 MS degrees, 7 Ph.D. degrees, and has contributed to 9 ongoing Ph.D. students. The results of the research are documented in 32 publications (23 of which are included on a companion CDROM) and 4 annual student design reports (included on a companion CDROM). The legacy of this critical funding is the Center for Aerospace Systems Analysis at Georgia Tech which is continuing the graduate program, the research, and the industry internships established by this grant.