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Constructing an Efficient Self-Tuning Aircraft Engine Model for Control and Health Management Applications

Self-tuning aircraft engine models can be applied for control and health management applications. The self-tuning feature of these models minimizes the mismatch between any given engine and the underlying engineering model describing an engine family. This paper provides details of the construction of a self-tuning engine model centered on a piecewise linear Kalman filter design. Starting from a nonlinear transient aerothermal model, a piecewise linear representation is first extracted. The linearization procedure creates a database of trim vectors and state-space matrices that are subsequently scheduled for interpolation based on engine operating point. A series of steady-state Kalman gains can next be constructed from a reduced-order form of the piecewise linear model. Reduction of the piecewise linear model to an observable dimension with respect to available sensed engine measurements can be achieved using either a subset or an optimal linear combination of "health" parameters, which describe engine performance. The resulting piecewise linear Kalman filter is then implemented for faster-than-real-time processing of sensed engine measurements, generating outputs appropriate for trending engine performance, estimating both measured and unmeasured parameters for control purposes, and performing on-board gas-path fault diagnostics. Computational efficiency is achieved by designing multidimensional interpolation algorithms that exploit the shared scheduling of multiple trim vectors and system matrices. An example application illustrates the accuracy of a self-tuning piecewise linear Kalman filter model when applied to a nonlinear turbofan engine simulation. Additional discussions focus on the issue of transient response accuracy and the advantages of a piecewise linear Kalman filter in the context of validation and verification. The techniques described provide a framework for constructing efficient self-tuning aircraft engine models from complex nonlinear simulations.Self-tuning aircraft engine models can be applied for control and health management applications. The self-tuning feature of these models minimizes the mismatch between any given engine and the underlying engineering model describing an engine family. This paper provides details of the construction of a self-tuning engine model centered on a piecewise linear Kalman filter design. Starting from a nonlinear transient aerothermal model, a piecewise linear representation is first extracted. The linearization procedure creates a database of trim vectors and state-space matrices that are subsequently scheduled for interpolation based on engine operating point. A series of steady-state Kalman gains can next be constructed from a reduced-order form of the piecewise linear model. Reduction of the piecewise linear model to an observable dimension with respect to available sensed engine measurements can be achieved using either a subset or an optimal linear combination of "health" parameters, which describe engine performance. The resulting piecewise linear Kalman filter is then implemented for faster-than-real-time processing of sensed engine measurements, generating outputs appropriate for trending engine performance, estimating both measured and unmeasured parameters for control purposes, and performing on-board gas-path fault diagnostics. Computational efficiency is achieved by designing multidimensional interpolation algorithms that exploit the shared scheduling of multiple trim vectors and system matrices. An example application illustrates the accuracy of a self-tuning piecewise linear Kalman filter model when applied to a nonlinear turbofan engine simulation. Additional discussions focus on the issue of transient response accuracy and the advantages of a piecewise linear Kalman filter in the context of validation and verification. The techniques described provide a framework for constructing efficient self-tuning aircraft engine models from complex nonlinear simulatns.

Armstrong, Jeffrey B.

Component model reduction via the projection and assembly method

This paper explains the projection and assembly model reduction method which has been used to derive reduced order component models for the Galileo spacecraft. Assembly of reduced order component models produces a reduced order system model which can then be used in multibody simulation codes for efficient run times. The methodology is explained and a proof is given showing the exact reproduction of selected significant system modes. Frequency bounds are obtained for all modes produced when the reduced order components are assembled. The projection and assembly method is demonstrated on two examples. The first example is a simplified model of the Galileo spacecraft, while the second example is the model of the Galileo spacecraft in its early mission configuration. When articulation of components is allowed, the method may not reproduce all system modes precisely. Remedies for this problem are suggested.

Kissel, Glen J.

A COMPACT model reduction methodology for articulated, multi-flexible bodies structures

To simulate the dynamical motion of articulated, multiflexible body structures, one can use multibody simulation packages such as DISCOS. To this end, one need appropriate reduced-order models for all the flexible components involved. The component modes projection and assembly model reduction methodology is one way to construct these reduced-order component models. However, the generated reduced-order system models typically contain high frequency extraneous modes. The presence of high frequency extraneous modes in a reduced-order system model forces us to use a small stepsize in the numerical integration of that model, resulting in an increase in the elapsed time of the integration process. To eliminate these high-frequency modes, we first identify and discard the component modes that 'contributed' to the generations of these modes. A sensitivity analysis is then used to determine how the remaining component modes should be perturbed in order to still closely capture the selected system modes. The effectiveness of the proposed methodology has been successfully verified using a finite-element model of the Galileo spacecraft.

Lee, Allan Y.

Probabilistic Prognosis of Non-Planar Fatigue Crack Growth

Quantifying the uncertainty in model parameters for the purpose of damage prognosis can be accomplished utilizing Bayesian inference and damage diagnosis data from sources such as non-destructive evaluation or structural health monitoring. The number of samples required to solve the Bayesian inverse problem through common sampling techniques (e.g., Markov chain Monte Carlo) renders high-fidelity finite element-based damage growth models unusable due to prohibitive computation times. However, these types of models are often the only option when attempting to model complex damage growth in real-world structures. Here, a recently developed high-fidelity crack growth model is used which, when compared to finite element-based modeling, has demonstrated reductions in computation times of three orders of magnitude through the use of surrogate models and machine learning. The model is flexible in that only the expensive computation of the crack driving forces is replaced by the surrogate models, leaving the remaining parameters accessible for uncertainty quantification. A probabilistic prognosis framework incorporating this model is developed and demonstrated for non-planar crack growth in a modified, edge-notched, aluminum tensile specimen. Predictions of remaining useful life are made over time for five updates of the damage diagnosis data, and prognostic metrics are utilized to evaluate the performance of the prognostic framework. Challenges specific to the probabilistic prognosis of non-planar fatigue crack growth are highlighted and discussed in the context of the experimental results.

Leser, Patrick E.

Low‐dimensional manifold learning for uncertainty quantification in complex multi‐scale stochastic systems

Broadly speaking, the goals of the project are to develop techniques to use manifold learning to develop reduced‐order and surrogate models for "hyper‐reduction" of very high‐dimensional complex multi‐scale systems. This is being achieved by employing a newly proposed form of manifold projection and learning that leverages recent advancements in computational geometry and data‐driven modeling. In particular, we are applying a manifold projection technique to project the solutions of very high‐dimensional systems onto the so‐called Grassmannmanifold, a Reimannian manifold comprised of orthonormal matrices. We then apply data‐driven machine learning techniques to classify the solutions on the manifold (e.g. clustering techniques) according to their proximity on the manifold and leverage a further nonlinear dimension reduction to organize the structured data on the manifold. Finally, we are developing novel techniques that enable us to directly interpolate the hyper‐reduced data such that we can predict the solution of the complex, high‐ dimensional system without need to call the full expensive computational model. Given their adherence to the underlying structure of the solution of the physical system, it is expected that these approximate solutions will be sufficiently constrained so as to (approximately) adhere to physical principles.

97 MATHEMATICS AND COMPUTING

Orthogonal canonical forms for second-order systems

The authors prove that a linear second-order system with arbitrary damping cannot be reduced to Hessenberg-triangular form by means of orthogonal transformations, while this reduction is always possible for the modal damping commonly assumed for models of flexible structures. The type of canonical form obtainable by means of orthogonal transformations acting on a second-order system is heavily dependent on the type of damping considered. If the damping matrix is merely positive semi-definite symmetric, it is generally not possible to obtain a reduction to Hessenberg-triangular form, while this reduction is trivial for zero or Rayleigh damping. If damping is modal, however, as is commonly assumed in structural models, the reduction exists and is nontrivial. Furthermore, reduction to triangular second-order Schur form is always possible for such damping: this canonical form appears likely to have applications to second-order system theory.

Williams, Trevor

Coupling flux balance analysis with reactive transport modeling through machine learning for rapid and stable simulation of microbial metabolic switching

Integrating genome-scale metabolic networks with reactive transport models (RTMs) provides a detailed description of the dynamic changes in microbial growth and metabolism. Despite promising demonstrations in the past, computational inefficiency has been pointed out as a critical issue to overcome because it requires repeated application of linear programming (LP) to obtain flux balance analysis (FBA) solutions in every time step and spatial grid. To address this challenge, we propose a new simulation method where we train and validate artificial neural networks (ANNs) using randomly sampled FBA solutions and incorporate the resulting surrogate FBA model (represented as algebraic equations) into RTMs as source/sink terms. We demonstrate the efficiency of our method via a case study of Shewanella oneidensis MR-1. During aerobic growth on lactate, S. oneidensis produces metabolic byproducts (such as pyruvate and acetate), which are subsequently consumed as alternative carbon sources when the preferred nutrients are depleted. To effectively simulate these complex dynamics, we used a cybernetic approach that models metabolic switches as the outcome of dynamic competition among multiple growth options. In both zero-dimensional batch and one-dimensional column configurations, the ANN-based surrogate models achieved substantial reduction of computational time by several orders of magnitude compared to the original LP-based FBA models. Moreover, the ANN models produced robust solutions without any special measures to prevent numerical instability. These developments significantly promote our ability to utilize genome-scale networks in complex, multi-physics, and multi-dimensional ecosystem modeling.

59 BASIC BIOLOGICAL SCIENCES

Solution of the Nonlinear High-Fidelity Generalized Method of Cells Micromechanics Relations via Order-Reduction Techniques

The High-Fidelity Generalized Method of Cells (HFGMC) is one technique, distinct from traditional finite element approaches, for accurately simulating nonlinear composite material behavior. In this work, the HFGMC global system of equations for doubly-periodic repeating unit cells with nonlinear constituents has been reduced in size through the novel application of a Petrov-Galerkin Proper Orthogonal Decomposition order-reduction scheme in order to improve its computational efficiency. Order-reduced models of an E-glass/Nylon 12 composite led to a 4.8 to 6.3x speedup in the equation assembly/solution runtime while maintaining model accuracy. This corresponded to a 21 to 38 percent reduction in total runtime. The significant difference in assembly/solution and total runtimes was attributed to the evaluation of integration point inelastic field quantities; this step was identical between the unreduced and order-reduced models. Nonetheless, order-reduced techniques offer the potential to significantly improve the computational efficiency of multiscale calculations.

Ricks, Trenton M.

Aeroservoelastic Control Law Development for the Integrated Adaptive Wing Technology Maturation Wind-Tunnel Test

The NASA Advanced Air Transport Technology (AATT) Project seeks to “explore and develop technologies and concepts for improved energy efficiency and environmental compatibility for fixed wing subsonic transports” [1]. The IAWTM project is a subproject within AATT and is a joint Boeing/NASA effort to, in part, demonstrate the active control systems necessary to employ high-aspect ratio wings for improved aerodynamic efficiency. The aircraft configuration under study for the IAWTM project is a generic jet transport based on the NASA Common Research Model (CRM) whose wing aspect ratio has been increased to 13.5 (as opposed to nominal CRM aspect ratio of 9) and whose development is given in Ref. [2]. A semi-span model of the high-aspect-ratio CRM with 10 trailing edge control surfaces is currently being fabricated and will be delivered to the NASA Langley Transonic Dynamics Tunnel (TDT). There, several tests will be conducted to demonstrate maneuver load alleviation (MLA), gust load alleviation (GLA), active flutter suppression (AFS), and drag reduction, all at transonic conditions. A layout of the wind tunnel model is shown in Fig. 1. The wind-tunnel model is a spar/pod wing design with a relatively rigid fuselage attached to a mounting structure (seen in Fig. 1), which in turn is attached to a load balance behind the tunnel wall. Shims exist that can be attached to force the load to go through the fuselage rather than through the balance so as not to damage the balance in the event of flutter. The spar/pod design is similar to that used in the Boeing truss-braced wing aeroelastic model tested in the TDT in 2013 [3]. There is a central spar running the span of the wing to which the pods are attached that form the aerodynamic shape of the wing. The pods are constructed of ribs for attachment to the spar and skins to create the outer mold line. There are ten active control surfaces that will be used for the test objectives discussed above. Three of these (two outboard ailerons and one inboard aileron) are high-speed electrohydraulic actuators, and the remaining seven are low-speed mini-plane flaps, which have slower servo motors that will be used primarily for drag and maneuver load reductions. Control laws must be developed for each test (MLA, GLA, AFS, and drag reduction) and must be able to work in tandem when two or more control strategies are being tested simultaneously (e.g., when control laws to mitigate maneuver loads and gust loads operate simultaneously). The development of these control laws requires accurate mathematical representations of the aerodynamics, structural dynamics, and control surface dynamics of the system. Taken together, this mathematical representation—which is often in state-space form— is the ASE model. Three low-order ASE models of differing fidelities were developed for the IAWTM test and will be presented here. The differences in fidelity appeared in the aerodynamic modeling—one model assumed purely linear aerodynamics, while the other two models used different techniques to linearize the aerodynamics about a nonlinear mean. Furthermore, simple observer-based full-state feedback controllers for each test (MLA, GLA, AFS, and drag reduction) were designed from these low-order ASE models and implemented in a higher-order, nonlinear computational ASE simulation to assess the effectiveness of each controller. Observers were designed from each of the three lower-order ASE models, and each (linear) observer was then used as an estimate of the nonlinear dynamics of the system. Using the estimated states and the full-state feedback controller, control surface commands were fed back to the higher-order, nonlinear ASE system. The insight gained during this development will be applied to control law development for the physical IAWTM wind-tunnel test.

Josiah M Waite

Adaptive model reduction for continuous systems via recursive rational interpolation

A method for adaptive identification of reduced-order models for continuous stable SISO and MIMO plants is presented. The method recursively finds a model whose transfer function (matrix) matches that of the plant on a set of frequencies chosen by the designer. The algorithm utilizes the Moving Discrete Fourier Transform (MDFT) to continuously monitor the frequency-domain profile of the system input and output signals. The MDFT is an efficient method of monitoring discrete points in the frequency domain of an evolving function of time. The model parameters are estimated from MDFT data using standard recursive parameter estimation techniques. The algorithm has been shown in simulations to be quite robust to additive noise in the inputs and outputs. A significant advantage of the method is that it enables a type of on-line model validation. This is accomplished by simultaneously identifying a number of models and comparing each with the plant in the frequency domain. Simulations of the method applied to an 8th-order SISO plant and a 10-state 2-input 2-output plant are presented. An example of on-line model validation applied to the SISO plant is also presented.

Lilly, John H.

Controls/CFD Interdisciplinary Research Software Generates Low-Order Linear Models for Control Design From Steady-State CFD Results

The NASA Lewis Research Center is developing analytical methods and software tools to create a bridge between the controls and computational fluid dynamics (CFD) disciplines. Traditionally, control design engineers have used coarse nonlinear simulations to generate information for the design of new propulsion system controls. However, such traditional methods are not adequate for modeling the propulsion systems of complex, high-speed vehicles like the High Speed Civil Transport. To properly model the relevant flow physics of high-speed propulsion systems, one must use simulations based on CFD methods. Such CFD simulations have become useful tools for engineers that are designing propulsion system components. The analysis techniques and software being developed as part of this effort are an attempt to evolve CFD into a useful tool for control design as well. One major aspect of this research is the generation of linear models from steady-state CFD results. CFD simulations, often used during the design of high-speed inlets, yield high resolution operating point data. Under a NASA grant, the University of Akron has developed analytical techniques and software tools that use these data to generate linear models for control design. The resulting linear models have the same number of states as the original CFD simulation, so they are still very large and computationally cumbersome. Model reduction techniques have been successfully applied to reduce these large linear models by several orders of magnitude without significantly changing the dynamic response. The result is an accurate, easy to use, low-order linear model that takes less time to generate than those generated by traditional means. The development of methods for generating low-order linear models from steady-state CFD is most complete at the one-dimensional level, where software is available to generate models with different kinds of input and output variables. One-dimensional methods have been extended somewhat so that linear models can also be generated from two- and three-dimensional steady-state results. Standard techniques are adequate for reducing the order of one-dimensional CFD-based linear models. However, reduction of linear models based on two- and three-dimensional CFD results is complicated by very sparse, ill-conditioned matrices. Some novel approaches are being investigated to solve this problem.

Melcher, Kevin J.

Model reduction and control of flexible structures using Krylov subspaces

Krylov vectors and the concept of parameter-matching are combined to develop a model reduction algorithm for a damped structural dynamics system. The reduced-order model obtained matches a certain number of low-frequency moments of the full-order system. The major application of the present method is to the control of flexible structures. It is shown that, in the control of flexible structures, there generally exist three types of control energy spillover, namely, the control spillover, the observation spillover, and dynamic spillover. The formulation based on Krylov subspaces can eliminate the control and the observation spillover, while leaving only the dynamic spillover to be considered. Two examples are used to illustrate the efficacy of the Krylov method.

Craig, Roy R., Jr.

Non-intrusive reduced-order modeling for dynamical systems with spatially localized features

This work presents a non-intrusive reduced-order modeling framework for dynamical systems with spatially localized features characterized by slow singular value decay. The proposed approach builds upon two existing methodologies for reduced and full-order non-intrusive modeling, namely Operator Inference (OpInf) and sparse Full-Order Model (sFOM) inference. We decompose the domain into two complementary subdomains that exhibit fast and slow singular value decay. The dynamics of the subdomain exhibiting slow singular value decay are learned with sFOM while the dynamics with intrinsically low dimensionality on the complementary subdomain are learned with OpInf. The resulting, coupled OpInf-sFOM formulation leverages the computational efficiency of OpInf and the high resolution of sFOM, and thus enables fast non-intrusive predictions for conditions beyond those sampled in the training data set. A novel regularization technique with a closed-form solution based on the Gershgorin disk theorem is introduced to promote stable sFOM and OpInf models. We also provide a data-driven indicator for subdomain selection and ensure solution smoothness over the interface via a post-processing interpolation step. We evaluate the efficiency of the approach in terms of offline and online speedup through a quantitative, parametric computational cost analysis. We demonstrate the coupled OpInf-sFOM formulation for two test cases: a one-dimensional Burgers’ model for which accurate predictions beyond the span of the training snapshots are presented, and a two-dimensional parametric model for the Pine Island Glacier ice thickness dynamics, for which the OpInf-sFOM model achieves an average prediction error on the order of 1% with an online speedup factor of approximately 8$\times$ compared to the numerical simulation.

42 ENGINEERING

Integrated Model Reduction and Control of Aircraft with Flexible Wings

This paper presents an integrated approach to the modeling and control of aircraft with exible wings. The coupled aircraft rigid body dynamics with a high-order elastic wing model can be represented in a nite dimensional state-space form. Given a set of desired output covariance, a model reduction process is performed by using the weighted Modal Cost Analysis (MCA). A dynamic output feedback controller, which is designed based on the reduced-order model, is developed by utilizing output covariance constraint (OCC) algorithm, and the resulting OCC design weighting matrix is used for the next iteration of the weighted cost analysis. This controller is then validated for full-order evaluation model to ensure that the aircraft's handling qualities are met and the uttering motion of the wings suppressed. An iterative algorithm is developed in CONDUIT environment to realize the integration of model reduction and controller design. The proposed integrated approach is applied to NASA Generic Transport Model (GTM) for demonstration.

AEROELASTIC

A pointing system design concept for Space Station attached payloads

A study has been conducted to recommend a pointing system design and architecture that can accommodate the articulated pointing requirements levied on the Space Station Freedom Attached Payload Pointing System. A conceptual design of a control system is developed using classical rate and position control techniques. A high fidelity simulation testbed has been developed as the principal tool for the pointing performance evaluation. Techniques of model reduction are applied to reduce the model order to a manageable size for incorporation into the testbed. The disturbance rich space station environment has been modeled, and nonlinearities such as bearing friction, motor and sensor noise are also considered. Simulations were performed with representatie payloads at nominal pointing orientations. The results show that the tight instrument pointing requirements and the severe Space Station disturbance environment render a marginal performance for a conventional (direct drive and hardmount) gimbal pointing system, particularly for lightweight payloads. A gimbal system that incorporates a passive base isolator and reactionless actuation appears to provide a significant imporvement in pointing performance over the conventional pointing systems.

Wong, Edward

Combining Static Analysis and Model Checking for Software Analysis

We present an iterative technique in which model checking and static analysis are combined to verify large software systems. The role of the static analysis is to compute partial order information which the model checker uses to reduce the state space. During exploration, the model checker also computes aliasing information that it gives to the static analyzer which can then refine its analysis. The result of this refined analysis is then fed back to the model checker which updates its partial order reduction. At each step of this iterative process, the static analysis computes optimistic information which results in an unsafe reduction of the state space. However we show that the process converges to a fired point at which time the partial order information is safe and the whole state space is explored.

Brat, Guillaume

Model reduction results for flexible space structures

This paper describes the novel subsystem balancing technique for obtaining reduced-order models of flexible structures, and investigates its properties fully. This method can be regarded as a combination of the best features of modal truncation (efficiency) and internal balancing (accuracy); it is particularly well suited to the typical practical case of structures which possess clusters of close modes. Numerical results are then presented demonstrating the results obtained by applying subsystem balancing to the Air Force Phillips Laboratory ASTREX testbed, the Jet Propulsion Laboratory antenna facility, and the NASA Marshall Space Flight Center ACES structure.

Williams, Trevor