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NASA NTRSDate not supplied

Lessons Learned in Concurrent Mission and Systems Design at NASA Glenn Research Center: Almost Fifteen Years of the Compass Team

This paper is a retrospective of the lessons learned during the almost 15-year history of the Compass concurrent mission and systems design team at NASA’s Glenn Research Center (GRC). It examines the key factors in the team’s evolution from a temporary group gathered to perform a single study to the successful, sustainable team it is today. Compass is a matrixed team of experts with various technical backgrounds and personalities. They collaborate over a two-week period either physically in a dedicated meeting space, or virtually to design a space system (Spacecraft, stage, science package, etc). Over the years, because of the rapid nature of the design studies, the team leadership has iterated on the optimal team member personality makeup, facility elements and tools as well as NASA GRC management support necessary to lead to sustained success.

systems engineering↗

NASA NTRS2016

Dynamic Systems Analysis for Turbine Based Aero Propulsion Systems

The aircraft engine design process seeks to optimize the overall system-level performance, weight, and cost for a given concept. Steady-state simulations and data are used to identify trade-offs that should be balanced to optimize the system in a process known as systems analysis. These systems analysis simulations and data may not adequately capture the true performance trade-offs that exist during transient operation. Dynamic systems analysis provides the capability for assessing the dynamic tradeoffs at an earlier stage of the engine design process. The dynamic systems analysis concept, developed tools, and potential benefit are presented in this paper. To provide this capability, the Tool for Turbine Engine Closed-loop Transient Analysis (TTECTrA) was developed to provide the user with an estimate of the closed-loop performance (response time) and operability (high pressure compressor surge margin) for a given engine design and set of control design requirements. TTECTrA along with engine deterioration information, can be used to develop a more generic relationship between performance and operability that can impact the engine design constraints and potentially lead to a more efficient engine.

dynamic analysis↗

NASA NTRS2005

Fitting Nonlinear Curves by use of Optimization Techniques

MULTIVAR is a FORTRAN 77 computer program that fits one of the members of a set of six multivariable mathematical models (five of which are nonlinear) to a multivariable set of data. The inputs to MULTIVAR include the data for the independent and dependent variables plus the user s choice of one of the models, one of the three optimization engines, and convergence criteria. By use of the chosen optimization engine, MULTIVAR finds values for the parameters of the chosen model so as to minimize the sum of squares of the residuals. One of the optimization engines implements a routine, developed in 1982, that utilizes the Broydon-Fletcher-Goldfarb-Shanno (BFGS) variable-metric method for unconstrained minimization in conjunction with a one-dimensional search technique that finds the minimum of an unconstrained function by polynomial interpolation and extrapolation without first finding bounds on the solution. The second optimization engine is a faster and more robust commercially available code, denoted Design Optimization Tool, that also uses the BFGS method. The third optimization engine is a robust and relatively fast routine that implements the Levenberg-Marquardt algorithm.

Hill, Scott A.↗

NASA NTRS1989

Numerical experience with a class of algorithms for nonlinear optimization using inexact function and gradient information

For optimization problems associated with engineering design, parameter estimation, image reconstruction, and other optimization/simulation applications, low accuracy function and gradient values are frequently much less expensive to obtain than high accuracy values. Here, researchers investigate the computational performance of trust region methods for nonlinear optimization when high accuracy evaluations are unavailable or prohibitively expensive, and confirm earlier theoretical predictions when the algorithm is convergent even with relative gradient errors of 0.5 or more. The proper choice of the amount of accuracy to use in function and gradient evaluations can result in orders-of-magnitude savings in computational cost.

Carter, Richard G.↗

NASA NTRS2003

Advanced Information Technology in Simulation Based Life Cycle Design

In this research a Collaborative Optimization (CO) approach for multidisciplinary systems design is used to develop a decision based design framework for non-deterministic optimization. To date CO strategies have been developed for use in application to deterministic systems design problems. In this research the decision based design (DBD) framework proposed by Hazelrigg is modified for use in a collaborative optimization framework. The Hazelrigg framework as originally proposed provides a single level optimization strategy that combines engineering decisions with business decisions in a single level optimization. By transforming this framework for use in collaborative optimization one can decompose the business and engineering decision making processes. In the new multilevel framework of Decision Based Collaborative Optimization (DBCO) the business decisions are made at the system level. These business decisions result in a set of engineering performance targets that disciplinary engineering design teams seek to satisfy as part of subspace optimizations. The Decision Based Collaborative Optimization framework more accurately models the existing relationship between business and engineering in multidisciplinary systems design.

Renaud, John E.↗

NASA NTRSDate not supplied

A Review Towards the Design Optimization of High-Performance Additively Manufactured Rotating Detonation Rocket Engine Injectors

Rotating Detonation Rocket Engines (RDRE) have been marketed primarily for their higher specific impulse potential over constant pressure (CP) liquid rocket engines. However, several other performance advantages exist such as heat transfer advantages for gas expander cycle, increased completeness of combustion at low chamber L*, compact engine design, reduced coolant channel pressure drop potential, and improved injector C* performance. NASA has paved the way for liquid engine system performance enhancement since the Apollo program and continues to do so with metal additive manufacturing (AM), new advanced materials, and advanced propulsion concepts. A team of propulsion development engineers at NASA are in the process of developing high-performance 7K lbf class RDRE hardware for their potential use in lander, upper stage, and even launch vehicle applications. Clear advantages have been demonstrated with AM including program cost and schedule reductions of up to 50%. It is well known that injector performance is integrally linked to the global performance of a combustion device. This is especially the case for RDREs since detonation stability is heavily dependent on the mixedness of propellants. A major goal of this work is to identify what has been done in the open experimental literature and what injectors design features are conducive to high performance in the detonation cycle. This paper reviews the available literature and reports the primary gaps in the knowledge base needed by the pressure gain combustion (PGC) community. Major conclusions are documented, and suggestions given towards the design of high-performance liquid RDRE injectors. In addition, the integration of metal AM into the design of liquid RDRE injector schemes is included.

rotating detonation rocket engine↗

NASA NTRS1969

Design and testing of liquid hydrogen-cooled, ultrahigh-speed ball bearings

Large-bore, liquid hydrogen-cooled, ultrahigh-speed, rolling contact bearings of an optimum design allow optimization of large rocket engine turbopumps in which bearing speed is a limiting factor. Optimum design for the bearings resulted from an application of liquid hydrogen used as a coolant.

Butner, M. F.↗

NASA NTRS1984

On optimal design for the blade-root/hub interface in jet engines

Two major problems identified with the design of the blade-root/hub interface are discussed. The first is the so-called friction contact problem which has two special features: unilateral contact and Coulomb's friction. One of the difficulties in this problem is that the portions of contact and sticking/sliding surfaces are not known a priori. The second is the shape optimization problem which is characterized either by the minimization of the maximum contact pressure or by the minimization of the equivalent stress on the boundary. Design variables are the shapes of the blade-root and the hub. It is noted that friction contact and shape optimization problems are strongly coupled in the present design problem.

Kikuchi, N.↗

NASA NTRS1989

SP-100 advanced radiator designs for thermoelectric and Stirling applications

Advanced radiator designs employing carbon-carbon liquid metal heat pipe technology, which significantly reduce the mass of the heat rejection subsystem for high temperature space technology systems such as the SP-100 are discussed. This technology is being developed to address the need for lightweight heat transfer components and structures for space applications. Heat pipe and subsystem designs were optimized for thermoelectric- and Stirling-engine-based SP-100 system designs. A multiple, deployed-petal radiator concept was selected for the heat rejection subsystem design as it provided minimum mass. Radiator stowage in the space transportation system cargo bay and deployment schemes were investigated for each of the optimized designs.

Moriarty, M. P.↗

NASA NTRS2012

Design and Performance Optimizations of Advanced Erosion-Resistant Low Conductivity Thermal Barrier Coatings for Rotorcraft Engines

Thermal barrier coatings will be more aggressively designed to protect gas turbine engine hot-section components in order to meet future rotorcraft engine higher fuel efficiency and lower emission goals. For thermal barrier coatings designed for rotorcraft turbine airfoil applications, further improved erosion and impact resistance are crucial for engine performance and durability, because the rotorcraft are often operated in the most severe sand erosive environments. Advanced low thermal conductivity and erosion-resistant thermal barrier coatings are being developed, with the current emphasis being placed on thermal barrier coating toughness improvements using multicomponent alloying and processing optimization approaches. The performance of the advanced thermal barrier coatings has been evaluated in a high temperature erosion burner rig and a laser heat-flux rig to simulate engine erosion and thermal gradient environments. The results have shown that the coating composition and architecture optimizations can effectively improve the erosion and impact resistance of the coating systems, while maintaining low thermal conductivity and cyclic oxidation durability

Zhu, Dongming↗

NASA NTRSDate not supplied

Providing Long-term Solar and Meteorological Resource Information from NASA Research through the GIS-Enabled POWER Web Services Portal

Solar and other renewable energy systems are optimized using geophysical parameters describing information about the solar resource and meteorological environments and how those environments may be changing in time. The Prediction of Worldwide Renewable Energy Resource (POWER) team at the NASA LaRC Research Center deployed its first version of the revitalized POWER geophysical parameter website that employs Esri Geographic Information System (GIS) tools. This web application provides access to both time series and climatological data sets spanning from a few days behind real-time back to the early 1980’s with a spatial resolution of 0.5 x 0.5 degree, thus extending over 30 years. The GIS tools enable, generate and store climatological averages using spatial queries and calculations in a spatial database resulting in greater accessibility to government agencies, industry and individuals. There is an API that provides data through a URL coding and can also invoked inside user software packages. Output data formats now include ASCII, CSV, geoTiff, JSON and .netCDF. Since May 2018, over 10.4 TB of data have been delivered to fulfill over 110 million data requests from 240,000 unique user IPs (https://power.larc.nasa.gov). This presentation provides an overview of this project and the current version of the new POWER web capabilities through to the end usage. Surface solar parameters are adapted from both the NASA/GEWEX (Global and Energy Water Cycle Exchange) SRB (Surface Radiation Budget) project and the CERES (Clouds and Earth’s Radiant Energy System) data products. The meteorological parameters are adapted from NASA’s MERRA-2 (Modern Era Retrospective-analysis for Research and Applications). We review uncertainty of various basic parameters using surface measurements. After the introduction, we specifically discuss various clusters of parameters for equator pointing tilted surfaces that provide for the estimation of optimal tilt angle by month and year. The discussion will emphasize a few examples of how solar and building engineers are using the data products. We will then preview the capabilities of Version 2 featuring examples of hourly solar and meteorological data products, customized user reports and expanded web mapping services from CERES data products. The web services provide a unique, expandable resource for renewable energy systems engineers to design, evaluate and optimize to environments worldwide.

Solar Resource↗

NASA NTRS2016

Optimization of Turbine Engine Cycle Analysis with Analytic Derivatives

A new engine cycle analysis tool, called Pycycle, was built using the OpenMDAO framework. Pycycle provides analytic derivatives allowing for an efficient use of gradient-based optimization methods on engine cycle models, without requiring the use of finite difference derivative approximation methods. To demonstrate this, a gradient-based design optimization was performed on a turbofan engine model. Results demonstrate very favorable performance compared to an optimization of an identical model using finite-difference approximated derivatives.

OpenMDAO↗

NASA NTRS1991

Formal and heuristic system decomposition methods in multidisciplinary synthesis

The multidisciplinary interactions which exist in large scale engineering design problems provide a unique set of difficulties. These difficulties are associated primarily with unwieldy numbers of design variables and constraints, and with the interdependencies of the discipline analysis modules. Such obstacles require design techniques which account for the inherent disciplinary couplings in the analyses and optimizations. The objective of this work was to develop an efficient holistic design synthesis methodology that takes advantage of the synergistic nature of integrated design. A general decomposition approach for optimization of large engineering systems is presented. The method is particularly applicable for multidisciplinary design problems which are characterized by closely coupled interactions among discipline analyses. The advantage of subsystem modularity allows for implementation of specialized methods for analysis and optimization, computational efficiency, and the ability to incorporate human intervention and decision making in the form of an expert systems capability. The resulting approach is not a method applicable to only a specific situation, but rather, a methodology which can be used for a large class of engineering design problems in which the system is non-hierarchic in nature.

Bloebaum, Christina L.↗

NASA NTRS1990

Spacecraft protective structures design optimization

The optimization of spacecraft protective structures design to defeat hypervelocity impacts of meteoroids and space debris is presented. A space debris environment model is incorporated into an overall optimization methodology employing engineering models developed to predict protective structures design requirements for hypervelocity impact loads. Several nonlinear optimization techniques are used to generate design parametrics based on environment, mission, and configuration variables for the Space Station Core Module Configuration. Results indicate that careful consideration of the spacecraft structural configuration and materials can partially offset the design consequences of dramatic increases in the orbital space debris environment. Furthermore, the use of nonlinear optimization techniques coupled with hypervelocity impact engineering models can provide significant design tradeoff insight through the use of parametric analyses.

Mog, Robert A.↗

NASA NTRS1980

Orbit transfer vehicle engine study. Volume 2: Technical report

The orbit transfer vehicle (OTV) engine study provided parametric performance, engine programmatic, and cost data on the complete propulsive spectrum that is available for a variety of high energy, space maneuvering missions. Candidate OTV engines from the near term RL 10 (and its derivatives) to advanced high performance expander and staged combustion cycle engines were examined. The RL 10/RL 10 derivative performance, cost and schedule data were updated and provisions defined which would be necessary to accommodate extended low thrust operation. Parametric performance, weight, envelope, and cost data were generated for advanced expander and staged combustion OTV engine concepts. A prepoint design study was conducted to optimize thrust chamber geometry and cooling, engine cycle variations, and controls for an advanced expander engine. Operation at low thrust was defined for the advanced expander engine and the feasibility and design impact of kitting was investigated. An analysis of crew safety and mission reliability was conducted for both the staged combustion and advanced expander OTV engine candidates.

Source record↗

NASA NTRS2020

Reliability Analysis of Complex NASA Systems with Model-Based Engineering

The emergence of model-based engineering, with Model- Based Systems Engineering (MBSE) leading the way, is transforming design and analysis methodologies. The recognized benefits to systems development include moving from document-centric information systems and document-centric project communication to a model-centric environment in which control of design changes in the life cycles is facilitated. In addition, a “single source of truth” about the system, that is up-to-date in all respects of the design, becomes the authoritative source of data and information about the system. This promotes consistency and efficiency in regard to integration of the system elements as the design emerges and thereby may further optimize the design. Therefore Reliability Engineers (REs) supporting NASA missions must be integrated into model-based engineering to ensure the outputs of their analyses are relevant and value-needed to the design, development, and operational processes for failure risks assessment and communication.

FMEA/FMECA↗

NASA NTRS2020

Reliability Analysis of Complex NASA Systems with Model Based Engineering

Reliability prediction↗

NASA NTRS2021

Model-Based SMA Initiative Phase 1 Report: Reliability Tips Excerpt

The emergence of model-based engineering, with Model- Based Systems Engineering (MBSE) leading the way, is transforming design and analysis methodologies. [7] The recognized benefits to systems development include moving from document-centric information systems and document-centric project communication to a model-centric environment in which control of design changes in the life cycles is facilitated. In addition, a “single source of truth” about the system, that is up-to-date in all respects of the design, becomes the authoritative source of data and information about the system. This promotes consistency and efficiency in regard to integration of the system elements as the design emerges and thereby may further optimize the designs. Therefore Reliability Engineers (REs) supporting NASA missions must be integrated into model-based engineering, using these recommended modeling techniques, to ensure the outputs of their analyses are relevant and value-needed to the design, development, and operational processes for failure risk assessment and communication.

Nancy J. Lindsey↗