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DOE OSTI2018

Demonstrating the Value of Human Factors for Process Design in a Controlled Experiment

A controlled between-groups experiment was conducted to demonstrate the value of human factors for process design. Most evidence to convey the benefits of human factors is derived from reactive studies of existing flawed systems designed with little or no human factors involvement. Controlled experiments conducted explicitly to demonstrate the benefits of human factors have been scarce since the 1990s. Further, most previous research focused on product or interface design as opposed to process design. The present study was designed to fill these research gaps. Toward that end, 24 Sandia National Laboratories employees completed a simple visual inspection task simulating receipt inspection. The experimental group process was designed to conform to human factors and visual inspection principles, whereas the control group process was designed without consideration of such principles. Results indicated the experimental group exhibited superior performance accuracy, lower workload, and more favorable usability ratings as compared to the control group. Given the differences observed in the simple task used in the present study, the author concluded that incorporating human factors should have even greater benefits for complex products and processes. The study provides evidence to help human factors practitioners revitalize the critical message regarding the benefits of human factors involvement for a new generation of designers.

42 ENGINEERING↗

DOE OSTI2017

Modeling and Simulation of Compression Molding Process for Sheet Molding Compound (SMC) of Chopped Carbon Fiber Composites

Compression molded SMC composed of chopped carbon fiber and resin polymer which balances the mechanical performance and manufacturing cost presents a promising solution for vehicle lightweight strategy. However, the performance of the SMC molded parts highly depends on the compression molding process and local microstructure, which greatly increases the cost for the part level performance testing and elongates the design cycle. ICME (Integrated Computational Material Engineering) approaches are thus necessary tools to reduce the number of experiments required during part design and speed up the deployment of the SMC materials. As the fundamental stage of the ICME workflow, commercial software packages for SMC compression molding exist yet remain not fully validated especially for chopped fiber systems. In this study, SMC plaques are prepared through compression molding process. The corresponding simulation models are built in Autodesk Moldflow with the same part geometry and processing conditions as in the molding tests. The output variables of the compression molding simulations, including press force history and fiber orientation of the part, are compared with experimental data. Influence of the processing conditions to the fiber orientation of the SMC plaque is also discussed. It is found that generally Autodesk Moldflow can achieve a good simulation of the compression molding process for chopped carbon fiber SMC, yet quantitative discrepancies still remain between predicted variables and experimental results.

36 MATERIALS SCIENCE↗

NASA NTRS1978

Aircraft simulation data management - A prototype system

Piloted flight simulations are used throughout the aircraft development process to evaluate design concepts, handling qualities and operational procedures. Simulation project managers are often inundated with data but without a convenient and efficient way to make the correlations and analyses necessary to evaluate system performance. A computer-based Simulation Management System (SIMS) is under development. SIMS will permit simulation project engineers to quickly acquire, access, display, edit, analyze, and document the information necessary to more efficiently manage the research program. SIMS features interactive, associative access to simulation data. This paper describes SIMDEM, a prototype system designed to demonstrate these concepts and procedures in order to obtain feedback from simulator users to guide system design.

Crane, D. F.↗

DOE OSTI2023

Advanced Simulation and Computing: ASC FY24 Implementation Plan

The DOE National Nuclear Security Administration (NNSA) Stockpile Stewardship Program (SSP) is an integrated technical program for maintaining the safety, security, and reliability of the U.S. nuclear stockpile. The SSP incorporates nuclear test data, computational modeling and simulation, and experimental facilities to advance understanding of nuclear weapons. The suite of data analyzed comes from activities including previous nuclear tests, stockpile surveillance, experimental research, and development and engineering programs. This integrated national program requires the continued use of experimental facilities and the computational capabilities to support the SSP missions. These component parts, in addition to an appropriately scaled production capability, enable NNSA to support stockpile requirements. The ultimate goal of the SSP, and thus of the Advanced Simulation and Computing (ASC) program, is to ensure that the U.S. maintains a safe, secure, and effective strategic deterrent. The ASC program is a cornerstone of the SSP, providing simulation capabilities and computational resources to support the annual stockpile assessment and certification process, study advanced nuclear weapons design and manufacturing processes, analyze accident scenarios and weapons aging, and provide the tools to enable stockpile Life Extension Programs (LEPs) and the resolution of Significant Finding Investigations (SFIs). This work requires a balance of resources, including technical staff, hardware, simulation software, and computer science solutions. The ASC program focuses on increasing the predictive capabilities in a three-dimensional (3D) simulation environment while maintaining support to the SSP. The Program continues to improve its unique tools for understanding and solving progressively more difficult stockpile problems (sufficient resolution, dimensionality, and scientific details), and quantifying critical margins and uncertainties. Resolving each issue requires increasingly difficult analyses because the aging process has progressively moved the stockpile further from the original test base. While the focus remains on the U.S. nuclear weapons program, where possible, the Program also enables the use of high-performance computing (HPC) and simulation tools to address broader national security needs, such as foreign nuclear weapon assessments and nuclear counterterrorism. The 2022 Nuclear Posture Review (NPR) calls for NNSA to “deliver a modern, adaptive nuclear security enterprise based on an integrated strategy for risk management, production-based resilience, science and technology innovation, and workforce initiatives.” Furthermore, “NNSA will establish a Science and Technology Innovation Initiative to accelerate the integration of science and technology (S&T) throughout its activities.” Executing this strategy necessitates the continued emphasis on developing and sustaining high-quality scientific and engineering staff, as well as supporting computational and experimental capabilities. These components constitute the foundation of the nuclear weapons program. The continued success of the SSP and LEPs is predicated upon the ability to credibly certify the stockpile, without a return to underground nuclear tests (UGTs). Shortly after the nuclear test moratorium entered into force in 1992, the Accelerated Strategic Computing Initiative (ASCI) was established to provide an extensive simulation capability to underpin stockpile certification. While computing and simulation have always been essential to the success of the nuclear weapons program, the program goal of ASCI was to execute NNSA’s vision of using these tools in support of the stockpile stewardship mission. The ASCI program was essential to the successful demonstration of the SSP, providing critical nuclear weapons simulation and modeling capabilities. ASCI officially evolved into the ASC program in fiscal year (FY) 2005, but the mission remains essentially the same: provide the simulation and computational capabilities that underpin the ability to maintain a safe, secure, effective nuclear weapon stockpile, without returning to underground nuclear testing. The capabilities that the ASC program provides at the national laboratories play a vital role in the nuclear security enterprise and are necessary for fulfilling the stockpile stewardship and life extension requirements outlined for NNSA. The Program develops modern simulation tools that provide insights into stockpile aging issues, provide the computational and simulation tools that enable designers and analysts to certify the current stockpile and life-extended nuclear weapons, and inform the decision-making process when any modifications in nuclear warheads or the associated manufacturing processes are deemed necessary. Furthermore, ASC is enhancing the predictive simulation capabilities that are essential to evaluate weapons effects, design experiments, and ensure test readiness. The ASC program continues to improve its unique tools to solve stockpile problems— with a focus on sufficient resolution, dimensionality, and scientific detail—to enable Quantification of Margins and Uncertainties (QMU) and to resolve the increasingly difficult analyses needed for stockpile stewardship. The needs of the Stockpile Management and Production Modernization programs (formerly Directed Stockpile Work) also drive the requirements for simulation and computational resources. These requirements include planned LEPs, stockpile support activities, and mitigation efforts against the potential for technical surprise. All of the weapons within the current stockpile are in some stage of the life extension process. The simulation and computational capabilities are crucial for successful execution of these life extensions and for ensuring NNSA can certify these life-extended weapons without conducting a UGT.

97 MATHEMATICS AND COMPUTING↗

NASA NTRS1972

Simulation of mass storage systems operating in a large data processing facility

A mass storage simulation program was written to aid system designers in the design of a data processing facility. It acts as a tool for measuring the overall effect on the facility of on-line mass storage systems, and it provides the means of measuring and comparing the performance of competing mass storage systems. The performance of the simulation program is demonstrated.

Holmes, R.↗

NASA NTRS2010

Control Design for a Generic Commercial Aircraft Engine

This paper describes the control algorithms and control design process for a generic commercial aircraft engine simulation of a 40,000 lb thrust class, two spool, high bypass ratio turbofan engine. The aircraft engine is a complex nonlinear system designed to operate over an extreme range of environmental conditions, at temperatures from approximately -60 to 120+ F, and at altitudes from below sea level to 40,000 ft, posing multiple control design constraints. The objective of this paper is to provide the reader an overview of the control design process, design considerations, and justifications as to why the particular architecture and limits have been chosen. The controller architecture contains a gain-scheduled Proportional Integral controller along with logic to protect the aircraft engine from exceeding any limits. Simulation results illustrate that the closed loop system meets the Federal Aviation Administration s thrust response requirements

Csank, Jeffrey↗

NASA NTRS2013

Designing Scenarios for Controller-in-the-Loop Air Traffic Simulations

Well prepared traffic scenarios contribute greatly to the success of controller-in-the-loop simulations. This paper describes each stage in the design process of realistic scenarios based on real-world traffic, to be used in the Airspace Operations Laboratory for simulations within the Air Traffic Management Technology Demonstration 1 effort. The steps from the initial analysis of real-world traffic, to the editing of individual aircraft records in the scenario file, until the final testing of the scenarios before the simulation conduct, are all described. The iterative nature of the design process and the various efforts necessary to reach the required fidelity, as well as the applied design strategies, challenges, and tools used during this process are also discussed.

ATD1↗

NASA NTRS1987

GTOSS: Generalized Tethered Object Simulation System

GTOSS represents a tether analysis complex which is described by addressing its family of modules. TOSS is a portable software subsystem specifically designed to be introduced into the environment of any existing vehicle dynamics simulation to add the capability of simulating multiple interacting objects (via multiple tethers). These objects may interact with each other as well as with the vehicle into whose environment TOSS is introduced. GTOSS is a stand alone tethered system analysis program, representing an example of TOSS having been married to a host simulation. RTOSS is the Results Data Base (RDB) subsystem designed to archive TOSS simulation results for future display processing. DTOSS is a display post processors designed to utilize the RDB. DTOSS extracts data from the RDB for multi-page printed time history displays. CTOSS is similar to DTOSS, but is designed to create ASCII plot files. The same time history data formats provided for DTOSS (for printing) are available via CTOSS for plotting. How these and other modules interact with each other is discussed.

Lang, David D.↗

DOE OSTI2023

Comparison of free vortex wake and blade element momentum results against large-eddy simulation results for highly flexible turbines under challenging inflow conditions

Abstract. Throughout wind energy development, there has been a push to increase wind turbine size due to the substantial economic benefits. However, increasing turbine size presents several challenges, both physically and computationally. Modeling large, highly flexible wind turbines requires highly accurate models to capture the complicated aeroelastic response due to large deflections and nonstraight blade geometries. Additionally, the development of floating offshore wind turbines requires modeling techniques that can predict large rotor and tower motion. Free vortex wake methods model such complex physics while remaining computationally tractable to perform key simulations necessary during the turbine design process. Recently, a free vortex wake model – cOnvecting LAgrangian Filaments (OLAF) – was added to the National Renewable Energy Laboratory's engineering tool OpenFAST to allow for the aerodynamic modeling of highly flexible turbines along with the aero-hydro-servo-elastic response capabilities of OpenFAST. In this work, free vortex wake and low-fidelity blade element momentum (BEM) results are compared to high-fidelity actuator-line computational fluid dynamics simulation results via the Simulator fOr Wind Farm Applications (SOWFA) method for a highly flexible downwind turbine for varying yaw misalignment, shear exponent, and turbulence intensity conditions. Through these comparisons, it was found that for all considered quantities of interest, SOWFA, OLAF, and BEM results compare well for steady inflow conditions with no yaw misalignment. For OLAF results, this strong agreement with the SOWFA results was consistent for all yaw misalignment values. The BEM results, however, deviated significantly more from the SOWFA results with increasing absolute yaw misalignment. Differences between OLAF and BEM results were dominated by the yaw misalignment angle, with varying shear exponent and turbulence intensity leading to more subtle differences. Overall, OLAF results were more consistent than BEM results when compared to SOWFA results under challenging inflow conditions.

17 WIND ENERGY↗

NASA NTRS2000

Effect of Jet Injection Angle and Number of Jets on Mixing and Emissions From a Reacting Crossflow at Atmospheric Pressure

The mixing of air jets into hot, fuel-rich products of a gas turbine primary zone is an important step in staged combustion. Often referred to as "quick quench," the mixing occurs with chemical conversion and substantial heat release. An experiment has been designed to simulate and study this process, and the effect of varying the entry angle (0 deg, 22.5 deg and 45 deg from normal) and number of the air jets (7, 9, and 11) into the main flow, while holding the jet-to-crossflow mass-low ratio, MR, and momentum-flux ratio, J, constant (MR = 2.5;J = 25). The geometry is a crossflow confined in a cylindrical duct with side-wall injection of jets issuing from orifices equally spaced around the perimeter. A specially designed reactor, operating on propane, presents a uniform mixture to a module containing air jet injection tubes that can be changed to vary orifice geometry. Species concentrations of O2, CO, CO2, NO(x) and HC were obtained one duct diameter upstream (in the rich zone), and primarily one duct radius downstream. From this information, penetration of the jet, the spatial extent of chemical reaction, mixing, and the optimum jet injection angle and number of jets can be deduced.

St.John, D.↗

NASA NTRS2010

The Kepler End-to-End Model: Creating High-Fidelity Simulations to Test Kepler Ground Processing

The Kepler mission is designed to detect the transit of Earth-like planets around Sun-like stars by observing 100,000 stellar targets. Developing and testing the Kepler ground-segment processing system, in particular the data analysis pipeline, requires high-fidelity simulated data. This simulated data is provided by the Kepler End-to-End Model (ETEM). ETEM simulates the astrophysics of planetary transits and other phenomena, properties of the Kepler spacecraft and the format of the downlinked data. Major challenges addressed by ETEM include the rapid production of large amounts of simulated data, extensibility and maintainability.

Bryson, Stephen T.↗

NASA NTRS1995

Controlling Air Traffic (Simulated) in the Presence of Automation (CATS PAu) 1995: A Study of Measurement Techniques for Situation Awareness in Air Traffic Control

As automated systems proliferate in aviation systems, human operators are taking on less and less of an active role in the jobs they once performed, often reducing what should be important jobs to tasks barely more complex than monitoring machines. When operators are forced into these roles, they risk slipping into hazardous states of awareness, which can lead to reduced skills, lack of vigilance, and the inability to react quickly and competently when there is a machine failure. Using Air Traffic Control (ATC) as a model, the present study developed tools for conducting tests focusing on levels of automation as they relate to situation awareness. Subjects participated in a two-and-a-half hour experiment that consisted of a training period followed by a simulation of air traffic control similar to the system presently used by the FAA, then an additional simulation employing automated assistance. Through an iterative design process utilizing numerous revisions and three experimental sessions, several measures for situational awareness in a simulated Air Traffic Control System were developed and are prepared for use in future experiments.

French, Jennifer R.↗

NASA NTRS2004

Transitioning from Software Requirements Models to Design Models

The Scenario Creation and Simulation Process (SCASP) includes the following steps: 1) Write Requirements; 2) Write Use Cases; 3) Prioritize Use Cases; 4) Write Nominal Scenarios; 5) Identify Relationships; 6) Refine/Generalize Scenarios; 7) Transform to State Machines. SCASP provides thorough simulation of use cases before design/implementation, resulting in: 1) Reduced cost; 2) Fewer misunderstandings; 3) Reuse of executable form of use cases. SCASP gives systematic guidelines on how to 1) Separate concerns in use case descriptions; 2) Elicit non-nominal scenarios (alternatives, exceptions, concurrent scenarios, etc.); 3) Transform those scenarios automatically into a set of concurrent state machines; 4) Execute those state machines, i.e., scenario simulation.

Whittle, Jon↗

NASA NTRS2002

Opportunities for Breakthroughs in Large-Scale Computational Simulation and Design

Opportunities for breakthroughs in the large-scale computational simulation and design of aerospace vehicles are presented. Computational fluid dynamics tools to be used within multidisciplinary analysis and design methods are emphasized. The opportunities stem from speedups and robustness improvements in the underlying unit operations associated with simulation (geometry modeling, grid generation, physical modeling, analysis, etc.). Further, an improved programming environment can synergistically integrate these unit operations to leverage the gains. The speedups result from reducing the problem setup time through geometry modeling and grid generation operations, and reducing the solution time through the operation counts associated with solving the discretized equations to a sufficient accuracy. The opportunities are addressed only at a general level here, but an extensive list of references containing further details is included. The opportunities discussed are being addressed through the Fast Adaptive Aerospace Tools (FAAST) element of the Advanced Systems Concept to Test (ASCoT) and the third Generation Reusable Launch Vehicles (RLV) projects at NASA Langley Research Center. The overall goal is to enable greater inroads into the design process with large-scale simulations.

Alexandrov, Natalia↗

DOE OSTI2023

Multidisciplinary design optimization in Architecture, Engineering, and Construction: a detailed review and call for collaboration

The design of buildings has become a complex and multidisciplinary problem involving multiple conflicting objectives as architects and designers address competing technical, economic, environmental, and societal concerns. This has been driving research in Architecture, Engineering, and Construction (AEC) toward rigorous multidisciplinary decision-making frameworks that generate and evaluate numerous design alternatives using multi-objective optimization in concert with simulation and analysis models of varying fidelity and computational expense. While such frameworks are well known and widely employed in the aerospace and systems engineering domains, efforts by design professionals and researchers in the AEC field are scattered at best. In this paper, we provide a detailed review of recent developments in optimization frameworks in the AEC field and subsequently highlight how such developments are largely compartmentalized into separate domains such as structural, energy, daylighting, and other performance factors. Herein, we further discuss the technical challenges involved in concurrent coupled multidisciplinary design optimization (MDO) in the AEC field such as interoperability issues between Building Information Modeling (BIM) environments, analysis/simulation tools, and optimization frameworks. We conclude by outlining research needed for more unified modeling and simulation-based optimization frameworks to aid in complex and multidisciplinary building design processes. We also highlight the need for the identification and development of multi-fidelity simulation tools for use across multiple design phases. As such, this paper contributes a novel roadmap to leverage aerospace and systems engineering research in MDO into the field of AEC, along with a call for researchers in the MDO community to seek collaborations in AEC field.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

NASA NTRS2007

High Fidelity, Fuel-Like Thermal Simulators for Non-Nuclear Testing: Analysis and Initial Test Results

Non-nuclear testing can be a valuable tool in the development of a space nuclear power system, providing system characterization data and allowing one to work through various fabrication, assembly and integration issues without the cost and time associated with a full ground nuclear test. In a non-nuclear test bed, electric heaters are used to simulate the heat from nuclear fuel. Testing with non-optimized heater elements allows one to assess thermal, heat transfer. and stress related attributes of a given system, but fails to demonstrate the dynamic response that would be present in an integrated, fueled reactor system. High fidelity thermal simulators that match both the static and the dynamic fuel pin performance that would be observed in an operating, fueled nuclear reactor can vastly increase the value of non-nuclear test results. With optimized simulators, the integration of thermal hydraulic hardware tests with simulated neutronic response provides a bridge between electrically heated testing and fueled nuclear testing. By implementing a neutronic response model to simulate the dynamic response that would be expected in a fueled reactor system, one can better understand system integration issues, characterize integrated system response times and response characteristics and assess potential design improvements at relatively small fiscal investment. Initial conceptual thermal simulator designs are determined by simple one-dimensional analysis at a single axial location and at steady state conditions; feasible concepts are then input into a detailed three-dimensional model for comparison to expected fuel pin performance. Static and dynamic fuel pin performance for a proposed reactor design is determined using SINDA/FLUINT thermal analysis software, and comparison is made between the expected nuclear performance and the performance of conceptual thermal simulator designs. Through a series of iterative analyses, a conceptual high fidelity design is developed: this is followed by engineering design, fabrication, and testing to validate the overall design process. Test results presented in this paper correspond to a "first cut" simulator design for a potential liquid metal (NaK) cooled reactor design that could be applied for Lunar surface power. Proposed refinements to this simulator design are also presented.

Bragg-Sitton, Shannon M.↗

DOE OSTI2015

Stand-Alone Dynamic System Simulation of a Fissile Solution System

Dynamic system simulations (DSS) of fissile solution systems (FSS) have been performed at Los Alamos National Laboratory (LANL) for several years. DSS have been designed and executed using the DESIRE (Direct Executing Simulation in Real Time) system, a platform ideal for expert system modelers, as it allows for direct mathematical specification of a model, and facilities for performing experiments and analyses with the model. Models built in DESIRE have been compared to historical data from several historic aqueous homogeneous reactors (AHR) showing close agreement between experimental data and model estimates. Historical systems modeled include: SUPO (Super Power), an AHR that operated at Los Alamos National Laboratory from 1951 to 1974; SILENE, which was operated by CEA at Valduc, France until 2011; KEWB (Kinetics Experiment Water Boiler) A-2 and B-5 cores, operated by North American Atomics during the 1960’s and 1970’s. SUPO is considered a benchmark for steady-state operations, SILENE for pulse, and KEWB as confirmatory for both modes. However, there are some simulation tasks that are not well-suited to DESIRE model implementation. These tasks include engineering design and analysis and providing a hardware simulator backend. It has been determined that executable simulation models would better suit these purposes, hence a process for converting DESIRE simulation models to executable simulation models was designed and implemented, and several models have been converted. DESIRE simulation models are converted to C++ executable models by an automated process. The conversion process is quick, accurate and repeatable, giving confidence that converted models will perform as well as the original DESIRE models. Extensive testing on the SUPO and accelerator driven subcritical system models has shown that the executable models perform almost identically to the DESIRE models. All major trends and events are simulated with excellent agreement and the steady-state results typically agree within a small fraction of a percent (always better than 0.1% and generally better than 0.01% agreement).

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

NASA NTRS2024

Hybrid Thermally Efficient Core (HyTEC) HyTEC Phase 1 – Combustor Final Report

The objective of the HyTEC – Combustor Technology project is to develop technology for a compact, low emissions, rich-burn combustor that maintains a high-level of durability. To accomplish this, the combustor will incorporate CMC liners and a CMC Dome to enable improved air utilization for mixing and NOx reduction. In particular, three technology areas were matured: metallic swirler attachment to the CMC dome, Nickel diffusion in CMC, and EBC advancements with improved durability. The maturation of these technology areas is critical to successfully designing a combustor for an engine intended to demonstrate increased thermal efficiency with integrated high-power density-core engine technologies. As part of the project, multiple swirler attachment architectures were matured through the design process, manufactured, and tested in simulated engine conditions. These architectures utilized two different approaches to attachment: a pressure loaded approach and a clamped approach. Each approach required testing at simulated engine conditions to mature the technology. These tests were developed to ensure that the probable failure mechanisms for each architecture were assessed relative to its long-term durability. After successfully testing both approaches, the pressure loaded approach was chosen based on its simplicity and its similarity to the attachment approach used on lean burn combustors. Finally, this successful testing resulted in the swirler attachment technology achieving TRL 4 status. Another aspect of concern with the metallic swirler attachment is the potential for nickel diffusion into the CMC to cause durability shortfalls. A series of tests were completed to understand both the amount of nickel that is expected to diffuse into the CMC and the effect this diffusion will have on mechanical properties of the CMC. After successfully completing this testing, the reduction in local mechanical properties was found to not have an impact on the overall durability of the CMC Dome. To further improve the overall durability, three different EBC coating architectures were also studied. One of these coatings being the current state of the art for CMC liners with the other two being proposed improvements. Coupons were produced using each coating and subjected to a series of laboratory testing. One coating was found to have an overall superior durability in laboratory testing and survived rig testing without indication of degradation. This successful testing resulted in the EBC technology achieving TRL 5 status. Overall, a design approach was successfully down-selected that achieves both the TPM requirements and the need for TRL 4+ status. This design incorporates a pressure loaded swirler attachment with an improved EBC coating (Architecture 1). This combination allows the continued use of a CMC dome and results in an improved durability for the proposed compact core combustor.

CMC↗