Techniques for Conducting Effective Concept Design and Design-to-Cost Trade Studies
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Design-to-Cost↗
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Techniques for Conducting Effective Concept Design and Design-to-Cost Trade Studies
Concept design plays a central role in project success as its product effectively locks the majority of system life cycle cost. Such extraordinary leverage presents a business case for conducting concept design in a credible fashion, particularly for first-of-a-kind systems that advance the state of the art and that have high design uncertainty. A key challenge, however, is to know when credible design convergence has been achieved in such systems. Using a space system example, this paper characterizes the level of convergence needed for concept design in the context of technical and programmatic resource margins available in preliminary design and highlights the importance of design and cost evaluation learning curves in determining credible convergence. It also provides techniques for selecting trade study cases that promote objective concept evaluation, help reveal unknowns, and expedite convergence within the trade space and conveys general practices for conducting effective concept design-to-cost studies.
Trade Studies↗
Techniques for Conducting Effective Concept Design and Design-to-Cost Trade Studies
Concept design plays a central role in project success as its product effectively locks the majority of system life cycle cost. Such extraordinary leverage presents a business case for conducting concept design in a credible fashion, particularly for first-of-a-kind systems that advance the state of the art and that have high design uncertainty. A key challenge, however, is to know when credible design convergence has been achieved in such systems. Using a space system example, this paper characterizes the level of convergence needed for concept design in the context of technical and programmatic resource margins available in preliminary design and highlights the importance of design and cost evaluation learning curves in determining credible convergence. It also provides techniques for selecting trade study cases that promote objective concept evaluation, help reveal unknowns, and expedite convergence within the trade space and conveys general practices for conducting effective concept design-to-cost studies.
Design To Cost↗
Cost Trade Between Multi-Junction, Gallium Arsenide, and Silicon Solar Cells
Multi-junction (MJ), gallium arsenide (GaAs), and silicon (Si) solar cells have respective test efficiencies of approximately 24%, 18.5% and 14.8%. Multi-junction and gallium arsenide solar cells weigh more than silicon solar 2 cells and cost approximately five times as much per unit power at the cell level. A trade is performed for the TRMM spacecraft to determine which of these cell types would have offered an overall performance and price advantage to the spacecraft. A trade is also performed for the multi-junction cells under the assumption that they will cost over ten times that of silicon cells at the cell level. The trade shows that the TRMM project, less the cost of the instrument, ground systems and mission operations, would spend approximately $552,000 dollars per kilogram to launch and suppon3science in the case of the spacecraft equipped with silicon solar cells. If these cells are changed out for gallium arsenide solar cells, an additional 31 kilograms of science can be launched and serviced at a price of approximately $90 thousand per kilogram. The weight reduction is shown to derive from the smaller area of the array and hence reductions in the weight of the array substrate and supporting structure. ff the silicon solar cells are changed out for multi-junction solar cells, an additional 45 kilograms of science above the silicon base line can be launched and supported at a price of approximately $58,000 per kilogram. The trade shows that even if the multi-junction cells are priced over ten times that of silicon cells, a price that is much higher than projected, that the additional 45 kilograms of science are launched and serviced at $180,000 per kilogram. This is still much less than the original $552,000 per kilogram to launch and service the science. Data and qualitative factors are presented to show that these figures are subject to a great deal of uncertainty. Nonetheless, the benefit of the higher efficiency solar cells for TRMM is far greater than the uncertainties in the analysis.
Gaddy, Edward M.↗
Reliability, Risk and Cost Trade-Offs for Composite Designs
Risk and cost trade-offs have been simulated using a probabilistic method. The probabilistic method accounts for all naturally-occurring uncertainties including those in constituent material properties, fabrication variables, structure geometry and loading conditions. The probability density function of first buckling load for a set of uncertain variables is computed. The probabilistic sensitivity factors of uncertain variables to the first buckling load is calculated. The reliability-based cost for a composite fuselage panel is defined and minimized with respect to requisite design parameters. The optimization is achieved by solving a system of nonlinear algebraic equations whose coefficients are functions of probabilistic sensitivity factors. With optimum design parameters such as the mean and coefficient of variation (representing range of scatter) of uncertain variables, the most efficient and economical manufacturing procedure can be selected. In this paper, optimum values of the requisite design parameters for a predetermined cost due to failure occurrence are computationally determined. The results for the fuselage panel analysis show that the higher the cost due to failure occurrence, the smaller the optimum coefficient of variation of fiber modulus (design parameter) in longitudinal direction.
Shiao, Michael C.↗
Earth Observatory Satellite system definition study. Report 3: Design cost trade-off studies and recommendations
An analysis of the design and cost tradeoff aspects of the Earth Observatory Satellite (EOS) development is presented. The design/cost factors that affect a series of mission/system level concepts are discussed. The subjects considered are as follows: (1) spacecraft subsystem cost tradeoffs, (2) ground system cost tradeoffs, and (3) program cost summary. Tables of data are provided to summarize the results of the analyses. Illustrations of the various spacecraft configurations are included.
Source record↗
Cost Validation Using PRICE H
PRICE H was introduced into the JPL cost estimation tool set circa 2003. It became more available at JPL when IPAO funded the NASA-wide site license for all NASA centers. PRICE H was mainly used as one of the cost tools to validate proposal grassroots cost estimates. Program offices at JPL view PRICE H as an additional crosscheck to Team X (JPL Concurrent Engineering Design Center) estimates. PRICE H became widely accepted ca, 2007 at JPL when the program offices moved away from grassroots cost estimation for Step 1 proposals. PRICE H is now one of the key cost tools used for cost validation, cost trades, and independent cost estimates.
cost estimation↗
Concepts and cost trade-offs for land vehicle antennas in satellite mobile communications
Several antenna design concepts, operating at UHF (821 to 825 MHz transmit and 866 to 870 MHz receive bands), with gain ranging between 6 and 12 dBic, that are suitable for land mobile vehicles are presented. The antennas may be used within CONUS and ALASKA to communicate to and from a geosynchronous satellite. Depending on the type of steering mechanism, the antennas are broken down into three categories; (1) electronically scanned arrays with phase shifters, (2) electronically switched arrays with switchable power dividers/combiners, and (3) mechanically steered arrays. The operating characteristics of two of these design concepts, one a conformal antenna with electronic beam steering and the other a nonconformal design with mechanical steering, were evaluated with regard to two and three satellite system. Cost estimates of various antenna concepts were made and plotted against their overall gain performance.
Haddad, H. A.↗
Cost Efficient-by-Design Microreactors: Trade-offs between cost, technical, and regulatory factors
This research evaluates a cost reduction investigation through adoption of a functional containment approach on the microreactor system and structure. Trade-offs between microreactor system designs, fuels and reactor module sizes are evaluated based on performance-based and risk-informed design procedures. Cost savings are evaluated against trade-offs in the reliability of passive heat removal systems, reactivity control, and radioactive material containment. Results can inform the Microreactor Program and reactor designs on “sweet spots” for microreactors that are cost-efficient while meeting required safety limits.
21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
The Design-To-Cost Manifold
Design-to-cost is a popular technique for controlling costs. Although qualitative techniques exist for implementing design to cost, quantitative methods are sparse. In the launch vehicle and spacecraft engineering process, the question whether to minimize mass is usually an issue. The lack of quantification in this issue leads to arguments on both sides. This paper presents a mathematical technique which both quantifies the design-to-cost process and the mass/complexity issue. Parametric cost analysis generates and applies mathematical formulas called cost estimating relationships. In their most common forms, they are continuous and differentiable. This property permits the application of the mathematics of differentiable manifolds. Although the terminology sounds formidable, the application of the techniques requires only a knowledge of linear algebra and ordinary differential equations, common subjects in undergraduate scientific and engineering curricula. When the cost c is expressed as a differentiable function of n system metrics, setting the cost c to be a constant generates an n-1 dimensional subspace of the space of system metrics such that any set of metric values in that space satisfies the constant design-to-cost criterion. This space is a differentiable manifold upon which all mathematical properties of a differentiable manifold may be applied. One important property is that an easily implemented system of ordinary differential equations exists which permits optimization of any function of the system metrics, mass for example, over the design-to-cost manifold. A dual set of equations defines the directions of maximum and minimum cost change. A simplified approximation of the PRICE H(TM) production-production cost is used to generate this set of differential equations over [mass, complexity] space. The equations are solved in closed form to obtain the one dimensional design-to-cost trade and design-for-cost spaces. Preliminary results indicate that cost is relatively insensitive to changes in mass and that the reduction of complexity, both in the manufacturing process and of the spacecraft, is dominant in reducing cost.
Dean, Edwin B.↗
Magnetic Gears: The Key to Robust, Cost-Effective Hydropower Drivetrains
Based on previous demonstrated success at fabricating 5 and 10 kW scale magnetic gearbox (MGB) prototypes, Emrgy and its partners (the project team) proposed to design and construct a 100 kW scale MGB with a 30:1 gear ratio for the low-head hydro applications. The Statement of Project Objectives included tasks covering: 1) Market Applicability; 2) Technical Metrics; 3) Design (initial); 4) Electromagnetic (EM) Load and Structural Analysis; 5) Modal Analysis; 6) Sealing Design and 7) Final Design during Budget Period 1. Budget Period 2 included tasks covering: 1) Materials Procurement and Test Plan Development; 2) Assembly; and 3) Testing. The Market Applicability study (Task 1) led to a clear conclusion and recommendation toward “Low Head” technologies for maximum market share of both New Stream Reach development as well as powering Non-Powered Dams. The findings of this study also identified the opportunity for a larger scale magnetic gearbox-based drive train as a function of increased torque, as opposed to increased speed. The Technical Metrics Study (Task 2) concluded a horizontal orientation was preferred, examined potential loss mechanisms, concluded that a Halbach Array magnetic design was preferred, established a 30:1 gear ratio as optimal, and established a power rating of 100 kW as optimal. The subsequent initial and final detailed design process included electro-magnetic (EM) load and structural analysis (Task 4), a Modal analysis (for vibration) (Task 5), and a sealing design (Task 6) to assure water impermeability. The final design package (Task 7) included 729 individual parts, 117 unique part numbers, and 15 assemblies. In order to facilitate procurement, the full bill of materials was broken down into several sub-components: 1) custom magnetic parts; 2) custom machined parts; 3) custom casted parts; and 4) commercial off the shelf (COTS) parts. The casted parts were fabricated by Oak Ridge National Laboratory (ORNL) via a Cooperative Research and Development Agreement (CRADA) with Emrgy and funded by the Advanced Manufacturing Office (AMO). The procurement effort (Task 8) ultimately covered three time periods based on challenges encountered in meeting the budgeted cost for the prototype. Following the first effort in the early stages of Budget Period 2 in 2017, a no-cost time extension was granted to seek alternative fabrication and procurement options. The project was re-booted in 2020 based on the new ORNL CRADA that would focus on five (5) of the more difficult and expensive parts using their advanced manufacturing expertise. Procurement efforts for the other custom machined parts resulted in quotations that still exceeded the budget by more than $\$$100k. This was, in part, also due to the concurrent COVID-19 pandemic that caused both supply chain disruptions and labor shortages. As the project continued, pricing and availability degraded further. In Q2 FY’22, it was decided to not proceed with the fabrication of the prototype (Task 9) based on budgetary limitations. Outcomes included a full and detailed design of a 100 kW magnetic gearbox and associated indented bill of materials (BOM) and CAD drawings, a full assembly instruction manual with an associated BOM for materials necessary to support assembly, the fabrication of the double Halbach magnetic array for the rotor/stator system, fabrication of five (5) sand-casted/machined parts (via CRADA with ORNL) and an initial draft of a comprehensive testing plan. The most significant non-outcome was the actual fabrication and testing of the prototype gearbox based on budget limitations. Lessons learned included the need for an Application / Design / Cost trade analysis to better elucidate the cost potential of the MGB in the projected volumes anticipated for future demand. This would better establish the efficacy of the original cost target ($\$$0.80/Watt) and/or the need for reconsideration of designs and applications. Likewise, additional consideration of the prototype nature of the gearbox – single use, short lifetime, etc. - either as a separate exercise or in place of the design process completed, to reduce the cost of the demonstration prototype device. Additionally, project continuity was cited as a significant risk based on the loss of the primary design engineering firm after Budget Period 1. A design analysis exercise was conducted at the conclusion of the project to identify potential areas for cost reduction. One concept considered was the removal of the inner ring of magnets (with associated changes in the outer ring magnets) to enable a horizontal collapse of the design. It was estimated this could reduce cost by 10-25% without impacting performance.
13 HYDRO ENERGY↗
Systems engineering and integration: Cost estimation and benefits analysis
Space Transportation Avionics hardware and software cost has traditionally been estimated in Phase A and B using cost techniques which predict cost as a function of various cost predictive variables such as weight, lines of code, functions to be performed, quantities of test hardware, quantities of flight hardware, design and development heritage, complexity, etc. The output of such analyses has been life cycle costs, economic benefits and related data. The major objectives of Cost Estimation and Benefits analysis are twofold: (1) to play a role in the evaluation of potential new space transportation avionics technologies, and (2) to benefit from emerging technological innovations. Both aspects of cost estimation and technology are discussed here. The role of cost analysis in the evaluation of potential technologies should be one of offering additional quantitative and qualitative information to aid decision-making. The cost analyses process needs to be fully integrated into the design process in such a way that cost trades, optimizations and sensitivities are understood. Current hardware cost models tend to primarily use weights, functional specifications, quantities, design heritage and complexity as metrics to predict cost. Software models mostly use functionality, volume of code, heritage and complexity as cost descriptive variables. Basic research needs to be initiated to develop metrics more responsive to the trades which are required for future launch vehicle avionics systems. These would include cost estimating capabilities that are sensitive to technological innovations such as improved materials and fabrication processes, computer aided design and manufacturing, self checkout and many others. In addition to basic cost estimating improvements, the process must be sensitive to the fact that no cost estimate can be quoted without also quoting a confidence associated with the estimate. In order to achieve this, better cost risk evaluation techniques are needed as well as improved usage of risk data by decision-makers. More and better ways to display and communicate cost and cost risk to management are required.
Dean, ED↗
Development and Application of a Risk Analysis Toolkit for Plant Resources Optimization
This report summarizes the R&D activities of the Risk Informed Asset Management (RIAM) project during fiscal year 2020 (FY20). This project focuses on the development of methods designed to optimize plant operations (e.g., maintenance/replacement schedule, optimal maintenance posture) provided system/component health/cost data. This project development lives in cooperation with the Plant Health Management (PHM) project which focuses on the development of methods that integrate component health data and propagate such information at the system level to evaluate most relevant sources of risk. This year’s activities for the RIAM project focused on the continuation of schedule optimization algorithms developed in FY19. While in FY19 we focused on both deterministic and stochastic capital budgeting methods, in FY20 we moved forward by implementing two versions of schedule optimization methods. The first one reformulates the capital budgeting problem in a distributionally robust form which allows the user to rely on data directly rather than proposing a distribution from the data itself. The second version reformulates the capital budgeting explicitly using risk measures as variables to maximize/minimize. Lastly, we focused on the development of methods designed to identify the optimal maintenance posture based on the Pareto Frontier analysis. Rather than performing a tradeoff analysis (i.e., identify the absolute best posture), the Pareto Frontier analysis performs a trade space exploration approach (i.e., identify value and costs of several postures and have the analyst perform the task of imposing desired value and cost constraints). This is performed by identifying maintenance postures that maximize value (e.g., system availability) and minimize operational costs, i.e., the Pareto frontier in a value-cost trade space.
97 MATHEMATICS AND COMPUTING↗
GPACC program cost work breakdown structure-dictionary. General purpose aft cargo carrier study, volume 3
The results of detailed cost estimates and economic analysis performed on the updated Model 101 configuration of the general purpose Aft Cargo Carrier (ACC) are given. The objective of this economic analysis is to provide the National Aeronautics and Space Administration (NASA) with information on the economics of using the ACC on the Space Transportation System (STS). The detailed cost estimates for the ACC are presented by a work breakdown structure (WBS) to ensure that all elements of cost are considered in the economic analysis and related subsystem trades. Costs reported by WBS provide NASA with a basis for comparing competing designs and provide detailed cost information that can be used to forecast phase C/D planning for new projects or programs derived from preliminary conceptual design studies. The scope covers all STS and STS/ACC launch vehicle cost impacts for delivering payloads to a 160 NM low Earth orbit (LEO).
Source record↗
DACC program cost and work breakdown structure-dictionary. General purpose aft cargo carrier study, volume 2
Results of detailed cost estimates and economic analysis performed on the updated 201 configuration of the dedicated Aft Cargo Carrier (DACC) are given. The objective of this economic analysis is to provide the National Aeronautics and Space Administration (NASA) with information on the economics of using the DACC on the Space Transportation System (STS). The detailed cost estimates for the DACC are presented by a work breakdown structure (WBS) to ensure that all elements of cost are considered in the economic analysis and related subsystem trades. Costs reported by WBS provide NASA with a basis for comparing competing designs and provide detailed cost information that can be used to forecast phase C/D planning for new projects or programs derived from preliminary conceptual design studies. The scope covers all STS and STS/DACC launch vehicle cost impacts for delivering an orbital transfer vehicle to a 120 NM low Earth orbit (LEO).
Source record↗
Technology Infusion of CodeSonar into the Space Network Ground Segment (RII07): Software Assurance Symposium Technical Summary
Presents a source code analysis tool (CodeSonar) for use in the Space Network Ground Segment. The Space Network requires 99.9% proficiency and 97.0% availability of systems. Software has historically accounted for an annual average of 28% of the Space Network loss of availability and proficiency. CSCI A and CSCI B account for 42% of the previous eight months of software data loss. The technology infusion of CodeSonar into the Space Network Ground segment is meant to aid in determining the impact of the technology on the project both in the expenditure of effort and the technical results of the technology. Running a CodeSonar analysis and performing a preliminary review of the results averaged 3.5 minutes per finding (approximately 20 hours total). An additional 40 hours is estimated to analyze the 37 findings deemed too complex for the initial review. Using CodeSonar's tools to suppress known non-problems, delta tool runs will not repeat findings that have been marked as non-problems, further reducing the time needed for review. The 'non-interesting' finding rate of 70% is a large number, but filtering, search, and detailed contextual features of CodeSonar reduce the time per finding. Integration of the tool into the build process may also provide further savings by preventing developers from having to configure and operate the tool separately. These preliminary results show the tool to be easy to use and incorporate into the engineering process. These findings also provide significant potential improvements in proficiency and availability on the part of the software. As time-to-fix data become available a better cost trade can be made on person hours saved versus tool cost. Selective factors may be necessary to determine where best to apply CodeSonar to balance cost and benefits.
Benson, Markland J.↗
Preliminary design, analysis, and costing of a dynamic scale model of the NASA space station
The difficulty of testing the next generation of large flexible space structures on the ground places an emphasis on other means for validating predicted on-orbit dynamic behavior. Scale model technology represents one way of verifying analytical predictions with ground test data. This study investigates the preliminary design, scaling and cost trades for a Space Station dynamic scale model. The scaling of nonlinear joint behavior is studied from theoretical and practical points of view. Suspension system interaction trades are conducted for the ISS Dual Keel Configuration and Build-Up Stages suspended in the proposed NASA/LaRC Large Spacecraft Laboratory. Key issues addressed are scaling laws, replication vs. simulation of components, manufacturing, suspension interactions, joint behavior, damping, articulation capability, and cost. These issues are the subject of parametric trades versus the scale model factor. The results of these detailed analyses are used to recommend scale factors for four different scale model options, each with varying degrees of replication. Potential problems in constructing and testing the scale model are identified, and recommendations for further study are outlined.
Gronet, M. J.↗
Optimal short-range trajectories for helicopters
An optimal flight path algorithm using a simplified altitude state model and a priori climb cruise descent flight profile was developed and applied to determine minimum fuel and minimum cost trajectories for a helicopter flying a fixed range trajectory. In addition, a method was developed for obtaining a performance model in simplified form which is based on standard flight manual data and which is applicable to the computation of optimal trajectories. The entire performance optimization algorithm is simple enough that on line trajectory optimization is feasible with a relatively small computer. The helicopter model used is the Silorsky S-61N. The results show that for this vehicle the optimal flight path and optimal cruise altitude can represent a 10% fuel saving on a minimum fuel trajectory. The optimal trajectories show considerable variability because of helicopter weight, ambient winds, and the relative cost trade off between time and fuel. In general, reasonable variations from the optimal velocities and cruise altitudes do not significantly degrade the optimal cost. For fuel optimal trajectories, the optimum cruise altitude varies from the maximum (12,000 ft) to the minimum (0 ft) depending on helicopter weight.
Slater, G. L.↗