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At least 19 records

Application of a design-build-team approach to low cost and weight composite fuselage structure

Relationships between manufacturing costs and design details must be understood to promote the application of advanced composite technologies to transport fuselage structures. A team approach, integrating the disciplines responsible for aircraft structural design and manufacturing, was developed to perform cost and weight trade studies for a twenty-foot diameter aft fuselage section. Baseline composite design and manufacturing concepts were selected for large quadrant panels in crown, side, and keel areas of the fuselage section. The associated technical issues were also identified. Detailed evaluation of crown panels indicated the potential for large weight savings and costs competitive with aluminum technology in the 1995 timeframe. Different processes and material forms were selected for the various elements that comprise the fuselage structure. Additional cost and weight savings potential was estimated for future advancements.

Ilcewicz, L. B.

Teacher Enhancement Institute

In a team building, team teaching strategy with four faculty, can learning strategies such as educational technology and problem based learning be provided to forty local teachers of primary, elementary, and secondary students? The impetus for the effort is to provide information about science and engineering at NASA and motivate students to pursue careers in science and technology. Teachers, identified and selected through a rigorous application procedure, participated in a two week workshop for a graduate credit. Teachers were exposed to computer applications such as INTERNET, MOSAIC, Power Machintosh word processing, NASA scientists, and laboratory experiments. Teachers were evaluated on level and quality of their participation, design of teacher application materials and relevant lesson plans and presentations. The results show that teachers, regardless of preparation and background, can learn science and engineering applications and develop relevant materials to transfer information to their classroom. Follow-up during the academic year will show that teachers are successfully using materials.

Simmons, Ron W.

Towards building a team of intelligent robots

Topics addressed include: collision-free motion planning of multiple robot arms; two-dimensional object recognition; and pictorial databases (storage and sharing of the representations of three-dimensional objects).

Varanasi, Murali R.

Developing Expert Teams with a Strong Safety Culture

Would you like to lead a world renowned team that draws out all the talents and expertise of its members and consistently out performs all others in the industry? Ever wonder why so many organizations fail to truly learn from past mistakes only to repeat the same ones at a later date? Are you a program/project manager or team member in a high-risk organization where the decisions made often carry the highest of consequences? Leadership, communication, team building, critical decision-making and continuous team improvement skills and behaviors are mere talking points without the attitudes, commitment and strategies necessary to make them the very fabric of a team. Developing Expert Teams with a Strong Safety Culture, will provide you with proven knowledge and strategies to take your team soaring to heights you may have not thought possible. A myriad of teams have applied these strategies and techniques within their organization team environments: military and commercial aviation, astronaut flight crews, Shuttle flight controllers, members of the Space Shuttle Program Mission Management Team, air traffic controllers, nuclear power control teams, surgical teams, and the fire service report having spectacular success. Many industry leaders are beginning to realize that although the circumstances and environments of these teams may differ greatly to their own, the core elements, governing principles and dynamics involved in managing and building a stellar safety conscious team remain identical.

Rogers, David G.

NASA Capacity Building Program Intern Team Findings Final Report

NASA’s Capacity Building Program (CBP) provides individuals and institutions with workforce development, training activities, and collaborative projects to strengthen understanding of Earth observations and expand their use around the world. The team of eight interns set out this summer to work with CBP leadership to explore opportunities & innovations and identify process improvements within the program. For the 10-week summer term, the interns virtually assembled from Washington, Montana, Virginia, Maine, and Puerto Rico to collaborate on this project. The work was divided into four sub-projects: Data Analysis, Communications, Web Development and Strategy.

Grace Finstrom

Broadening JPL’s Mission Formulation Paradigm with Human Centered Design

Within NASA’s highly competitive environment for funding, Human Centered Design (HCD) and cybernetics could provide advantages to proposers during the mission formulation phase. Opportunities are limited when it comes to funding new science missions. Proposers are challenged to make a compelling case about the scientific desirability, technical feasibility, and resource viability of their concepts. Organizations follow established processes for proposal development using teams that typically include scientists, engineers, and managers. These team members are highly experienced subject matter experts (SME) in their own disciplines, and can respond to requirements from the solicitation. However, they are typically not trained as designers and communicators. Their approach is rooted within NASA’s science and technology paradigm. How can we improve the proposal development process, refine workflow between team members, and deliver clear and appealing offerings to the stakeholders and evaluators? These questions have been addressed by today’s most innovative companies (e.g., Apple, Google, 3M, Dyson), where the design process is not limited simply to engineering and management, but involves an all-encompassing approach drawing from fields such as social sciences, design, and the arts. Like these commercial enterprises, NASA currently employs systems thinking and integrated design, but can benefit further by moving beyond its current practices, which are mostly driven by rigid engineering, technology, science, and project management considerations. At JPL’s Innovation Foundry and through the Solar System Mission Formulation Office, we broadened this paradigm by including HCD in the mission formulation workflow. Our goal was to create a proposal with improved clarity and appeal, thus helping our team to communicate its message and aid evaluators with their work. In this paper we provide examples and lessons learned from our recent proposal development effort using HCD. We discuss touch points where we infused non-linear designerly approaches and cybernetic circularity into the workflow. Implemented design topics include operational design for team building; process design throughout distinct phases of the proposal development and writing process; communication design for streamlined exchange of information within the team and to stakeholders; interaction design; graphic design; and creating boundary objects. While these approaches may feel new or foreign to SMEs and managers in the aerospace community, they produced significant benefits in this mission formulation effort. We will describe how such approaches can be used to broaden NASA’s technology-driven paradigm through design, thus creating an environment which fosters innovation, improved communication, and strategic advantage for proposers and their organizations.

Turner, Neal

Activation Energy

Teaming is so common in today's project management environment that most of us assume it comes naturally. We further assume that when presented with meaningful and challenging work, project teams will naturally engage in productive activity to complete their tasks. This assumption is expressed in the simple (but false) equation: Team + Work = Teamwork. Although this equation appears simple and straightforward, it is far from true for most project organizations whose reality is a complex web of institutional norms based on individual achievement and rewards. This is illustrated by the very first successful team experience from my early Air Force career. As a young lieutenant, I was sent to Squadron Officer School, which was the first in the series of Air Force professional military education courses I was required to complete during my career. We were immediately formed into teams of twelve officers. Much of the course featured competition between these teams. As the most junior member of my team, I quickly observed the tremendous pressure to show individual leadership capability. At one point early in the course, almost everyone in our group was vying to become the team leader. This conflict was so intense that it caused us to fail miserably in our first outdoor team building exercise. We spent so much time fighting over leadership that we were unable to complete any of the events on the outdoor obstacle course. This complete lack of success was so disheartening to me that I gave our team little hope for future success. What followed was a very intense period of bickering, conflict, and even shouting matches as our dysfunctional team tried to cope with our early failures and find some way to succeed. British physician and researcher Wilfred Bion (Experiences in Groups, 1961) discovered that there are powerful psychological forces inherent in all groups that divert from accomplishing their primary tasks. To overcome these restraining forces and use the potential power of the team, greater emphasis must be placed on establishing and maintaining group cohesiveness. This relationship is expressed in the revised (true) mathematical equation: Team + Work (on the Team) = Teamwork.

Gadeken, Owen

Modeling Spacecraft Safe Mode Events

Spacecraft enter a ‘safe mode’ to protect the vehicle when a potentially harmful anomaly occurs. This minimally functioning state isolates faults, establishes contact with Earth, and orients the vehicle into a power positive attitude until operators intervene. Though ‘safings’ are inherently unpredictable, mission teams build in time margin during operations to determine root causes and restore functionality. Planning and managing this margin is both critical and enabling on mission architectures dependent on near-continuous operability – such as a low-thrust electric propulsion mission. To better quantify the occurrences and severity of safe mode anomalies, the Jet Propulsion Laboratory (JPL) has assembled a database of safings from past and active missions. Currently nearly 240 records are captured from 21 beyond-Earth missions, stemming from a collaboration between teams at JPL, Ames Research Center, Goddard Space Flight Center, and the Johns Hopkins University Applied Physics Laboratory. This paper discusses the event database, explores a statistical approach in modeling the occurrences and severity of safing events, presents a simulation technique, and details recommendations and future work to benefit future concepts.

Nicholas, Austin

Crew productivity issues in long-duration space flight

Considerable evidence suggests the importance of teamwork, coordination, and conflict resolution to the performance and survival of isolated, confined groups in high-technology environments. With the advent of long-duration space flight, group-related issues of crew functioning will take on added significance. This paper discusses the influence of crew roles, status, leadership, and norms on the performance of small, confined groups, and offers guidelines and suggestions regarding organizational design, crew selection, training, and team building for crew productivity and social well-being in long-duration spaceflight.

Nicholas, John M.

Advanced technology commercial fuselage structure

Boeing's program for Advanced Technology Composite Aircraft Structure (ATCAS) has focused on the manufacturing and performance issues associated with a wide body commercial transport fuselage. The primary goal of ATCAS is to demonstrate cost and weight savings over a 1995 aluminum benchmark. A 31 foot section of fuselage directly behind the wing to body intersection was selected for study purposes. This paper summarizes ATCAS contract plans and review progress to date. The six year ATCAS program will study technical issues for crown, side, and keel areas of the fuselage. All structural details in these areas will be included in design studies that incorporate a design build team (DBT) approach. Manufacturing technologies will be developed for concepts deemed by the DBT to have the greatest potential for cost and weight savings. Assembly issues for large, stiff, quadrant panels will receive special attention. Supporting technologies and mechanical tests will concentrate on the major issues identified for fuselage. These include damage tolerance, pressure containment, splices, load redistribution, post-buckled structure, and durability/life. Progress to date includes DBT selection of baseline fuselage concepts; cost and weight comparisons for crown panel designs; initial panel fabrication for manufacturing and structural mechanics research; and toughened material studies related to keel panels. Initial ATCAS studies have shown that NASA's Advanced Composite Technology program goals for cost and weight savings are attainable for composite fuselage.

Ilcewicz, L. B.

Cost studies for commercial fuselage crown designs

Studies were conducted to evaluate the cost and weight potential of advanced composite design concepts in the crown region of a commercial transport. Two designs from each of three design families were developed using an integrated design-build team. A range of design concepts and manufacturing processes were included to allow isolation and comparison of cost centers. Detailed manufacturing/assembly plans were developed as the basis for cost estimates. Each of the six designs was found to have advantages over the 1995 aluminum benchmark in cost and weight trade studies. Large quadrant panels and cobonded frames were found to save significant assembly labor costs. Comparisons of high- and intermediate-performance fiber systems were made for skin and stringer applications. Advanced tow placement was found to be an efficient process for skin lay up. Further analysis revealed attractive processes for stringers and frames. Optimized designs were informally developed for each design family, combining the most attractive concepts and processes within that family. A single optimized design was selected as the most promising, and the potential for further optimization was estimated. Technical issues and barriers were identified.

Walker, T. H.

Process and assembly plans for low cost commercial fuselage structure

Cost and weight reduction for a composite structure is a result of selecting design concepts that can be built using efficient low cost manufacturing and assembly processes. Since design and manufacturing are inherently cost dependent, concurrent engineering in the form of a Design-Build Team (DBT) is essential for low cost designs. Detailed cost analysis from DBT designs and hardware verification must be performed to identify the cost drivers and relationships between design and manufacturing processes. Results from the global evaluation are used to quantitatively rank design, identify cost centers for higher ranking design concepts, define and prioritize a list of technical/economic issues and barriers, and identify parameters that control concept response. These results are then used for final design optimization.

Willden, Kurtis

Composite fuselage crown panel manufacturing technology

Commercial fuselage structures contain significant challenges in attempting to save manufacturing costs with advanced composite technology. Assembly issues, materials costs, and fabrication of elements with complex geometry are each expected to drive the cost of composite fuselage structure. Key technologies, such as large crown panel fabrication, were pursued for low cost. An intricate bond panel design and manufacturing concept were selected based on the efforts of the Design Build Team. The manufacturing processes selected for the intricate bond design include multiple large panel fabrication with Advanced Tow Placement (ATP) process, innovative cure tooling concepts, resin transfer molding of long fuselage frames, and use of low cost materials forms. The process optimization for final design/manufacturing configuration included factory simulations and hardware demonstrations. These efforts and other optimization tasks were instrumental in reducing costs by 18 pct. and weight by 45 pct. relative to an aluminum baseline. The qualitative and quantitative results of the manufacturing demonstrations were used to assess manufacturing risks and technology readiness.

Willden, Kurtis

Composite fuselage crown panel manufacturing technology

Commercial fuselage structures contain significant challenges in attempting to save manufacturing costs with advanced composite technology. Assembly issues, material costs, and fabrication of elements with complex geometry are each expected to drive the cost of composite fuselage structures. Boeing's efforts under the NASA ACT program have pursued key technologies for low-cost, large crown panel fabrication. An intricate bond panel design and manufacturing concepts were selected based on the efforts of the Design Build Team (DBT). The manufacturing processes selected for the intricate bond design include multiple large panel fabrication with the Advanced Tow Placement (ATP) process, innovative cure tooling concepts, resin transfer molding of long fuselage frames, and utilization of low-cost material forms. The process optimization for final design/manufacturing configuration included factory simulations and hardware demonstrations. These efforts and other optimization tasks were instrumental in reducing cost by 18 percent and weight by 45 percent relative to an aluminum baseline. The qualitative and quantitative results of the manufacturing demonstrations were used to assess manufacturing risks and technology readiness.

Willden, Kurtis

Manufacturing scale-up of composite fuselage crown panels

The goal of the Boeing effort under the NASA ACT program is to reduce manufacturing costs of composite fuselage structure. Materials, fabrication of complex subcomponents and assembly issues are expected to drive the costs of composite fuselage structure. Several manufacturing concepts for the crown section of the fuselage were evaluated through the efforts of a Design Build Team (DBT). A skin-stringer-frame intricate bond design that required no fasteners for the panel assembly was selected for further manufacturing demonstrations. The manufacturing processes selected for the intricate bond design include Advanced Tow Placement (ATP) for multiple skin fabrication, resin transfer molding (RTM) of fuselage frames, innovative cure tooling, and utilization of low-cost material forms. Optimization of these processes for final design/manufacturing configuration was evaluated through the fabrication of several intricate bond panels. Panels up to 7 ft. by 10 ft. in size were fabricated to simulate half scale production parts. The qualitative and quantitative results of these manufacturing demonstrations were used to assess manufacturing risks and technology readiness for production.

Willden, Kurtis

Global cost and weight evaluation of fuselage keel design concepts

The Boeing program entitled Advanced Technology Composite Aircraft Structure (ATCAS) is focused on the application of affordable composite technology to pressurized fuselage structure of future aircraft. As part of this effort, a design study was conducted on the keel section of the aft fuselage. A design build team (DBT) approach was used to identify and evaluate several design concepts which incorporated different material systems, fabrication processes, structural configurations, and subassembly details. The design concepts were developed in sufficient detail to accurately assess their potential for cost and weight savings as compared with a metal baseline representing current wide body technology. The cost and weight results, along with an appraisal of performance and producibility risks, are used to identify a globally optimized keel design; one which offers the most promising cost and weight advantages over metal construction. Lastly, an assessment is given of the potential for further cost and weight reductions of the selected keel design during local optimization.

Flynn, B. W.