Transcript Role of EASY5 in Integrated Product Development

Role of EASY5
in
Integrated Product Development
Frank Gombos
([email protected])
Boeing
Canoga Park, CA
Rocketdyne
Propulsion & Power
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Summary
 This presentation focuses on the role of EASY5 in the integrated
product development of Liquid Propellant Rocket Engines at
Rocketdyne
 Describes specific applications supported by EASY5, as part of
Rocketdyne’s Advanced Process Integration Development (RAPID)
program
 Product concept definition and optimization
 Steady-state and transient performance analysis
 Subsystem design and optimization
 Control system development and verification
Goals of the RAPID program are:
• Reducing development cost
• Shortening time to market
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Elements of RAPID
Cost as Input Variable
Suppliers
Fabricators
Validators
Maintainers
Integrated
Product
Definition
• 3D geometry (virtual
prototype)
• Variability - process
capable design
• Risk reduction
Designers
Testers
Analysts
Customers
Computer aided knowledge environment
Lessons learned
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Integration of Engine System Models
Other Design and
Analysis
Tools
Optimizer
Geometry
(CAD
System I/F)
Steady-State
Engine Model
Turbopump
Model
EASY5 Model
Synergy &
Data Xfer
Transient
Engine Model
Propellant
Performance
& Fluid
Property
Databases
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Real-Time
Control System
Model
Valves&Controls
Models
Controls Software
(Autocode Generator)
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Concept Definition & Optimization
System
Requirements
Candidate
Design
Concept
Selection
Engine
Optimization
Cost & Technical
Assessment
Design
Definition
EASY5 Model
Detail Component
Analysis and
Design.
Transient Analysis.
Engine Optimization and Transient
models are key part of the
design optimization process
MAT Script
Independent
Variables
Call to optimizer
routine
EASY5 Model
Solution
Calculated obj. function
MAT Objective Function
(calls EASY5 model)
Optimized
System
Limit parameters
MAT Implicit Constraint
Function
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Expected benefits of EASY5 Conversion
 Reduced cycle time and cost
 Icon driven model development, simplified model building and
debugging
 Configuration controlled model libraries (developed by
technology specialists, saves time, and prevents the same error)
 Reduced model maintenance cost
 “Single Source of model” approach
 Eliminates model duplication, data reentry
 Single model development effort for control system development
and software test
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Steady-State Optimizer/Engine Balance Model
EASY5 Conversion Status
 Utilizes EASY5 icon driven modeling capability and legacy code
 Based on experimental version of MAT in EASY5
 Incorporates our legacy optimization algorithm code
 Integrated into the Matrix Algebra Tool (MAT) by the EASY5 Group
 Minimizes or maximizes user’s defined object function
 Optimizes up to 20 user’s selected independent variables subjected to
explicit constraints
 Includes as many implicit constraints as specified by user
Utilization of MAT/EASY5 for system optimization (involving
numerical iterations) has been demonstrated
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MAT/EASY5 Optimization Process
EASY5
MAT
MAT Script
Independent Variables
with Explicit Constraints,
and Iteration Limit
Call to optimizer
routine
EASY5 Model
Solution
Calculated object function
MAT Objective Function
(calls EASY5 model)
MAT Implicit Constraint
Function
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Optimized
System
(Engine
Balance
Model)
Limit parameters
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Steady-State Iterations in EASY5 Style
Initialization,
and
Initial Guess
EASY5 steady-state
solver generates solution
Iterated parameters,
affecting design constraints
Time delayed
iterated
parameters
(prevents
implicit
loop)
1
System
Equations
Recalculate
System Equations
_______
 s+1
PI
Controller
1
_______
 s+1
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+
Design Constraints
(input)
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Steady-State Engine Balance Model
Fuel System
Oxidizer System
• EASY model duplicated
steady-state flow, pressure, and
energy balance generated by the
legacy code
Thrust Chamber
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Transient Engine System Model
 A key design tool that simulates the engine transient performance:

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

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Engine system startup and shutdown characteristics
Control valve sequencing and closed-loop control characteristics
Component transient characteristics
Vehicle critical parameters
Propellant consumption
 Defines safe valve sequence for engine start, throttle, & cutoff:
 In-flight
 Ground test
 Receives design parameters from the Steady-State Engine System
model
 Developed EASY5 macro component library for Rocket Engine
components with cryogenic propellants
 Based on our legacy code written in FORTRAN
 Switch-state representation for efficient computation
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High Fidelity Rocket Engine Transient Model
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Real-Time Control System Model
 A control system design and verification tool that provides the
following capabilities:
 Tool for the controller hardware and software requirements development
 Provides a modeling platform for software design and verification
 Reduced order version of the high fidelity Transient Engine System
Model
 Receives design parameters from the high fidelity Transient Model
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Real-Time Engine System Model
EASY5 Real-time model
matched legacy code
predictions
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Conclusions
 EASY5 offers an integrated solution for Rocket Engine
system modeling
 Adaptability of EASY5 for new applications such as steadystate analysis and design optimization have been
demonstrated
 EASY5 supports overall design optimization, provides a
bridge between modeling applications and knowledge bases,
and can be linked to CAD systems
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