Role of EASY5 in Integrated Product Development

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Role of EASY5 in Integrated Product Development

• Frank Gombos(frank.j.gombos_at_boeing.com)
• BoeingCanoga Park, CA

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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 Rocketdynes 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
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Integration of Engine System Models
Other Design and Analysis Tools
Geometry (CAD System I/F)
Optimizer
EASY5
Steady-State Engine Model
Turbopump Model
EASY5 Model Synergy Data Xfer
ValvesControls Models
Transient Engine Model
Propellant Performance Fluid Property Databases
Real-Time Control System Model
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
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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 ModelEASY5
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 users defined object
  function
• Optimizes up to 20 users selected independent
  variables subjected to explicit constraints
• Includes as many implicit constraints as
  specified by user

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MAT/EASY5 Optimization Process
EASY5
MAT
MAT Script
Independent Variables with Explicit
Constraints, and Iteration Limit
EASY5 Model
Solution
Call to optimizer routine
Optimized System (Engine Balance Model)
Calculated object function
MAT Objective Function (calls EASY5 model)
MAT Implicit Constraint Function
Limit parameters
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Steady-State Iterations in EASY5 Style
EASY5 steady-state solver generates solution
Initialization, and Initial Guess
Iterated parameters, affecting design constraints
1 _______ ? s1
System Equations
Time delayed iterated parameters (prevents
implicit loop)
Recalculate System Equations
PI Controller
-
1 _______ ? s1

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
• 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 steady-state 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