Role of EASY5 in Integrated Product Development

1. Role of EASY5 in Integrated Product Development Frank Gombos(frank.j.gombos@boeing.com) BoeingCanoga Park, CA

2. 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

3. Cost as Input Variable Suppliers IntegratedProduct Definition Designers Fabricators Testers • 3D geometry (virtual prototype) • Variability - process capable design • Risk reduction Validators Analysts Maintainers Customers Computer aided knowledge environmentLessons learned Elements of RAPID

4. Integration of Engine System Models Other Design and Analysis Tools Optimizer Geometry (CAD System I/F) EASY5 Steady-State Engine Model Turbopump Model EASY5 Model Synergy & Data Xfer Valves&Controls Models Transient Engine Model Propellant Performance & Fluid Property Databases Real-Time Control System Model Controls Software (Autocode Generator)

5. MAT Script Independent Variables EASY5 Model Solution Call to optimizer routine Optimized System Calculated obj. function MAT Objective Function (calls EASY5 model) Limit parameters MAT Implicit Constraint Function 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

6. 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

7. Utilization of MAT/EASY5 for system optimization (involving numerical iterations) has been demonstrated 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 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

8. 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) Limit parameters MAT Implicit Constraint Function

9. Steady-State Iterations in EASY5 Style EASY5 steady-state solver generates solution Initialization, and Initial Guess Iterated parameters, affecting design constraints 1 _______  s+1 System Equations Time delayed iterated parameters (prevents implicit loop) Recalculate System Equations PI Controller - 1 _______  s+1 + Design Constraints (input)

10. Steady-State Engine Balance Model Fuel SystemOxidizer System • EASY model duplicated • steady-state flow, pressure, and • energy balance generated by the • legacy code Thrust Chamber

11. 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

12. High Fidelity Rocket Engine Transient Model

13. 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

14. Real-Time Engine System Model EASY5 Real-time model matched legacy code predictions

15. 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