Model-Based, Multiscale Self-Tuning Controller Developed for Active Combustion Control

New challenges concerning system health-monitoring and life-extending robust controls for the Ultra-Efficient Engine Technology Project, as well as other advanced engine and power system concepts at NASA and elsewhere, have renewed the control community s interest in smart, model-based methods. In particular, these challenges have further motivated efforts at the NASA Glenn Research Center to exploit the versatility and superiority of the dynamic features extraction of multiscale analysis for controls--such as with "wavelets" and "wavelet filter-banks.' The accomplishments reported herein pertain to the active suppression of combustion instabilities in liquid-fuel combustors via fuel modulation. The fundamentals and initial success of this innovation were reported for a unique demonstration of active combustion control (a research collaboration of NASA Glenn with Pratt & Whitney and the United Technologies Research Center, UTRC). This demonstration, conducted in 2002 at UTRC on the NASA single nozzle rig (SNR) combustor, was the first known suppression of high-frequency instability with a liquid-fueled combustor. The SNR is based on a high-powered military engine combustor that exhibited well-known instabilities

A Novel Technique for Running the NASA Legacy Code LAPIN Synchronously With Simulations Developed Using Simulink

This report presents a method for running a dynamic legacy inlet simulation in concert with another dynamic simulation that uses a graphical interface. The legacy code, NASA's LArge Perturbation INlet (LAPIN) model, was coded using the FORTRAN 77 (The Portland Group, Lake Oswego, OR) programming language to run in a command shell similar to other applications that used the Microsoft Disk Operating System (MS-DOS) (Microsoft Corporation, Redmond, WA). Simulink (MathWorks, Natick, MA) is a dynamic simulation that runs on a modern graphical operating system. The product of this work has both simulations, LAPIN and Simulink, running synchronously on the same computer with periodic data exchanges. Implementing the method described in this paper avoided extensive changes to the legacy code and preserved its basic operating procedure. This paper presents a novel method that promotes inter-task data communication between the synchronously running processes

Hypersonic Vehicle Propulsion System Control Model Development Roadmap and Activities

The NASA Fundamental Aeronautics Program Hypersonic project is directed towards fundamental research for two classes of hypersonic vehicles: highly reliable reusable launch systems (HRRLS) and high-mass Mars entry systems (HMMES). The objective of the hypersonic guidance, navigation, and control (GN&C) discipline team is to develop advanced guidance and control algorithms to enable efficient and effective operation of these challenging vehicles. The ongoing work at the NASA Glenn Research Center supports the hypersonic GN&C effort in developing tools to aid the design of advanced control algorithms that specifically address the propulsion system of the HRRLSclass vehicles. These tools are being developed in conjunction with complementary research and development activities in hypersonic propulsion at Glenn and elsewhere. This report is focused on obtaining control-relevant dynamic models of an HRRLS-type hypersonic vehicle propulsion system

Comparisons of Rig and Engine Dynamic Events in the Compressor of an Axi-Centrifugal Turboshaft Engine

Steady state and dynamic data were acquired in a T55-L-712 compressor rig. In addition, a T55-L-12 engine was instrumented and similar data were acquired. Rig and engine stall/surge data were analyzed using modal techniques. This paper compares rig and engine preliminary results for the ground idle (approximately 60% of design speed) point. The results of these analyses indicate both rig and engine dynamic event are preceded by indications of traveling wave energy in front of the compressor face. For both rig and engine, the traveling wave energy contains broad band energy with some prominent narrow peaks and, while the events are similar in many ways, some noticeable differences exist between the results of the analyses of rig data and engine data

A Framework for Simulating Turbine-Based Combined-Cycle Inlet Mode-Transition

A simulation framework based on the Memory-Mapped-Files technique was created to operate multiple numerical processes in locked time-steps and send I/O data synchronously across to one-another to simulate system-dynamics. This simulation scheme is currently used to study the complex interactions between inlet flow-dynamics, variable-geometry actuation mechanisms, and flow-controls in the transition from the supersonic to hypersonic conditions and vice-versa. A study of Mode-Transition Control for a high-speed inlet wind-tunnel model with this MMF-based framework is presented to illustrate this scheme and demonstrate its usefulness in simulating supersonic and hypersonic inlet dynamics and controls or other types of complex systems

Structural Design Considerations for a 50 kW-Class Solar Array for NASA's Asteroid Redirect Mission

NASA is planning an Asteroid Redirect Mission (ARM) to take place in the 2020s. To enable this multi-year mission, a 40 kW class solar electric propulsion (SEP) system powered by an advanced 50 kW class solar array will be required. Powered by the SEP module (SEPM), the ARM vehicle will travel to a large near-Earth asteroid, descend to its surface, capture a multi-metric ton (t) asteroid boulder, ascend from the surface and return to the Earth-moon system to ultimately place the ARM vehicle and its captured asteroid boulder into a stable distant orbit. During the years that follow, astronauts flying in the Orion multipurpose crew vehicle (MPCV) will dock with the ARM vehicle and conduct extra-vehicular activity (EVA) operations to explore and sample the asteroid boulder. This paper will review the top structural design considerations to successfully implement this 50 kW class solar array that must meet unprecedented performance levels. These considerations include beyond state-of-the-art metrics for specific mass, specific volume, deployed area, deployed solar array wing (SAW) keep in zone (KIZ), deployed strength and deployed frequency. Analytical and design results are presented that support definition of stowed KIZ and launch restraint interface definition. An offset boom is defined to meet the deployed SAW KIZ. The resulting parametric impact of the offset boom length on spacecraft moment of inertias and deployed SAW quasistatic and dynamic load cases are also presented. Load cases include ARM spacecraft thruster plume impingement, asteroid surface operations and Orion docking operations which drive the required SAW deployed strength and damping. The authors conclude that to support NASA's ARM power needs, an advanced SAW is required with mass performance better than 125 W/kg, stowed volume better than 40 kW/cu m, a deployed area of 200 sq m (100 sq m for each of two SAWs), a deployed SAW offset distance of nominally 3-4 m, a deployed SAW quasistatic strength of nominally 0.1 g in any direction, a deployed loading displacement under 2 m, a deployed fundamental frequency above 0.1 Hz and deployed damping of at least 1%. These parameters must be met on top of challenging mission environments and ground testing requirements unique to the ARM project

Observer-Based Magnetic Bearing Controller Developed for Aerospace Flywheels

A prototype of a versatile, observer-based magnetic bearing controller for aerospace flywheels was successfully developed and demonstrated on a magnetic bearing test rig (see the photograph) and an actual flywheel module. The objective of this development included a fast, yet low risk, control development process, and a robust, high-performance controller for a large variety of flywheels. This required a good system model, an efficient development procedure, and a model-based controller that addressed the key problems associated with flywheel and bearing imbalance, sensor error, and vibration. The model used in this control development and tuning procedure included the flexible rotor dynamics and motor-induced vibrations. Such a model was essential for low-risk scheduling of speed-dependent control parameters and for reliable evaluation of novel control strategies. The successfully tested control prototype utilized an extended Kalman filter to estimate the true rotor principal-axis motion from the raw sensor position feedback. For control refinement, the extended Kalman filter also estimated and eliminated the combined effects of mass-imbalance and sensor runouts from the input data. A key advantage of the design based on the extended Kalman filter is its ability to accurately estimate both the rotor's principal-axis position and gyroscopic rates with the least amount of phase lag. This is important for control parameter scheduling to dampen the gyroscopic motions. Because of large uncertainties in the magnetic bearing and imbalance characteristics, this state-estimation scheme alone is insufficient for containing the rotor motion within the desired 1-mil excursion radius. A nonlinear gain adjustment based on an estimation of the principal-axis orbit size was needed to provide a coarse (nonoptimal), but robust, control of the orbit growth. Control current minimization was achieved with a (steepest gradient) search of synchronous errors in the principal-axis position input data. Actual flywheel tests of this observer-based controller (developed entirely in-house) at the NASA Glenn Research Center showed that the model correctly predicted the rotor orbit growth as a function of rotational speed, and it demonstrated the capability of gain adjustments to arrest this growth. Data from these tests on an actual flywheel module spun to 26,000 rpm proved that the controller was able to contain the shaft motion to within much less than 0.5 mils of radial excursion with axis currents less than 300 mA in root-mean-square estimate. The test speed range was limited because of thermal expansion concerns for this particular flywheel unit, not because of any deficiency in the controller. Simulations for this unit indicated that the controller should be robust up to its top operating speed of 60,000 rpm. Aside from these important achievements, and most significantly, it took less than 1 week to adapt this controller from the simple test rig to the actual flywheel and to demonstrate full five-axis levitation and control. This demonstration showed that both the controller and the model-based development and tuning framework are easily adaptable to a wide range of rotors and bearing configurations and, hence, are capable of reducing design risks and costs for many future flywheel technology developments

Model-Based Self-Tuning Multiscale Method for Combustion Control

A multi-scale representation of the combustor dynamics was used to create a self-tuning, scalable controller to suppress multiple instability modes in a liquid-fueled aero engine-derived combustor operating at engine-like conditions. Its self-tuning features designed to handle the uncertainties in the combustor dynamics and time-delays are essential for control performance and robustness. The controller was implemented to modulate a high-frequency fuel valve with feedback from dynamic pressure sensors. This scalable algorithm suppressed pressure oscillations of different instability modes by as much as 90 percent without the peak-splitting effect. The self-tuning logic guided the adjustment of controller parameters and converged quickly toward phase-lock for optimal suppression of the instabilities. The forced-response characteristics of the control model compare well with those of the test rig on both the frequency-domain and the time-domain

Control Activity in Support of NASA Turbine Based Combined Cycle (TBCC) Research

Control research for a Turbine Based Combined Cycle (TBCC) propulsion system is the current focus of the Hypersonic Guidance, Navigation, and Control (GN&C) discipline team. The ongoing work at the NASA Glenn Research Center (GRC) supports the Hypersonic GN&C effort in developing tools to aid the design of control algorithms to manage a TBCC airbreathing propulsion system during a critical operating period. The critical operating period being addressed in this paper is the span when the propulsion system transitions from one cycle to another, referred to as mode transition. One such tool, that is a basic need for control system design activities, is computational models (hereto forth referred to as models) of the propulsion system. The models of interest for designing and testing controllers are Control Development Models (CDMs) and Control Validation Models (CVMs). CDMs and CVMs are needed for each of the following propulsion system elements: inlet, turbine engine, ram/scram dual-mode combustor, and nozzle. This paper presents an overall architecture for a TBCC propulsion system model that includes all of the propulsion system elements. Efforts are under way, focusing on one of the propulsion system elements, to develop CDMs and CVMs for a TBCC propulsion system inlet. The TBCC inlet aerodynamic design being modeled is that of the Combined-Cycle Engine (CCE) Testbed. The CCE Testbed is a large-scale model of an aerodynamic design that was verified in a small-scale screening experiment. The modeling approach includes employing existing state-of-the-art simulation codes, developing new dynamic simulations, and performing system identification experiments on the hardware in the NASA GRC 10 by10-Foot Supersonic Wind Tunnel. The developed CDMs and CVMs will be available for control studies prior to hardware buildup. The system identification experiments on the CCE Testbed will characterize the necessary dynamics to be represented in CDMs for control design. These system identification models will also be the reference models to validate the CDM and CVM models. Validated models will give value to the tools used to develop the models

Hypersonic Vehicle Propulsion System Simplified Model Development

This document addresses the modeling task plan for the hypersonic GN&C GRC team members. The overall propulsion system modeling task plan is a multi-step process and the task plan identified in this document addresses the first steps (short term modeling goals). The procedures and tools produced from this effort will be useful for creating simplified dynamic models applicable to a hypersonic vehicle propulsion system. The document continues with the GRC short term modeling goal. Next, a general description of the desired simplified model is presented along with simulations that are available to varying degrees. The simulations may be available in electronic form (FORTRAN, CFD, MatLab,...) or in paper form in published documents. Finally, roadmaps outlining possible avenues towards realizing simplified model are presented