Energy Efficient Propulsion Systems Execution Optimization Simulation CAD CAM

Energy Efficient Propulsion Systems Execution Optimization Simulation CAD/CAM J. Brent Staubach & Michael Winter Pratt & Whitney United Technologies Corporation Energy & Computation MIT th 2006 May 10

Computing Power Will Fundamentally Change How We Design Gas Turbines Computer Speed - 2 x Every 18 months - # Transistors (Ks) • Transistor Scaling • Manufacturing: Copper, Si. Ge, • Parallelization: chip, board, rack • Quantum Computing IBM & Intel Expect Continued Growth Network Speed - 2 x Every 9 months - Cost of a Three Minute Phone Call From New York To London Cost of Sending 1012 Bits Data Across Country Has Dropped From $150, 000 in 1970 To 12 cents In 2000 Tremendous Growth Billion X Speed by 2025 Hardware: 100, 00 X Massive Parallel Grid Computing, Assume ~10, 000 X RELEASE THIS POWER ON DESIGN PROCESSES • Review Current Manual Design Optimization Practices • Computer Based Design & Key Enablers • Future New Design Paradigms; Less Time; Fewer People

System Engineering Process Driven by Product Needs Propulsion System Complexity Driving Need for More Robust Systems Engineering Process and Tools Propulsion has Become a System of Systems

Modern Gas Turbine Optimization Is An Exercise In Managing Complexity ~ 80, 000 PARTS ~5000 PART NUMBERS ~ 200 MAJOR PART NUMBERS REQUIRING 3 D FEA/CFD ANALYSIS ~ 5000 -10, 000 PARAMETRIC CAD VARIABLES DEFINE MAJOR PART NUMBERS ~ 200 MAN-YEAR ANALYTICAL DESIGN EFFORT ~ 200 MAN-YEARS DRAFTING / ME EFFORT

Complexity Is Managed By Decomposing The Design, Coordinating & Re-assembling via The SIPT/CIPT/IPT SYSTEM INTEGRATED PRODUCT TEAM CIPT TURBINE AERO BURNER TURBINE AERO STRUCTURES CIPT COMPRESSOR AERO TURBINE STRUCTURES BURNER STRUCTURES COMPRESSOR STRUCTURES TURBINE COMPRESSOR MECHANICAL AERO BURNER MECHANICAL COMPRESSOR MECHANICAL FAN TURBINE AERO. MFG. FAN STRUCTURES. FAN MECHANICAL. • IPTs ARE THE ORGANIZATIONAL MECHANISM THAT ENABLES A BALANCED DESIGN - MANUAL MULTI-DISCIPLINARY DESIGN LOCAL OPTIMIZATION

Within Modules & Disciplines Sophisticated Simulation Based Design Systems Have Evolved

Complex Designs Are Inherently & Brutally Iterative, Bounded By Best Practice Rules. . . . CAD MODEL PHYSICS MODEL DESIGN SPACE WORK INSTRUCTIONS - NON LINEAR - MULTI MODAL - DISCONTINUOUS - NOISEY - HIGHLY CONSTRAINED DESIGN STANDARD WORK CRITERIA VALIDATED ANALYSIS DECISION PREFERRED CONFIGURATIONS ENGINEER MAY ITERATE 100 s TO 1000 s OF TIMES TO GET SATISFACTORY RESULTS -- MANUALLY !

. . . and Complex Designs Are Iterated Across Disciplines & Organizations. . .

. . . And Iterations Can Take Place Across The Globe • OUTSOURCING • INTER-DIVISIONAL • PARTNERSHIPS • CUSTOMERS

Iterations Are Simplified By Employing A Range Of Fidelity PRODUCT DEVELOPMENT PHASES Concept Initiation 0 Concept Optimization I Preliminary Design 2 KNOWLEDGE DESIGN SPACE 0 D 1 D Detailed Design INFORMATION 3 D 2 D 3 Validation/ Certification 4 Airplane Validation Service & Support 5 DATA 4 D STAFFING VTE NEW ENGINE FIDELITY • REQUIRES EXTENSIVE KNOWLEDGE TO JUDGE LOW FIDELITY MODELS • STAFFING EXPLODES WITH FIDELITY: ANOTHER “CURSE OF DIMENSIONALITY”

Result Is Manual “Human” Based Multidisciplinary Design Optimization – At Best SYSTEM OPTIMIZATION ENSURE CONFORMANCE TO CUSTOMER NEEDS & BUSINESS GOALS COMPONENT OPTIMIZATION TEAMS - HUMAN INTERACTION EXECUTE MANUAL MDO PART OPTIMIZATION ISOLATED MULTI-FIDELITY DESIGN SYSTEMS Labor Intensive, Compartmentalized Design Process That Relies On Teams, Management, & Procedures

Gains Can Be Made By Shifting From “Human” To “Computer” Based MDO “HUMAN” BASED “COMPUTER” BASED WORKFLOW, RULES, And DESIGN ITERATIONS AUTOMATED WITHIN And ACROSS SYSTEMS & DISCIPLINES -- LABOR INTENSIVE -- SYSTEM SUB-SYSTEM A SUB-SYSTEM B MANUAL WORK FLOW per PROCESS MAPS AUTOMATE WORKFLOW MANUAL CAD/CAE MODEL BUILDING & EXECUTION per STANDARD WORK AUTOMATE MODEL BUILDING & EXECUTION MANUAL EXPLORATION TO FIND OPTIMAL DESIGNS THAT MEET TECHNOLOGY LEVELS AUTOMATE DESIGN EXPLORATION

Technologies Are Progressing To Enable Large Scale Computer Based MDO SYSTEM ANALYSIS INTEGRATION FRAMEWORKS FIPER CHALLENGES -CYCLE BALANCE -2 ND FLOWS -TRANSIENTS ASSESSMENT MODELING ROBUST PARAMETRIC MASTER MODEL COMPUTER BASED MDO NAVIGATE THE VIRTUAL DESIGN SPACE PHYSICS - SOLVE TURBULENCE - MULTIDISCIPLINARY ANALYSIS (MDA) - MATERIAL PROPERTIES - PROBABILISTICS COST - MFG - MAINTENANCE - NEGOTIATED GRID COMPUTING CHALLENGES -LARGE ASSEMBLIES -TOPOLOGICAL -GENERATIVE - DIRECT MFG CHALLENGES -SECURITY - POLITE COEXISTENCE - FAULT TOLERANCE

Implementation Path: Electronic Enterprise Engineering LIBRARY OF “WRAPPED” TOOLS INTEGRATION FRAMEWORK ELECTRONIC PROCESS MAPS ELECTRONIC IPT COMPUTER BASED OPTIMIZATION SYSTEM OPTIMIZER IPT 1&2 IPT 1 A B B B D E F C F G G VALIDATED CERTIFIED EMBEDDED KNOWLEDGE CONTROLLED IPT 3 OPTIMIZER G IPT 2 C C B A B H A OPTIMIZER C A C IPT 3 D E F G INTEGRATE THIRD PARTY & LEGACY TOOLS INDUSTRY ACCEPTED COMMERCIAL TOOLS INTEGRATED INTO ELECTRONIC PROCESS MAPS & ASSOCIATED WITH WORK INSTRUCTIONS WORK FLOW MANAGEMENT AUTOMATE ITERATION COLLABORATIVE ENGINEERING SATISFY CRITERIA SECURE B 2 B GRID COMPUTING

Large Scale Computer Based MDO Is Already Practical 3 D Aero-Vibratory Shape Optimization Of A Cooled Turbine Airfoil (Single Row RANS CFD, Cooled UG Parametric Model, 3 D ANSYS Vibes)

Large Scale Computer Based MDO Is Already Becoming Practical 3 D Shape Optimization Based On Hybrid Genetic Algorithm & Rule System (3 D RANS Multi Row CFD, Population Size 80, Total Runs 2400, Run Time 48 hrs on 40 CPUs) Discovered “bowed” rotor To control tip leakage Vortex

Efficient Scalable System Problem Formulations Are Becoming Understood For Gas Turbine Design

Will Enable New Design Paradigms CUSTOMER NEEDS UNDERSTAND THE FUTURE CREATE TECHNOLOGY ENGINEERS COMPUTER BASED DESIGN RUN 24/7 365 DAYS A YEAR CONTINUOUS DETAILED DESIGN IMPROVE MODELS RE-FORMULATE PROBLEM SOLVE ALL POSSIBLE APPLICATIONS @ TECHNOLOGY READINESS LEVEL UPGRADE COMPUTER BASED DESIGN “MACHINE” CUSTOMER REQ. EXCEED TECHNOLOGY LESS TIME FEWER PEOPLE

Powering Change…………. Powering Freedom