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Manufacturing Process Simulation for the Prediction of Tool-Part-Interaction and Ply Wrinkling
(2019)
The utilization of phase change material (PCM) for latent heat storage and thermal control of spacecraft has been demonstrated in the past in few missions only. One limiting factor was the fact that all concepts developed so far envisioned the PCM to be applied as an additional capacitor, encapsulated in its own housing, leading to mass, efficiency and accommodation challenges. Recently, the application of PCM within the scan cavity of a GEOS type satellite has been suggested, in order to tackle thermal issues due to direct sun intrusion (Choi, M., 2014). However, the application of PCM in such complex mechanical structures is extremely challenging. A new concept to tackle this issue is currently under development at the FH Aachen University of Applied Sciences. The concept "Infused Thermal Solutions (ITS)" is based on the idea to 3D print metallic structures in their regular functional shape, but double walled with internal lattice support structures, allowing the infusion of a PCM layer directly into the voids and eliminating the need for additional parts and interfaces. Together with OHB System, FH Aachen theoretically studied the application of this technology to the Meteosat Third Generation (MTG) Infra-Red Sounder (IRS) instrument. The study focuses on the scan cavity and entrance baffling assembly (EBA) of the IRS. It consists of thermal analyses, 3D-redesign and bread boarding of a scaled and PCM infused EBA version. In the thermal design of the alternative EBA, PCM was applied directly into the EBA, simulating the worst hot case sun intrusion of the mission. By applying 4kg of PCM (to a 60kg baffle) the EBA temperature excursions during sun intrusion were limited from 140K to 30K, leading to a significant thermo-opto-elastic performance gain. This paper introduces the ITS concept development status.
In parallel to the evolution of the Planetary Defense Conference, the exploration of small solar system bodies has advanced from fast fly-bys on the sidelines of missions to the planets to the implementation of dedicated sample-return and in-situ analysis missions. Spacecraft of all sizes have landed, touch-and-go sampled, been gently beached, or impacted at hypervelocity on asteroid and comet surfaces. More have flown by close enough to image their surfaces in detail or sample their immediate environment, often as part of an extended or re-purposed mission. And finally, full-scale planetary defense experiment missions are in the making. Highly efficient low-thrust propulsion is increasingly applied beyond commercial use also in mainstream and flagship science missions, in combination with gravity assist propulsion. Another development in the same years is the growth of small spacecraft solutions, not in size but in numbers and individual capabilities. The on-going NASA OSIRIS-REx and JAXA HAYABUSA2 missions exemplify the trend as well as the upcoming NEA SCOUT mission or the landers MINERVA-II and MASCOT recently deployed on Ryugu. We outline likely as well as possible and efficient routes of continuation of all these developments towards a propellant-less and highly efficient class of spacecraft for small solar system body exploration: small spacecraft solar sails designed for carefree handling and equipped with carried landers and application modules, for all asteroid user communities –planetary science, planetary defence, and in-situ resource utilization. This projection builds on the experience gained in the development of deployable membrane structures leading up to the successful ground deployment test of a (20 m)² solar sail at DLR Cologne and in the 20 years since. It draws on the background of extensive trajectory optimization studies, the qualified technology of the DLR GOSSAMER-1 deployment demonstrator, and the MASCOT asteroid lander. These enable ‘now-term’ as well as near-term hardware solutions, and thus responsive fast-paced development. Mission types directly applicable to planetary defense include: single and Multiple NEA Rendezvous ((M)NR) for mitigation precursor, target monitoring and deflection follow-up tasks; sail-propelled head-on retrograde kinetic impactors (RKI) for mitigation; and deployable membrane based methods to modify the asteroid’s properties or interact with it. The DLR-ESTEC GOSSAMER Roadmap initiated studies of missions uniquely feasible with solar sails such as Displaced L1 (DL1) space weather advance warning and monitoring and Solar Polar Orbiter (SPO) delivery which demonstrate the capability of near-term solar sails to achieve NEA rendezvous in any kind of orbit, from Earth-coorbital to extremely inclined and even retrograde orbits. For those mission types using separable payloads, such as SPO, (M)NR and RKI, design concepts can be derived from the separable Boom Sail Deployment Units characteristic of DLR GOSSAMER solar sail technology, nanolanders like MASCOT, or microlanders like the JAXA-DLR Jupiter Trojan Asteroid Lander for the OKEANOS mission which can shuttle from the sail to the asteroids visited and enable multiple NEA sample-return missions. These are an ideal match for solar sails in micro-spacecraft format whose launch configurations are compatible with ESPA and ASAP secondary payload platforms.
Searching optimal continuous-thrust trajectories is usually a difficult and time-consuming task. The solution quality of traditional optimal-control methods depends strongly on an adequate initial guess because the solution is typically close to the initial guess, which may be far from the (unknown) global optimum. Evolutionary neurocontrol attacks continuous-thrust optimization problems from the perspective of artificial intelligence and machine learning, combining artificial neural networks and evolutionary algorithms. This chapter describes the method and shows some example results for single- and multi-phase continuous-thrust trajectory optimization problems to assess its performance. Evolutionary neurocontrol can explore the trajectory search space more exhaustively than a human expert can do with traditional optimal-control methods. Especially for difficult problems, it usually finds solutions that are closer to the global optimum. Another fundamental advantage is that continuous-thrust trajectories can be optimized without an initial guess and without expert supervision.
Recent Unmanned Aerial Vehicle (UAV) design procedures rely on full aircraft steady-state Reynolds-Averaged-Navier-Stokes (RANS) analyses in early design stages. Small sensor turrets are included in such simulations, even though their aerodynamic properties show highly unsteady behavior. Very little is known about the effects of this approach on the simulation outcomes of small turrets. Therefore, the flow around a model turret at a Reynolds number of 47,400 is simulated with a steady-state RANS approach and compared to experimental data. Lift, drag, and surface pressure show good agreement with the experiment. The RANS model predicts the separation location too far downstream and shows a larger recirculation region aft of the body. Both characteristic arch and horseshoe vortex structures are visualized and qualitatively match the ones found by the experiment. The Reynolds number dependence of the drag coefficient follows the trend of a sphere within a distinct range. The outcomes indicate that a steady-state RANS model of a small sensor turret is able to give results that are useful for UAV engineering purposes but might not be suited for detailed insight into flow properties.
In this paper, an approach to propulsion system modelling for hybrid-electric general aviation aircraft is presented. Because the focus is on general aviation aircraft, only combinations of electric motors and reciprocating combustion engines are explored. Gas turbine hybrids will not be considered. The level of the component's models is appropriate for the conceptual design stage. They are simple and adaptable, so that a wide range of designs with morphologically different propulsive system architectures can be quickly compared. Modelling strategies for both mass and efficiency of each part of the propulsion system (engine, motor, battery and propeller) will be presented.
An overview on dry low NOx micromix combustor development for hydrogen-rich gas turbine applications
(2019)
Wie sieht das unbemannte Flugzeug von Übermorgen aus? Dieser Frage stellen sich Forscher an der Fachhochschule Aachen. Die weltweit rasant fortschreitende Entwicklung des Marktes für unbemannte Fluggeräte (UAVs - „Unmanned Aerial Vehicles“) bietet großes Potenzial für Wachstum und Wertschöpfung. Unbemannte fliegende Systeme können – für bestimmte Anwendungsgebiete – wesentlich günstiger, kleiner und effizienter ausgelegt werden als bemannte Lösungen. Dabei sind sich viele Unternehmen über das mögliche Potential dieser Technologie noch gar nicht bewusst.
A hybrid-electric propulsion system combines the advantages of fuel-based systems and battery powered systems and offers new design freedom. To take full advantage of this technology, aircraft designers must be aware of its key differences, compared to conventional, carbon-fuel based, propulsion systems. This paper gives an overview of the challenges and potential benefits associated with the design of aircraft that use hybrid-electric propulsion systems. It offers an introduction of the most popular hybrid-electric propulsion architectures and critically assess them against the conventional and fully electric propulsion configurations. The effects on operational aspects and design aspects are covered. Special consideration is given to the application of hybrid-electric propulsion technology to both unmanned and vertical take-off and landing aircraft. The authors conclude that electric propulsion technology has the potential to revolutionize aircraft design. However, new and innovative methods must be researched, to realize the full benefit of the technology.
Optical Instruments require an extremely stable thermal surrounding to prevent loss of data quality by misalignments of the instrument components resulting from material deformation due to temperature f luctuations (e.g. from solar intrusion). Phase Change Material (PCM) can be applied as a thermal damper to achieve a more uniform temperature distribution. The challenge of this method is, among others, the integration of PCM into affected areas. If correctly designed, incoming heat is latently absorbed during phase change of the PCM, i.e. the temperature of a structure remains almost constant. In a cold phase, the heat during phase change is released again latently until the PCM returns to its original state of aggregation. Thus, the structure is thermally stabilized. At FH Aachen– University of Applied Sciences research is conducted to apply PCM directly into the structures of affected components (baffles, optical benches, electronic boxes, etc.). Through the application of Additive Manufacturing, the necessary voids are directly printed into these structures and filled later with PCM. Additive Manufacturing enables complex structures that would not have been possible with conservative manufacturing methods. A corresponding Breadboard was developed and manufactured by Selective Laser Melting (SLM). The current state of research includes the handling and analysis of the Breadboard, tests and a correlation of the thermal model. The results have shown analytically and practically that it is possible to use PCM as an integral part of the structure as a thermal damper. The results serve as a basis for the further development of the technology, which should maximize performance and enable the integration of PCM into much more complex structures.
The search for life on Mars and in the Solar System - strategies, logistics and infrastructures
(2018)
The question "Are we alone in the Universe?" is perhaps the most fundamental one that affects mankind. How can we address the search for life in our Solar System? Mars, Enceladus and Europa are the focus of the search for life outside the terrestrial biosphere. While it is more likely to find remnants of life (fossils of extinct life) on Mars because of its past short time window of the surface habitability, it is probably more likely to find traces of extant life on the icy moons and ocean worlds of Jupiter and Saturn. Nevertheless, even on Mars there could still be a chance to find extant life in niches near to the surface or in just discovered subglacial lakes beneath the South Pole ice cap. Here, the different approaches for the detection of traces of life in the form of biosignatures including pre-biotic molecules will be presented. We will outline the required infrastructure for this enterprise and give examples of future mission concepts to investigate the presence of life on other planets and moons. Finally, we will provide suggestions on methods, techniques, operations and strategies for preparation and realization of future life detection missions.
Urbane Mobilitätskonzepte der Zukunft erfordern neue Unternehmensformen, idealerweise aus Old Economy und New Economy, sowie eine enge Anbindung an die gesellschaftsrelevante Zukunftsforschung. Für neue Fahrzeugkonzepte des Carsharing bedeutet dies, dass alle kostenverursachenden Faktoren erfasst und analysiert werden müssen. Die FH Aachen, share2drive und FEV geben einen Ausblick auf die zukünftige Fahrzeugklasse der Personal Public Vehicles als „Rolling Device“.
Digitalisierung bezeichnet die Nutzung großer Datenmengen, die zu einer umfassenden Vernetzung aller Bereiche der Wirtschaft und Gesellschaft führen wird (BMWi, 2015 und ähnlich Köhler/Wollschläger, 2014: 79). Sie umfasst die Erhebung von analogen Informationen („Big Data“ in einem engen Sinne; z.B. O´Leary, 2013), ihre Speicherung in einem digitaltechnischen System (lokale Speicherung oder „Cloud Computing“ durch die Weiterentwickelung des Internets; z.B. Hashem et al., 2015: 101), die Analyse und Interpretation sowie den Transfer in andere Systeme („Internet der Dinge“ bzw. „Internet of Things“; z.B. Ashton, 2009).
Die Batterie ist eine der absolut zentralen Komponenten des Elektrofahrzeugs. Die serielle Entwicklung und Produktion dieser Batterien und die Verbesserung der Leistungen wird entscheidend für den Erfolg der Elektromobilität sein. Die Batterie ist jedoch nicht das einzige elektrofahrzeugspezifische System, das neu entwickelt, umkonzipiert oder verbessert werden muss. So sind ebenso die Entwicklung der neuen Fahrzeugstruktur sowie des elektrifizierten Antriebsstranges Teil dieses Kapitels. Weiterhin wird ein Blick auf das bedeutende Thema des Thermomanagements geworfen.
For fuel flexibility enhancement hydrogen represents a possible alternative gas turbine fuel within future low emission power generation, in case of hydrogen production by the use of renewable energy sources such as wind energy or biomass. Kawasaki Heavy Industries, Ltd. (KHI) has research and development projects for future hydrogen society; production of hydrogen gas, refinement and liquefaction for transportation and storage, and utilization with gas turbine / gas engine for the generation of electricity. In the development of hydrogen gas turbines, a key technology is the stable and low NOx hydrogen combustion, especially Dry Low Emission (DLE) or Dry Low NOx (DLN) hydrogen combustion. Due to the large difference in the physical properties of hydrogen compared to other fuels such as natural gas, well established gas turbine combustion systems cannot be directly applied for DLE hydrogen combustion. Thus, the development of DLE hydrogen combustion technologies is an essential and challenging task for the future of hydrogen fueled gas turbines. The DLE Micro-Mix combustion principle for hydrogen fuel has been in development for many years to significantly reduce NOx emissions. This combustion principle is based on cross-flow mixing of air and gaseous hydrogen which reacts in multiple miniaturized “diffusion-type” flames. The major advantages of this combustion principle are the inherent safety against flashback and the low NOx-emissions due to a very short residence time of the reactants in the flame region of the micro-flames.
Manufacturing process simulation (MPS) has become more and more important for aviation and the automobile industry. A highly competitive market requires the use of high performance metals and composite materials in combination with reduced manufacturing cost and time as well as a minimization of the time to market for a new product. However, the use of such materials is expensive and requires sophisticated manufacturing processes. An experience based process and tooling design followed by a lengthy trial-and-error optimization is just not contemporary anymore. Instead, a tooling design process aided by simulation is used more often. This paper provides an overview of the capabilities of MPS in the fields of sheet metal forming and prepreg autoclave manufacturing of composite parts summarizing the resulting benefits for tooling design and manufacturing engineering. The simulation technology is explained briefly in order to show several simplification and optimization techniques for developing industrialized simulation approaches. Small case studies provide examples of an efficient application on an industrial scale.
The Dry-Low-NOx (DLN) Micromix combustion technology has been developed as low emission combustion principle for industrial gas turbines fueled with hydrogen or syngas. The combustion process is based on the phenomenon of jet-in-crossflow-mixing (JICF). Fuel is injected perpendicular into the air-cross-flow and burned in a multitude of miniaturized, diffusion-like flames. The miniaturization of the flames leads to a significant reduction of NOx emissions due to the very short residence time of reactants in the flame. In the Micromix research approach, computational fluid dynamics (CFD) analyses are validated toward experimental results. The combination of numerical and experimental methods allows an efficient design and optimization of DLN Micromix combustors concerning combustion stability and low NOx emissions. The paper presents a comparison of several numerical combustion models for hydrogen and hydrogen-rich syngas. They differ in the complexity of the underlying reaction mechanism and the associated computational effort. The performance of a hybrid eddy-break-up (EBU) model with a one-step global reaction is compared to a complex chemistry model and a flamelet generated manifolds (FGM) model, both using detailed reaction schemes for hydrogen or syngas combustion. Validation of numerical results is based on exhaust gas compositions available from experimental investigation on DLN Micromix combustors. The conducted evaluation confirms that the applied detailed combustion mechanisms are able to predict the general physics of the DLN-Micromix combustion process accurately. The FGM method proved to be generally suitable to reduce the computational effort while maintaining the accuracy of detailed chemistry.
Physical interaction with small solar system bodies (SSSB) is key for in-situ resource utilization (ISRU). The design of mining missions requires good understanding of SSSB properties, including composition, surface and interior structure, and thermal environment. But as the saying goes "If you've seen one asteroid, you've seen one Asteroid": Although some patterns may begin to appear, a stable and reliable scheme of SSSB classification still has to be evolved. Identified commonalities would enable generic ISRU technology and spacecraft design approaches with a high degree of re-use. Strategic approaches require much broader in-depth characterization of the SSSB populations of interest to the ISRU community. The DLR-ESTEC GOSSAMER Roadmap Science Working Groups identified target-flexible Multiple Near-Earth asteroid (NEA) Rendezvous (MNR) as one of the missions only feasible with solar sail propulsion, showed the ability to access any inclination and a wide range of heliocentric distances as well as continuous operation close to Earth's orbit where low delta-v objects reside.
Physical interaction with small solar system bodies (SSSB) is the next step in planetary science, planetary in-situ resource utilization (ISRU), and planetary defense (PD). It requires a broader understanding of the surface properties of the target objects, with particular interest focused on those near Earth. Knowledge of composition, multi-scale surface structure, thermal response, and interior structure is required to design, validate and operate missions addressing these three fields. The current level of understanding is occasionally simplified into the phrase, ”If you’ve seen one asteroid, you’ve seen one asteroid”, meaning that the in-situ characterization of SSSBs has yet to cross the threshold towards a robust and stable scheme of classification. This would enable generic features in spacecraft design, particularly for ISRU and science missions. Currently, it is necessary to characterize any potential target object sufficiently by a dedicated pre-cursor mission to design the mission which then interacts with the object in a complex fashion. To open up strategic approaches, much broader in-depth characterization of potential target objects would be highly desirable. In SSSB science missions, MASCOT-like nano-landers and instrument carriers which integrate at the instrument level to their mothership have met interest. By its size, MASCOT is compatible with small interplanetary missions. The DLR-ESTEC Gossamer Roadmap Science Working Groups‘ studies identified Multiple Near-Earth asteroid (NEA) Rendezvous (MNR) as one of the space science missions only feasible with solar sail propulsion. The Solar Polar Orbiter (SPO) study showed the ability to access any inclination, theDisplaced-L1 (DL1) mission operates close to Earth, where objects of interest to PD and for ISRU reside. Other studies outline the unique capability of solar sails to provide access to all SSSB, at least within the orbit of Jupiter, and significant progress has been made to explore the performance envelope of near-term solar sails for MNR. However, it is difficult for
sailcraft to interact physically with a SSSB. We expand and extend the philosophy of the recently qualified DLR Gossamer solar sail deployment technology using efficient multiple sub-spacecraft integration to also include landers for one-way in-situ investigations and sample-return missions by synergetic integration and operation of sail and lander. The MASCOT design concept and its characteristic features have created an ideal counterpart for thisand has already been adapted to the needs of the AIM spacecraft, former part of the NASA-ESA AIDA missionDesigning the 69th International Astronautical Congress (IAC), Bremen, Germany, 1-5 October 2018. IAC-18-F1.2.3 Page 2 of 17 combined spacecraft for piggy-back launch accommodation enables low-cost massively parallel access to the NEA population.
The quest for life on other planets is closely connected with the search for water in liquid state. Recent discoveries of deep oceans on icy moons like Europa and Enceladus have spurred an intensive discussion about how these waters can be accessed. The challenge of this endeavor lies in the unforeseeable requirements on instrumental characteristics both with respect to the scientific and technical methods. The TRIPLE/nanoAUV initiative is aiming at developing a mission concept for exploring exo-oceans and demonstrating the achievements in an earth-analogue context, exploring the ocean under the ice shield of Antarctica and lakes like Dome-C on the Antarctic continent.
On the flight performance impact of landing gear drag reduction methods for unmanned air vehicles
(2018)
The flight performance impact of three different landing gear configurations on a small, fixed-wing UAV is analyzed with a combination of RANS CFD calculations and an incremental flight performance algorithm. A standard fixed landing gear configuration is taken as a baseline, while the influence of retracting the landing gear or applying streamlined fairings is investigated. A retraction leads to a significant parasite drag reduction, while also fairings promise large savings. The increase in lift-to-drag ratio is reduced at high lift coefficients due to the influence of induced drag. All configurations are tested on three different design missions with an incremental flight performance algorithm. A trade-off study is performed using the retracted or faired landing gear's weight increase as a variable. The analysis reveals only small mission performance gains as the aerodynamic improvements are negated by weight penalties. A new workflow for decision-making is presented that allows to estimate if a change in landing gear configuration is beneficial for a small UAV.
Die urbane Mobilität ist im Wandel und insbesondere neue innovative Geschäftsmodelle werden einen wesentlichen Teil zur Lösung von künftigen Mobilitätsbedürfnissen beitragen. Die sogenannte „Shared Mobility“ gilt aktuell neben der Elektrifizierung des Antriebes und autonomem Fahrzeugtechnologien als einer der wichtigsten Trendthemen in der Automobilindustrie. Neue Mobilitätsdienstleistungen verlangen dabei verstärkt auch neue Fahrzeugkonzepte.
Impact of electric propulsion technology and mission requirements on the performance of VTOL UAVs
(2018)
One of the engineering challenges in aviation is the design of transitioning vertical take-off and landing (VTOL) aircraft. Thrust-borne flight implies a higher mass fraction of the propulsion system, as well as much increased energy consumption in the take-off and landing phases. This mass increase is typically higher for aircraft with a separate lift propulsion system than for aircraft that use the cruise propulsion system to support a dedicated lift system. However, for a cost–benefit trade study, it is necessary to quantify the impact the VTOL requirement and propulsion configuration has on aircraft mass and size. For this reason, sizing studies are conducted. This paper explores the impact of considering a supplemental electric propulsion system for achieving hovering flight. Key variables in this study, apart from the lift system configuration, are the rotor disk loading and hover flight time, as well as the electrical systems technology level for both batteries and motors. Payload and endurance are typically used as the measures of merit for unmanned aircraft that carry electro-optical sensors, and therefore the analysis focuses on these particular parameters.
Following the successful PHILAE landing with ESA's ROSETTA probe and the launch of the MINERVA rovers and the Mobile Asteroid Surface Scout, MASCOT, aboard the JAXA space probe, HAYABUSA2, to asteroid (162173) Ryugu, small landers have found increasing interest. Integrated at the instrument level in their mothership they support small solar system body studies. With efficient capabilities, resource-friendly design and inherent robustness they are an attractive exploration mission element. We discuss advantages and constraints of small sub-spacecraft, focusing on emerging areas of activity such as asteroid diversity studies, planetary defence, and asteroid mining, on the background of our projects PHILAE, MASCOT, MASCOT2, the JAXA-DLR Solar Power Sail Lander Design Study, and others. The GOSSAMER-1 solar sail deployment concept also involves independent separable sub-spacecraft operating synchronized to deploy the sail. Small spacecraft require big changes in the way we do things and occasionally a little more effort than would be anticipated based on a traditional large spacecraft approach. In a Constraints-Driven Engineering environment we apply Concurrent Design and Engineering (CD/CE), Concurrent Assembly, Integration and Verification (CAIV) and Model-Based Systems Engineering (MBSE). Near-term solar sails will likely be small spacecraft which we expect to harmonize well with nano-scale separable instrument payload packages.
The scientific interest in near-Earth asteroids (NEAs) and the classification of some of those as potentially hazardous asteroid for the Earth stipulated the interest in NEA exploration. Close-up observations of these objects will increase drastically our knowledge about the overall NEA population. For this reason, a multiple NEA rendezvous mission through solar sailing is investigated, taking advantage of the propellantless nature of this groundbreaking propulsion technology. Considering a spacecraft based on the DLR/ESA Gossamer technology, this work focuses on the search of possible sequences of NEA encounters. The effectiveness of this approach is demonstrated through a number of fully-optimized trajectories. The results show that it is possible to visit five NEAs within 10 years with near-term solar-sail technology. Moreover, a study on a reduced NEA database demonstrates the reliability of the approach used, showing that 58% of the sequences found with an approximated trajectory model can be converted into real solar-sail trajectories. Lastly, this second study shows the effectiveness of the proposed automatic optimization algorithm, which is able to find solutions for a large number of mission scenarios without any input required from the user.
The invention pertains to a CellDrum electrode arrangement for measuring mechanical stress, comprising a mechanical holder (1 ) and a non-conductive membrane (4), whereby the membrane (4) is at least partially fixed at its circumference to the mechanical holder (1), keeping it in place when the membrane (4) may bend due to forces acting on the membrane (4), the mechanical holder (1) and the membrane (4) forming a container, whereby the membrane (1) within the container comprises an cell- membrane compound layer or biological material (3) adhered to the deformable membrane 4 which in response to stimulation by an agent may exert mechanical stress to the membrane (4) such that the membrane bending stage changes whereby the container may be filled with an electrolyte, whereby an electric contact (2) is arranged allowing to contact said electrolyte when filled into to the container, whereby within a predefined geometry to the fixing of the membrane (4) an electrode (7) is arranged, whereby the electrode (7) is electrically insulated with respect to the electric contact (2) as well as said electrolyte, whereby mechanical stress due to an agent may be measured as a change in capacitance.