1. Page - 1 Rocketdyne Propulsion & Power Role of EASY5 in Integrated Product Development Frank Gombos (frank.j.gombos@boeing.com) Boeing Canoga Park, CA

2. Page - 2 Rocketdyne Propulsion & Power 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 Goals of the RAPID program are: Reducing development cost Shortening time to market

3. Page - 3 Rocketdyne Propulsion & Power Elements of RAPID Suppliers Fabricators Validators Maintainers Designers Testers Analysts Cost as Input Variable 3D geometry (virtual prototype) Variability - process capable design Risk reduction Integrated Product Definition Computer aided knowledge environment Lessons learned Customers

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

5. Page - 5 Rocketdyne Propulsion & Power Concept Definition & Optimization System Requirements System Requirements Candidate Design Concept Selection Candidate Design Concept Selection Engine Optimization Engine Optimization Cost & Technical Assessment Cost & Technical Assessment Design Definition Design Definition Detail Component Analysis and Design. Transient Analysis. Detail Component Analysis and Design. Transient Analysis. Solution MAT Script MAT Objective Function (calls EASY5 model) MAT Implicit Constraint Function Independent Variables Call to optimizer routine Optimized System EASY5 Model Calculated obj. function Limit parameters EASY5 Model Engine Optimization and Transient models are key part of the design optimization process

6. Page - 6 Rocketdyne Propulsion & Power 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. Page - 7 Rocketdyne Propulsion & Power Steady-State Optimizer/Engine Balance Model EASY5 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 Utilization of MAT/EASY5 for system optimization (involving numerical iterations) has been demonstrated

8. Page - 8 Rocketdyne Propulsion & Power MAT/EASY5 Optimization Process MAT EASY5 Solution MAT Script MAT Objective Function (calls EASY5 model) MAT Implicit Constraint Function Independent Variables with Explicit Constraints, and Iteration Limit Call to optimizer routine Optimized System (Engine Balance Model) EASY5 Model Calculated object function Limit parameters

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

10. Page - 10 Rocketdyne Propulsion & Power Steady-State Engine Balance Model EASY model duplicated steady-state flow, pressure, and energy balance generated by the legacy code Thrust Chamber Fuel System Oxidizer System

11. Page - 11 Rocketdyne Propulsion & Power 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. Page - 12 Rocketdyne Propulsion & Power High Fidelity Rocket Engine Transient Model

13. Page - 13 Rocketdyne Propulsion & Power 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. Page - 14 Rocketdyne Propulsion & Power Real-Time Engine System Model EASY5 Real-time model matched legacy code predictions EASY5 Real-time model matched legacy code predictions

15. Page - 15 Rocketdyne Propulsion & Power 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