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Energy Efficient Propulsion Systems Simulation Execution Optimization CAD/CAM J . Brent Staubach & Michael Winter Pratt & Whitney United Technologies Corporation Energy & Computation MIT May 10 th 2006 Computing Power Will Fundamentally Change How We Design Gas Turbines

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energy efficient propulsion systems
Energy Efficient Propulsion Systems

Simulation

Execution

Optimization

CAD/CAM

J. Brent Staubach & Michael Winter

Pratt & Whitney

United Technologies Corporation

Energy & Computation

MIT

May 10th 2006

computing power will fundamentally change how we design gas turbines
Computing Power Will Fundamentally Change How We Design Gas Turbines

RELEASE THIS POWER ON DESIGN PROCESSES

Computer Speed

- 2x Every 18 months -

Network Speed

- 2x Every 9 months -

Tremendous

Growth

Billion X Speed

by 2025

Hardware: 100,00X

Massive Parallel Grid

Computing, Assume

~10,000X

Cost of

Sending

1012 Bits

Data Across

Country Has

Dropped From

$150,000 in 1970

To 12 cents

In 2000

  • Transistor Scaling
  • Manufacturing: Copper, SiGe,
  • Parallelization: chip,
  • board, rack
  • Quantum Computing

Cost of a

Three

Minute

Phone

Call From

New York

To

London

# Transistors (Ks)

IBM & Intel

Expect Continued

Growth

  • 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
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
Modern Gas Turbine Optimization Is An Exercise In Managing Complexity

~ 80,000 PARTS

~5000 PART NUMBERS

~ 200 MAJOR PART NUMBERS

REQUIRING 3D 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
Complexity Is Managed By Decomposing The Design, Coordinating & Re-assembling via The SIPT/CIPT/IPT

CIPT

CIPT

CIPT

CIPT

SYSTEM

INTEGRATED

T

P

EAM

RODUCT

TURBINE

TURBINE

BURNER

TURBINE

COMPRESSOR

TURBINE

FAN

AERO

AERO

AERO

STRUCTURES

AERO

AERO.

MFG.

TURBINE

BURNER

BURNER

COMPRESSOR

FAN

STRUCTURES

STRUCTURES

STRUCTURES

STRUCTURES

STRUCTURES.

COMPRESSOR

TURBINE

BURNER

COMPRESSOR

FAN

AERO

MECHANICAL

MECHANICAL

MECHANICAL

MECHANICAL.

  • IPTsARE THE ORGANIZATIONAL MECHANISM THAT ENABLES A BALANCED
  • DESIGN - MANUAL MULTI-DISCIPLINARY DESIGN LOCAL OPTIMIZATION
complex designs are inherently brutally iterative bounded by best practice rules
Complex Designs Are Inherently & Brutally Iterative, Bounded By Best Practice Rules . . . . . . . .

STANDARD

WORK

CAD

MODEL

PHYSICS

MODEL

DESIGN SPACE

- NON LINEAR

- MULTI MODAL

- DISCONTINUOUS

- NOISEY

- HIGHLY CONSTRAINED

WORK

INSTRUCTIONS

CRITERIA

VALIDATED

ANALYSIS

PREFERRED

CONFIGURATIONS

DESIGN

DECISION

ENGINEER MAY ITERATE 100s TO 1000s OF TIMES TO GET

SATISFACTORY RESULTS -- MANUALLY !

and iterations can take place across the globe
. . . And Iterations Can Take Place Across The Globe
  • INTER-DIVISIONAL
  • CUSTOMERS
  • OUTSOURCING
  • PARTNERSHIPS
iterations are simplified by employing a range of fidelity
Iterations Are Simplified By Employing A Range Of Fidelity

KNOWLEDGE INFORMATION DATA

PRODUCT DEVELOPMENT PHASES

DESIGN

SPACE

VTE

2D

3D

4D

0D

1D

Concept

Concept

Preliminary

Airplane

Service &

Validation/

0

I

Detailed Design

5

2

Initiation

Optimization

4

Design

3

Validation

Support

Certification

NEW

ENGINE

STAFFING

  • STAFFING EXPLODES WITH FIDELITY: ANOTHER “CURSE OF DIMENSIONALITY”

FIDELITY

  • REQUIRES EXTENSIVE KNOWLEDGE TO JUDGE LOW FIDELITY MODELS
result is manual human based multidisciplinary design optimization at best
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

SYSTEM

  • Labor Intensive, Compartmentalized Design Process
  • That Relies On Teams, Management, & Procedures
gains can be made by shifting from human to computer based mdo
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 --

SUB-SYSTEM B

SUB-SYSTEM A

SYSTEM

MANUAL WORK FLOW per PROCESS

MAPS

MANUAL CAD/CAE MODEL BUILDING

& EXECUTION per STANDARD WORK

MANUAL EXPLORATION TO FIND

OPTIMAL DESIGNS THAT MEET

TECHNOLOGY LEVELS

AUTOMATE WORKFLOW

AUTOMATE MODEL BUILDING & EXECUTION

AUTOMATE DESIGN EXPLORATION

technologies are progressing to enable large scale computer based mdo
Technologies Are Progressing To Enable Large Scale Computer Based MDO

INTEGRATION FRAMEWORKS

SYSTEM ANALYSIS

FIPER

  • CHALLENGES
  • CYCLE BALANCE
  • 2ND FLOWS
  • TRANSIENTS

ROBUST

PARAMETRIC

MASTER MODEL

ASSESSMENT

MODELING

COMPUTER BASED

MDO

NAVIGATE

THE VIRTUAL

DESIGN SPACE

PHYSICS

CHALLENGES

-LARGE ASSEMBLIES

-TOPOLOGICAL

-GENERATIVE

- DIRECT MFG

  • - SOLVE TURBULENCE
  • - MULTIDISCIPLINARY ANALYSIS (MDA)
  • MATERIAL PROPERTIES
  • PROBABILISTICS

GRID COMPUTING

COST

  • CHALLENGES
  • SECURITY
  • POLITE COEXISTENCE
  • FAULT TOLERANCE

- MFG

- MAINTENANCE

- NEGOTIATED

implementation path electronic enterprise engineering
Implementation Path: Electronic Enterprise Engineering

COMPUTER BASED

OPTIMIZATION

LIBRARY OF

“WRAPPED” TOOLS

INTEGRATION

FRAMEWORK

ELECTRONIC

PROCESS MAPS

ELECTRONIC

IPT

IPT 1&2

IPT 1

SYSTEM

OPTIMIZER

IPT 2

G

A

E

C

H

D

F

B

OPTIMIZER

IPT 3

OPTIMIZER

IPT 3

VALIDATED

CERTIFIED

EMBEDDED

KNOWLEDGE

CONTROLLED

INTEGRATE

THIRD PARTY

& LEGACY TOOLS

INDUSTRY

ACCEPTED

COMMERCIAL

TOOLS

INTEGRATED

INTO

ELECTRONIC

PROCESS MAPS

& ASSOCIATED

WITH WORK

INSTRUCTIONS

WORK FLOW

MANAGEMENT

COLLABORATIVE

ENGINEERING

SECURE B2B

AUTOMATE

ITERATION

SATISFY

CRITERIA

GRID

COMPUTING

B

A

G

E

D

D

A

F

E

F

C

G

C

B

B

C

G

B

C

A

large scale computer based mdo is already practical
Large Scale Computer Based MDO Is AlreadyPractical

3D Aero-Vibratory Shape Optimization Of A Cooled Turbine Airfoil

(Single Row RANS CFD, Cooled UG Parametric Model, 3D ANSYS Vibes)

large scale computer based mdo is already becoming practical
Large Scale Computer Based MDO Is AlreadyBecoming Practical

3D Shape Optimization Based On Hybrid Genetic Algorithm & Rule System

(3D RANS Multi Row CFD, Population Size 80, Total Runs 2400, Run Time 48 hrs on 40CPUs)

Discovered “bowed” rotor

To control tip leakage

Vortex

will enable new design paradigms
Will Enable New Design Paradigms

CUSTOMER NEEDS

UNDERSTAND THE FUTURE

CREATE TECHNOLOGY

IMPROVE MODELS

RE-FORMULATE PROBLEM

UPGRADE COMPUTER

BASED DESIGN “MACHINE”

RUN 24/7 365 DAYS

A YEAR

CONTINUOUS

DETAILED DESIGN

SOLVE ALL POSSIBLE

APPLICATIONS @

TECHNOLOGY

READINESS LEVEL

ENGINEERS

COMPUTER BASED DESIGN

CUSTOMER REQ. EXCEED TECHNOLOGY

LESS TIME

FEWER PEOPLE