Multidisciplinary Design Optimization Application to Conceptual Design of University-class Microsatellite Projects

Esta tesis se ha realizado en el contexto del proyecto UPMSat-2, que es un microsatélite diseñado, construido y operado por el Instituto Universitario de Microgravedad "Ignacio Da Riva" (IDR / UPM) de la Universidad Politécnica de Madrid. Aplicación de la metodología Ingeniería Concurrente (Concurrent Engineering: CE) en el marco de la aplicación de diseño multidisciplinar (Multidisciplinary Design Optimization: MDO) es uno de los principales objetivos del presente trabajo. En los últimos años, ha habido un interés continuo en la participación de los grupos de investigación de las universidades en los estudios de la tecnología espacial a través de sus propios microsatélites. La participación en este tipo de proyectos tiene algunos desafíos inherentes, tales como presupuestos y servicios limitados. Además, debido al hecho de que el objetivo principal de estos proyectos es fundamentalmente educativo, por lo general hay incertidumbres en cuanto a su misión en órbita y cargas útiles en las primeras fases del proyecto. Por otro lado, existen limitaciones predeterminadas para sus presupuestos de masa, volumen y energía, debido al hecho de que la mayoría de ellos están considerados como una carga útil auxiliar para el lanzamiento. De este modo, el costo de lanzamiento se reduce considerablemente. En este contexto, el subsistema estructural del satélite es uno de los más afectados por las restricciones que impone el lanzador. Esto puede afectar a diferentes aspectos, incluyendo las dimensiones, la resistencia y los requisitos de frecuencia. En la primera parte de esta tesis, la atención se centra en el desarrollo de una herramienta de diseño del subsistema estructural que evalúa, no sólo las propiedades de la estructura primaria como variables, sino también algunas variables de nivel de sistema del satélite, como la masa de la carga útil y la masa y las dimensiones extremas de satélite. Este enfoque permite que el equipo de diseño obtenga una mejor visión del diseño en un espacio de diseño extendido. La herramienta de diseño estructural se basa en las fórmulas y los supuestos apropiados, incluyendo los modelos estáticos y dinámicos del satélite. Un algoritmo genético (Genetic Algorithm: GA) se aplica al espacio de diseño para optimizaciones de objetivo único y también multiobjetivo. El resultado de la optimización multiobjetivo es un Pareto-optimal basado en dos objetivo, la masa total de satélites mínimo y el máximo presupuesto de masa de carga útil. Por otro lado, la aplicación de los microsatélites en misiones espaciales es de interés por su menor coste y tiempo de desarrollo. La gran necesidad de las aplicaciones de teledetección es un fuerte impulsor de su popularidad en este tipo de misiones espaciales. Las misiones de tele-observación por satélite son esenciales para la investigación de los recursos de la tierra y el medio ambiente. En estas misiones existen interrelaciones estrechas entre diferentes requisitos como la altitud orbital, tiempo de revisita, el ciclo de vida y la resolución. Además, todos estos requisitos puede afectar a toda las características de diseño. Durante los últimos años la aplicación de CE en las misiones espaciales ha demostrado una gran ventaja para llegar al diseño óptimo, teniendo en cuenta tanto el rendimiento y el costo del proyecto. Un ejemplo bien conocido de la aplicación de CE es la CDF (Facilidad Diseño Concurrente) de la ESA (Agencia Espacial Europea). Está claro que para los proyectos de microsatélites universitarios tener o desarrollar una instalación de este tipo parece estar más allá de las capacidades del proyecto. Sin embargo, la práctica de la CE a cualquier escala puede ser beneficiosa para los microsatélites universitarios también. En la segunda parte de esta tesis, la atención se centra en el desarrollo de una estructura de optimización de diseño multidisciplinar (Multidisciplinary Design Optimization: MDO) aplicable a la fase de diseño conceptual de microsatélites de teledetección. Este enfoque permite que el equipo de diseño conozca la interacción entre las diferentes variables de diseño. El esquema MDO presentado no sólo incluye variables de nivel de sistema, tales como la masa total del satélite y la potencia total, sino también los requisitos de la misión como la resolución y tiempo de revisita. El proceso de diseño de microsatélites se divide en tres disciplinas; a) diseño de órbita, b) diseño de carga útil y c) diseño de plataforma. En primer lugar, se calculan diferentes parámetros de misión para un rango práctico de órbitas helio-síncronas (sun-synchronous orbits: SS-Os). Luego, según los parámetros orbitales y los datos de un instrumento como referencia, se calcula la masa y la potencia de la carga útil. El diseño de la plataforma del satélite se estima a partir de los datos de la masa y potencia de los diferentes subsistemas utilizando relaciones empíricas de diseño. El diseño del subsistema de potencia se realiza teniendo en cuenta variables de diseño más detalladas, como el escenario de la misión y diferentes tipos de células solares y baterías. El escenario se selecciona, de modo de obtener una banda de cobertura sobre la superficie terrestre paralelo al Ecuador después de cada intervalo de revisita. Con el objetivo de evaluar las interrelaciones entre las diferentes variables en el espacio de diseño, todas las disciplinas de diseño mencionados se combinan en un código unificado. Por último, una forma básica de MDO se ajusta a la herramienta de diseño de sistema de satélite. La optimización del diseño se realiza por medio de un GA con el único objetivo de minimizar la masa total de microsatélite. Según los resultados obtenidos de la aplicación del MDO, existen diferentes puntos de diseños óptimos, pero con diferentes variables de misión. Este análisis demuestra la aplicabilidad de MDO para los estudios de ingeniería de sistema en la fase de diseño conceptual en este tipo de proyectos. La principal conclusión de esta tesis, es que el diseño clásico de los satélites que por lo general comienza con la definición de la misión y la carga útil no es necesariamente la mejor metodología para todos los proyectos de satélites. Un microsatélite universitario, es un ejemplo de este tipo de proyectos. Por eso, se han desarrollado un conjunto de herramientas de diseño para encarar los estudios de la fase inicial de diseño. Este conjunto de herramientas incluye diferentes disciplinas de diseño centrados en el subsistema estructural y teniendo en cuenta una carga útil desconocida a priori. Los resultados demuestran que la mínima masa total del satélite y la máxima masa disponible para una carga útil desconocida a priori, son objetivos conflictivos. En este contexto para encontrar un Pareto-optimal se ha aplicado una optimización multiobjetivo. Según los resultados se concluye que la selección de la masa total por satélite en el rango de 40-60 kg puede considerarse como óptima para un proyecto de microsatélites universitario con carga útil desconocida a priori. También la metodología CE se ha aplicado al proceso de diseño conceptual de microsatélites de teledetección. Los resultados de la aplicación del CE proporcionan una clara comprensión de la interacción entre los requisitos de diseño de sistemas de satélites, tales como la masa total del microsatélite y la potencia y los requisitos de la misión como la resolución y el tiempo de revisita. La aplicación de MDO se hace con la minimización de la masa total de microsatélite. Los resultados de la aplicación de MDO aclaran la relación clara entre los diferentes requisitos de diseño del sistema y de misión, así como que permiten seleccionar las líneas de base para el diseño óptimo con el objetivo seleccionado en las primeras fase de diseño. ABSTRACT This thesis is done in the context of UPMSat-2 project, which is a microsatellite under design and manufacturing at the Instituto Universitario de Microgravedad “Ignacio Da Riva” (IDR/UPM) of the Universidad Politécnica de Madrid. Application of Concurrent Engineering (CE) methodology in the framework of Multidisciplinary Design application (MDO) is one of the main objectives of the present work. In recent years, there has been continuing interest in the participation of university research groups in space technology studies by means of their own microsatellites. The involvement in such projects has some inherent challenges, such as limited budget and facilities. Also, due to the fact that the main objective of these projects is for educational purposes, usually there are uncertainties regarding their in orbit mission and scientific payloads at the early phases of the project. On the other hand, there are predetermined limitations for their mass and volume budgets owing to the fact that most of them are launched as an auxiliary payload in which the launch cost is reduced considerably. The satellite structure subsystem is the one which is most affected by the launcher constraints. This can affect different aspects, including dimensions, strength and frequency requirements. In the first part of this thesis, the main focus is on developing a structural design sizing tool containing not only the primary structures properties as variables but also the satellite system level variables such as payload mass budget and satellite total mass and dimensions. This approach enables the design team to obtain better insight into the design in an extended design envelope. The structural design sizing tool is based on the analytical structural design formulas and appropriate assumptions including both static and dynamic models of the satellite. A Genetic Algorithm (GA) is applied to the design space for both single and multiobejective optimizations. The result of the multiobjective optimization is a Pareto-optimal based on two objectives, minimum satellite total mass and maximum payload mass budget. On the other hand, the application of the microsatellites is of interest for their less cost and response time. The high need for the remote sensing applications is a strong driver of their popularity in space missions. The satellite remote sensing missions are essential for long term research around the condition of the earth resources and environment. In remote sensing missions there are tight interrelations between different requirements such as orbital altitude, revisit time, mission cycle life and spatial resolution. Also, all of these requirements can affect the whole design characteristics. During the last years application of the CE in the space missions has demonstrated a great advantage to reach the optimum design base lines considering both the performance and the cost of the project. A well-known example of CE application is ESA (European Space Agency) CDF (Concurrent Design Facility). It is clear that for the university-class microsatellite projects having or developing such a facility seems beyond the project capabilities. Nevertheless practicing CE at any scale can be beneficiary for the university-class microsatellite projects. In the second part of this thesis, the main focus is on developing a MDO framework applicable to the conceptual design phase of the remote sensing microsatellites. This approach enables the design team to evaluate the interaction between the different system design variables. The presented MDO framework contains not only the system level variables such as the satellite total mass and total power, but also the mission requirements like the spatial resolution and the revisit time. The microsatellite sizing process is divided into the three major design disciplines; a) orbit design, b) payload sizing and c) bus sizing. First, different mission parameters for a practical range of sun-synchronous orbits (SS-Os) are calculated. Then, according to the orbital parameters and a reference remote sensing instrument, mass and power of the payload are calculated. Satellite bus sizing is done based on mass and power calculation of the different subsystems using design estimation relationships. In the satellite bus sizing, the power subsystem design is realized by considering more detailed design variables including a mission scenario and different types of solar cells and batteries. The mission scenario is selected in order to obtain a coverage belt on the earth surface parallel to the earth equatorial after each revisit time. In order to evaluate the interrelations between the different variables inside the design space all the mentioned design disciplines are combined in a unified code. The integrated satellite system sizing tool developed in this section is considered as an application of the CE to the conceptual design of the remote sensing microsatellite projects. Finally, in order to apply the MDO methodology to the design problem, a basic MDO framework is adjusted to the developed satellite system design tool. Design optimization is done by means of a GA single objective algorithm with the objective function as minimizing the microsatellite total mass. According to the results of MDO application, there exist different optimum design points all with the minimum satellite total mass but with different mission variables. This output demonstrates the successful applicability of MDO approach for system engineering trade-off studies at the conceptual design phase of the design in such projects. The main conclusion of this thesis is that the classical design approach for the satellite design which usually starts with the mission and payload definition is not necessarily the best approach for all of the satellite projects. The university-class microsatellite is an example for such projects. Due to this fact an integrated satellite sizing tool including different design disciplines focusing on the structural subsystem and considering unknown payload is developed. According to the results the satellite total mass and available mass for the unknown payload are conflictive objectives. In order to find the Pareto-optimal a multiobjective GA optimization is conducted. Based on the optimization results it is concluded that selecting the satellite total mass in the range of 40-60 kg can be considered as an optimum approach for a university-class microsatellite project with unknown payload(s). Also, the CE methodology is applied to the remote sensing microsatellites conceptual design process. The results of CE application provide a clear understanding of the interaction between satellite system design requirements such as satellite total mass and power and the satellite mission variables such as revisit time and spatial resolution. The MDO application is done with the total mass minimization of a remote sensing satellite. The results from the MDO application clarify the unclear relationship between different system and mission design variables as well as the optimum design base lines according to the selected objective during the initial design phases.

Supporting the design and development of Project Based Learning courses.

The use of Project Based Learning has spread widely over the last decades, not only throughout countries but also among disciplines. One of the most significant characteristics of this methodology is the use of ill-structured problems as central activity during the course, which represents an important difficulty for both teachers and students. This work presents a model, supported by a tool, focused on helping teachers and students in Project Based Learning, overcoming these difficulties. Firstly, teachers are guided in designing the project following the main principles of this methodology. Once the project has been specified at the desired level of depth, the same tool helps students to finish the project specification and organize the implementation. Collaborative work among different users is allowed in both phases. This tool has been satisfactorily tested designing two real projects used in Computer Engineering and Software Engineering degrees.

Seismic soil-interaction on earth retaining structures. Performance-based seismic design of a Retaining Wall

The design of containment walls suffering seismic loads traditionally has been realized with methods based on pseudoanalitic procedures such as Mononobe- Okabe's method, which it has led in certain occasions to insecure designs, that they have produced the ruin of many containment walls suffering the action of an earthquake. A method is proposed in this papers for the design of containment walls in different soils, suffering to the action of an earthquake, based on the Performance-Based Seismic Design.

Performance-based seismic design of a retaining wall

The design of containment walls suffering seismic loads traditionally has been realized with methods based on pseudoanalitic procedures such as Mononobe-Okabe's method, which it has led in certain occasions to insecure designs, that they have produced the ruin of many containment walls suffering the action of an earthquake. The recommendations gathered in Mononobe-Okabe's theory have been included in numerous Codes of Seismic Design. It is clear that a revision of these recommendations must be done. At present there is taking place an important review of the design methods of anti-seismic structures such as containment walls placed in an area of numerous earthquakes, by means of the introduction at the beginning of the decade of 1990 the Displacement Response Spectrum (DRS) and the Capacity Demand Diagram (CDD) that suppose an important change in the way of presenting the Elastic Response Spectrum (ERS). On the other hand in case of action of an earthquake, the dynamic characteristics of a soil have been referred traditionally to the speed of the shear waves that can be generated in a site, together with the characteristics of plasticity and damping of the soil. The Principle of the energy conservation explains why a shear upward propagating seismic wave can be amplified when travelling from a medium with high shear wave velocity (rock) to other medium with lower velocity (soil deposit), as it happened in the earthquake of Mexico of 1985. This amplification is a function of the speed gradient or of the contrast of impedances in the border of both types of mediums. A method is proposed in this paper for the design of containment walls in different soils, suffering to the action of an earthquake, based on the Performance-Based Seismic Design.

A knowledge based application for industrialization design

After being designed, a product has to be manufactured, which means converting concepts and information into a real, physical object. This requires a big amount of resources and a careful planning. The product manufacturing must be designed too, and that is called Industrialization Design. An accepted methodology for this activity is starting defining simple structures and then progressively increasing the detail degree of the manufacturing solution. The impact of decisions taken at first stages of Industrialization Design is remarkable, and software tools to assist designers are required. In this paper a Knowledge Based Application prototype for the Industrialization Design is presented. The application is implemented within the environment CATIA V5/DELMIA. A case study with a simple Product from aerospace sector illustrates the prototype development.

Simplified serviceability design of jointless structures. Experimental verification and application to typical bridge and building structures

In this article an experimental campaign aimed at validating a previously published simplified serviceability design method of the columns of long jointless structures is presented. The proposed method is also extended to include tension stiffening effects which proved to be significant in structures with small amount of reinforcement subjected to small axial loading. This extension allows significant improvement of predictions for this type of element. The campaign involved columns with different reinforcement and squashing load ratios, given that these parameters had been identified as crucial when designing columns subjected to imposed displacements. Experimental results are presented and discussed, with particular regard to cracking behaviour and structural stiffness. Considerations on tension stiffening effects are also made. Finally, the application of the method to typical bridge and building cases is presented, showing the feasibility of jointless construction, and the limits which should be respected.

Design and construction of the Barriga Dam spillway through an improved wedge-shaped block technology

The Barriga Dam (Burgos, Spain) is a unique case study because its trapezoid spillway is located on the dam body and is composed of wedge-shaped concrete blocks (WSB) that include certain relevant improvements. This note summarizes the main features of the studies, the key aspects of the final design of the WSB and their placement on the dam, and important details of the spillway design. The design team concluded the study by showing the suitability of this enhanced technology for application to small dams and ponds in the short term, even with unit flows above 5 m2/s.

Code assessment and modelling for Design Basis Accident Analysis of the European sodium fast reactor design. Part I: System description, modelling and benchmarking

The new reactor concepts proposed in the Generation IV International Forum (GIF) are conceived to improve the use of natural resources, reduce the amount of high-level radioactive waste and excel in their reliability and safe operation. Among these novel designs sodium fast reactors (SFRs) stand out due to their technological feasibility as demonstrated in several countries during the last decades. As part of the contribution of EURATOM to GIF the CP-ESFR is a collaborative project with the objective, among others, to perform extensive analysis on safety issues involving renewed SFR demonstrator designs. The verification of computational tools able to simulate the plant behaviour under postulated accidental conditions by code-to-code comparison was identified as a key point to ensure reactor safety. In this line, several organizations employed coupled neutronic and thermal-hydraulic system codes able to simulate complex and specific phenomena involving multi-physics studies adapted to this particular fast reactor technology. In the “Introduction” of this paper the framework of this study is discussed, the second section describes the envisaged plant design and the commonly agreed upon modelling guidelines. The third section presents a comparative analysis of the calculations performed by each organisation applying their models and codes to a common agreed transient with the objective to harmonize the models as well as validating the implementation of all relevant physical phenomena in the different system codes.

Code assessment and modelling for Design Basis Accident analysis of the European Sodium Fast Reactor design. Part II: Optimised core and representative transients analysis

The new reactor concepts proposed in the Generation IV International Forum require the development and validation of computational tools able to assess their safety performance. In the first part of this paper the models of the ESFR design developed by several organisations in the framework of the CP-ESFR project were presented and their reliability validated via a benchmarking exercise. This second part of the paper includes the application of those tools for the analysis of design basis accident (DBC) scenarios of the reference design. Further, this paper also introduces the main features of the core optimisation process carried out within the project with the objective to enhance the core safety performance through the reduction of the positive coolant density reactivity effect. The influence of this optimised core design on the reactor safety performance during the previously analysed transients is also discussed. The conclusion provides an overview of the work performed by the partners involved in the project towards the development and enhancement of computational tools specifically tailored to the evaluation of the safety performance of the Generation IV innovative nuclear reactor designs.

Design, development and evaluation of a portable recording system to capture dynamic presentations using the teacher's tablet PC

Computers and multimedia equipment have improved a lot in the last years. They have reduced their cost and size while at the same time increased their capabilities. These improvements allowed us to design and implement a portable recording system that also integrates the teacher´s tablet PC to capture what he/she writes on the slides and all that happens in it. This paper explains this system in detail and the validation of the recordings that we did after using it to record all the lectures the “Communications Software” course in our university. The results show that pupils used the recordings for different purposes and consider them useful for a variety of things, especially after missing a lecture.

The historical heritage of domestic architecture is a reliable model for a satisfactory design. The case of the Mediterranean region

The purpose of this paper is to expose the importance of observing cultural systems present in a territory as a reference for the design of urban infrastructures in the new cities and regions of rapid development. If we accept the idea that architecture is an instrument or cultural system developed by man to act as an intermediary to the environment, it is necessary to understand the elemental interaction between man and his environment to meet a satisfactory design. To illustrate this purpose, we present the case of the Eurasian Mediterranean region, where the architectural culture acts as a cultural system of adaptation to the environment and it is formed by an ancient process of selection. From simple observation of architectural types, construction systems and environmental mechanisms treasured in mediterranean historical heritage we can extract crucial information about this elemental interaction. Mediterranean architectural culture has environmental mechanisms responding to the needs of basics habitability, ethnics and passive conditioning. These mechanisms can be basis of an innovative design without compromising the diversity and lifestyles of human groups in the region. The main fundament of our investigation is the determination of the historical heritage of domestic architecture as holder of the formation process of these mechanisms. The result allows us to affirm that the successful introduction of new urban infrastructures in an area need a reliable reference and it must be a cultural system that entailing in essence the environmental conditioning of human existence. The urban infrastructures must be sustainable, understood and accepted by the inhabitants. The last condition is more important when the urban infrastructures are implemented in areas that are developing rapidly or when there is no architectural culture.

Engineering privacy requirements valuable lessons from another realm

The Privacy by Design approach to systems engineering introduces privacy requirements in the early stages of development, instead of patching up a built system afterwards. However, 'vague', 'disconnected from technology', or 'aspirational' are some terms employed nowadays to refer to the privacy principles which must lead the development process. Although privacy has become a first-class citizen in the realm of non-functional requirements and some methodological frameworks help developers by providing design guidance, software engineers often miss a solid reference detailing which specific, technical requirements they must abide by, and a systematic methodology to follow. In this position paper, we look into a domain that has already successfully tackled these problems -web accessibility-, and propose translating their findings into the realm of privacy requirements engineering, analyzing as well the gaps not yet covered by current privacy initiatives.

Basics on design and analysis of SE experiments: widespread shortcomings

Keynote speech about experimental design

Strengthening and measuring project management competences of engineering students

Since 2010 the Industrial Engineering School at Universidad Politécnica de Madrid (ETSII UPM) has its Plan Study accredited by ABET. Since then a big motivation has been promoted from the management team encouraging teachers to work on the measurement and strengthening of student¿s competences. Generic skills or behavior acquired significant importance in the workplace, particularly in relation to project management. Because of this, and framed within the requirements of the European Higher Education Area (EHEA), the curriculum of the new degrees are being developed under the competence-based learning. This situation leads to the need to have a clear measurement tool skills as a basis for developing them within the curriculum. A group of multidisciplinary teachers have been working together during two years to design measuring instruments valid for engineering students.

Engineering analysis of ITER In-Vessel Viewing System guide tube

The In Vessel Viewing System (IVVS) will be one of the essential machine diagnostic systems at ITER to provide information about the status of in-vessel and plasma facing components and to evaluate the dust inside the Vacuum Vessel. The current design consists of six scanning probes and their deployment systems, which are placed in dedicated ports at the divertor level. These units are located in resident guiding tubes 10 m long, which allow the IVVS probes to go from their storage location to the scanning position by means of a simple straight translation. Moreover, each resident tube is supported inside the corresponding Vacuum Vessel and Cryostat port extensions, which are part of the primary confinement barrier. As the Vacuum Vessel and the Cryostat will move with respect to each other during operation (especially during baking) and during incidents and accidents (disruptions, vertical displacement events, seismic events), the structural integrity of the resident tube and the surrounding vacuum boundaries would be compromised if the required flexibility and supports are not appropriately assured. This paper focuses on the integration of the present design of the IVVS into the Vacuum Vessel and Cryostat environment. It presents the adopted strategy to withstand all the main interfacing loads without damaging the confinement barriers and the corresponding analysis supporting it.