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Nonlinear Analysis of Modes and Causes of Failure of an Engineering System
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RQC is a Naval Architect, Marine Engineer, Senior Engineering Consultant, Mechanical, Aerodynamic, and Structural Systems Expert, Research Scientist, Failure Analysis Expert, Engineering Simulation Specialist with world-class expertise in simulation of large engineering systems involving mechanical, structural, and aerodynamic components, structural analyses, mathematical and statistical analyses, system failure analyses, and configuration management and quality assurance.
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The material presented in this case study reflects the author's over fifty years experience in engineering and program management, half of these with divisions of Northrop Grumman, and a broad educational background that includes graduate degrees in engineering from MIT with concentration in applied mechanics, a graduate degree from MIT in industrial management with concentration in operations research and Ph.D., in mathematics from UCLA. This work was done as a consultant to the US Air Force's Aerostat Program Office. Its purpose was to analyze causes of failures and to recommend changes in design and operating procedures to improve the system's survivability and availability.
Since a) the winch-tether-balloon system has a large number of degrees of freedom and involves structural, mechanical, and aerodynamic elements, with man in the loop responsible for inhauling, outhauling, and maintaining a safe operational altitude, its mathematical modeling; and b) the critical failure modes involve shock loading due to gusty winds; it was necessary to use the best available tools - Matlab-Simulink and Mathematica - to derive the differential equation set, build the simulation model, and design the graphics and animation package. After the model was validated by comparing the results of simulation with observed data, it was used to ask the "what-if" questions of interest to the Program Office in selecting areas of design improvement and reconsidering the operational envelope and operating procedures. A side benefit of simulation models with good graphics and animation is that they can also be used for crew training.
What-if Questions
There are a number of options that the Program Office could consider to mitigate the effects of gust loads. The simplest is to increase the reserve buoyancy by pumping more helium in the main compartment and withdrawing air from the ballonet. Higher lift would reduce the likelihood of a crash of the moored aerostat. A more complex solution would be to redesign the carriage under the mooring boom to improve its alignment with the balloon as it weathervanes around the mooring tower. This can involve modification of the damper under the carriage or a control system with a feedback loop to keep the two bodies in line. The simulation modules developed under this project proved to be very useful in conducting extensive parametric studies to evaluate the cost-benefit relationships of such solutions.
An equally important use of these models was in ILS planning. A clearer understanding of the risks and likelihood of failures helps the Program Office in budgeting for, and planning the procurement of, spare systems to achieve a suitable level of system availability.
Conclusion
The approach and techniques that were used in studying aerostat survivability have broader applications for engineering systems of different types. The widespread current use of Mathematica and Matlab-Simulink in fields ranging from automotive and aerospace engineering to bioengineering illustrates this fact. Of course, the effectiveness of the use of these tools depends entirely on skills that are employed in problem formulation. To organizations that are planning a new product for which the specifications need to be written, or those that are in the life-cycle support phase and wish to use the operational experience for product improvement, we feel certain that our services can be of enormous use.
| Naval Architect, Marine Engineer, Senior Engineering Consultant, Mechanical, Aerodynamic, and Structural Systems Expert, Research Scientist, Failure Analysis Expert, Engineering Simulation Specialist, simulation of large engineering systems involving mechanical, structural, and aerodynamic components, structural analyses, mathematical and statistical analyses, system failure analyses, and configuration management and quality assurance. | |
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