Abstract:
An integrated engineering analysis system comprises: a) a first integrated computational process, the first process being comprised of a plurality of computational solvers adapted to compute characteristics of a first component; b) a second integrated computational process, the second process being comprised of a plurality of computational solvers adapted to compute characteristics of a second component; and c) communication paths between corresponding computational solvers of the first and second computational processes.

Description:
BACKGROUND OF THE INVENTION 
       [0001]    The technology described herein relates to systems for performing integrated engineering analyses. 
         [0002]    In highly complex engineering situations where the final product or design has a numerous amount of interrelated mechanical parts and/or functions, the engineering design process consists of a plurality of independent modeling problems wherein the solution of each of the modeling problems is determined by running a series of simulations or solving a series of problems whereby the solution of the first simulation and/or problem is inputted into the next simulation and/or problem until the variance between the last solution and the second to last solution is at a minimum and/or within predetermined tolerances. 
         [0003]    However, and in design problems where there is a plurality of independent modeling scenarios and each of the inputs and/or outputs of the scenarios is related to or has a significant effect on the result of one or more of the other scenarios, the solution process is quite tedious and cumbersome. 
         [0004]    For example, an ideal input for a first simulation may result in an unacceptable result for a second simulation. Accordingly, and in situations where each of the modeling scenarios is run in a “stand alone” process, the simulations must be reexecuted until each one of the simulations results in an output which is within the predetermined tolerances of the design. 
         [0005]    For example, in designing an aircraft engine, and for purposes of illustrating just one problem encountered in such a design, the reliability, weight, performance, and, ultimately, the life of rotating turbo-machinery in an aircraft engine is inherently dependent upon the operating temperature distributions within the components of the machine. The determination of these operating temperatures is very complex. In order to determine these temperatures, the calculation of the values of many independent parameters that are the results of individual subprocesses themselves, must be determined. 
         [0006]    Although engineering analysis systems and processes have been developed which integrate the analysis subprocesses for a given component, there remains a need for engineering analysis systems and processes that account for interdependencies among multiple adjacent and/or interactive components. 
       BRIEF DESCRIPTION OF THE INVENTION 
       [0007]    In one aspect, an integrated engineering analysis system is described. The system comprises: a) a first integrated computational process, the first process being comprised of a plurality of computational solvers adapted to compute characteristics of a first component; b) a second integrated computational process, the second process being comprised of a plurality of computational solvers adapted to compute characteristics of a second component; and c) communication paths between corresponding computational solvers of the first and second computational processes. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0008]    The accompanying drawings illustrate several embodiments of the technology described herein, wherein: 
           [0009]      FIG. 1  is a block diagram of an integrated engineering analysis process in an exemplary embodiment of the present invention; and 
           [0010]      FIG. 2  is a block diagram of an intended use of the integrated engineering analysis process of  FIG. 1 ; and 
           [0011]      FIG. 3  is a block diagram of an integrated engineering analysis system and process in accordance with an exemplary embodiment of the present invention. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0012]    Referring now to  FIG. 1 , an integrated engineering analysis process  10  with solution feedback is illustrated. An initial guess or estimate  12  provides a first initial value  14  and a second initial value  16 . Initial estimate  12  determines values  14  and  16  in response to a first condition  18  which is either inputted into initial estimate  12  or is a component part of initial estimate  12  which determines initial values  14  and  16 . 
         [0013]    A first subprocess  20  receives a first initial value  14  and provides an output  22 . Output  22  is dependent upon the value of first initial value  14 . First subprocess  20  can be or include a computer algorithm which receives an input in the form of first initial value  14  and accordingly calculates output  22 . 
         [0014]    A second subprocess  24  receives output  22  and provides an output  26 . Output  26  is dependent upon the value of output  22 . Second subprocess  22  can be or include a computer algorithm which receives an input in the form of output  22  and accordingly calculates output  26 . 
         [0015]    A third subprocess  28  receives output  26  and second initial value  16  and provides outputs  30  and  32 . Output  30  and  32  are dependent upon output  26  and second initial value  16 . Third subprocess  28  can also be or include a computer algorithm that receives inputs in the form of output  26  and initial value  16  which in response to the values of the output  26  and value  16  provides outputs  30  and  32 . 
         [0016]    A fourth subprocess  34  receives second initial value  16  and outputs  30  and  32 . Fourth subprocess  34  produces outputs  36  and  38 . Outputs  36  and  38  are dependent upon second initial value  16  and outputs  30  and  32 . In addition, fourth subprocess  34  can also be or include a computer algorithm that receives inputs in the form of initial value  16  and outputs  30  and  32 . In response to these inputs fourth subprocess  34  calculates and provides outputs  36  and  38 . 
         [0017]    A fifth subprocess  40  receives second initial value  16  and outputs  30 ,  32 ,  36 , and  38 . Fifth subprocess  40  produces a final output  42 . Final output  42  is dependent upon second initial value  16  and outputs  30 ,  32 ,  36 , and  38 . Similarly, fifth subprocess  40  can be or include a computer algorithm which in response to initial value  16  and outputs  30 ,  32 ,  36 , and  38  calculates a final output  42 . 
         [0018]    Final output  42  is now inputted into a final subprocess  44 . Final subprocess  44  produces outputs  46  and  48 . Outputs  46  and  48  are dependent upon the value of final output  42 . Final subprocess  44  can also be or include a computer algorithm which in response to the value of final output  42  calculates outputs  46  and  48 . Outputs  46  and  48  correspond to initial values  14  and  16  respectively. For example, initial value  14  is determined by the initial estimation and output  46  is a value that is comparable to initial value  14 ; however, output  46  is determined by a series of calculations and integrated steps which are set in motion by initial values  14  and  16 . Additionally, and for example, initial value  14  and output  46  can be temperature readings of a specific location and/or material. However, the value of output  46  may be significantly different than initial value  14  due to the fact that output  46  is dependent upon a series of integrated engineering calculations which are based in part upon initial value  14 . 
         [0019]    Outputs  46  and  48  are inputted into a decision node  50  which determines whether or not outputs  46  and  48  are sufficiently close to or converged with their respective initial input values  14  and  16 . A range which represents a tolerance range that is acceptable between values  14  and  16  and outputs  46  and  48  can define the convergence of initial input values  14  and  16  to outputs  46  and  48 . 
         [0020]    If not, outputs  46  and  48  replace initial values  14  and  16  and engineering analysis process  10  is run again, however, outputs  46  and  48  are used instead of initial values  14  and  16 . Engineering analysis process  10  is repeated until outputs  46  and  48  are determined to be at the desired value decision node  50 . At this point, decision node  50  instructs engineering analysis process  10  to stop. 
         [0021]    Since the process began with an initial assumption  18  it is almost certain that the first outputs  46  and  48  will not be within the predetermined tolerances. 
         [0022]    As an alternative, and as required by the type of engineering analysis being performed, the number of subprocesses and their corresponding inputs and outputs may be varied. 
         [0023]    A command code or module  52  communicates with each of the subprocesses and determines whether an input has been received and, accordingly, instructs the subprocess to run and provides designated output. 
         [0024]    Accordingly, command code  52  determines which of the subprocesses to run and the sequence in which they are to be run. In addition, and as an alternative, command code  52  can be provided with boundary conditions, which set limits for each subprocess. Therefore, and if the result is outside the predetermined range, command code  52  will stop the analysis and request recalculation or new values to be inputted into the appropriate subprocess. 
         [0025]    Integrated engineering analysis process  10  allows an engineer to run numerous simulations while varying the inputs in order to determine the effect on the final output. Attempting such a task in a situation where each of the subprocesses was a “stand alone” procedure would require many more calculations and comparisons which in comparison to the analysis process of instant application would be quite tedious and cumbersome, as well as involving a significant amount of additional time. 
         [0026]    One contemplated use of the process is an integrated engineering analysis process with solution feedback for an aircraft engine design. This embodiment is illustrated in  FIG. 2 . Here initial guess or assumption  12  calculates air and metal temperatures ( 14 ,  16 ) for component parts of an aircraft engine in response to an initial assumption  18 . 
         [0027]    The metal temperature  14  is inputted into subprocess  20 , which calculates the mechanical deflection of the metal components of an aircraft engine in response to the metal temperature  14 . In addition to the metal temperature, and as will be discussed in more detail below, the engine speed, cavity pressures, and other forces influence the mechanical deflection of the metal components (subroutines  24 ,  28 ,  34 , and  40 ). Using these subroutines, and their outputs, the mechanical deflection of the metal components is calculated. These boundary conditions can be applied to a mechanical model  21  (illustrated by the dashed lines in  FIG. 2 ) that calculates the mechanical deflection. The boundary conditions can be applied directly to mechanical model  21  directly as needed by the integrated engineering analysis process  10 . 
         [0028]    Mechanical model  21  may use the same mesh as integrated engineering analysis process  10  model. When dissimilar meshes are used an added temperature mapping subprocess is required for integrated engineering analysis process  10 . There are several potential differences between mechanical model  21  and analysis process  10  model. The mechanical model can be a subset of the analysis process  10  model if, for instance, the calculation of mechanical deflections is desired for only the metal components to be used in clearance calculations (subprocess  24 ). The mechanical model can include finite element modeling elements that are unique to stress-deflection calculations and not present in analysis process  10  model. It may require representation of features not required in analysis process  10  model, e.g. blades, bolts, and nuts. The mechanical model can include rotor and stator parts including components with different rotor speeds. When analysis process  21  uses a 2D model, special modeling techniques may be used to account for bolthole stiffness reductions and to reduce hoop-load strength for non-axisymmetric features. Special modeling techniques are also used to represent the airfoils in the mechanical model. 
         [0029]    Here, output  22  of second subprocess  20  is the mechanical deflection value. It is noted, and for illustration purposes, that the mechanical deflection value  22  is dependent upon the temperature value  14  and other values such as engine speed and cavity pressures. 
         [0030]    Output  22  is now inputted into subprocess  24  which in this embodiment calculates the resulting clearance between the mechanical parts (output  26 ). Again, and for purposes of illustration, it is noted that the clearance value is dependent upon the deflection value (output  22 ) of a mechanical part which in turn is dependent upon the metal temperature (initial value  14 ). 
         [0031]    Output  26  and initial value  16  are now inputted into subprocess  28  which in this embodiment calculates flow and pressure values (outputs  30  and  32 ). Again, it is noted that the flow and pressure values are dependent upon the clearance and air temperature values. 
         [0032]    Here it is of particular importance to note that output  26  is the result of three subprocesses ( 12 ,  20  and  24 ) while initial value  16  is the result of one subprocess  12 . 
         [0033]    As contemplated with the instant application, integrated engineering analysis process  10  is able to provide outputs ( 30  and  32 ) that are dependent upon inputs having origins of differing complexity. 
         [0034]    As contemplated in the instant application, integrated engineering analysis process  10  and, in particular, the subprocess  28  provides two outputs  30  and  32  which are dependent upon the input of outputs  26  and  16 , one of which is a result of three independent calculations. 
         [0035]    Accordingly, integrated engineering analysis process  10  provides a problem solving approach wherein multiple results of simulations and/or equations having interdependent characteristics are accounted for in the final solution. 
         [0036]    Referring back now to  FIG. 2 , initial value  16  and outputs  30  and  32  are now inputted into subprocess  34  which in this embodiment calculates the cavity and seal windage and swirl values (outputs  36  and  38 ). 
         [0037]    Finally, initial value  16  and outputs  30 ,  32 ,  36 , and  38  are inputted into subprocess  40  which will calculate the boundary condition values (output  42 ). These boundary conditions are now inputted into subprocess  44  in order to calculate outputs  46  (T metal ) and  48  (T air ). It is noted that outputs  46  and  48  are comparable to initial values  14  and  16  respectively. 
         [0038]    Decision node  50  determines whether or not outputs  46  and  48  are within predetermined tolerances. If so, the process is stopped, however, on the other hand if outputs  46  and  48  are not within the predetermined tolerances they are inputted into continuing analysis process  10  in place of initial values  14  and  16  and even tighter speculation is rerun with outputs  46  and  48  as the initial values. Therefore, the subprocesses of integrated and engineering analysis  10 , dependent upon the prior said of outputs  46  and  48 , will calculate a new set of outputs  46  and  48 . 
         [0039]    It is noted that in this embodiment the calculation of output values of many independent parameters are determined by an integrated manner which provides feedback among the various parameters or subprocesses so that all of the interdependencies are represented in the calculation of each of the values. 
         [0040]    For example, and referring in particular to  FIG. 2  which references an aircraft engine design problem, it is noted that the temperatures, and accordingly, the resulting values dependent upon these temperatures, will vary significantly as the engine moves from a non-operating temperature to an operational temperature. 
         [0041]    Integrated engineering analysis process  10  in one embodiment provides a process for calculating the temperatures of components of turbomachinery. This process combines the calculation of metal temperatures with the calculation of cooling flow rates and temperatures including, the interdependent aspects of these physical processes. For example, the calculation of metal temperatures is combined with the calculation of cooling flow rates and temperatures and pressures and also the calculations of mechanical deflection as well as the interdependent aspects of these processes. These processes may also include the calculation of mechanical deflection of both a rotating feature and a stationary feature at a flow restriction. In addition, logic simulating control system regulation of controllable engine devices can also be incorporated into the calculation. 
         [0042]    As shown in  FIG. 3 , a plurality (i.e., two or more) integrated processes such as described above are performed concurrently on a plurality of components to be designed via a fully integrated system and process. For example, in the embodiment of  FIG. 3 , three components are computationally analyzed, each with a plurality of individual solvers which are fully integrated both within a component and also between adjacent components. The computed results of each solver are communicated back and forth between all neighboring solvers of all models to be using, for example, message passing interface (MPI) protocols to obtain a fully coupled convergence. Therefore, no one model will converge in a standalone sense, thus assuring that all of the interdependencies are accounted for in a consistent and accurate manner. This approach provides improved computational efficiency and accuracy, and permits simulations to be performed of the behavior and performance of multiple adjacent components. When employed to perform computations for the modules of an aircraft gas turbine engine, for example, an analysis of the performance of the engine may be performed. 
         [0043]    Thus, an integrated automatic, real-time process for thermal analysis, flow analysis, cavity (windage and swirl) analysis, labyrinth seal analysis, mechanical deflection analysis, and clearance analysis is provided. Moreover, there is communication between the various elements in the integrated process of the instant application. In addition, and as an alternative, the hierarchy of integrated analysis process  10  can be altered to accommodate various design features and/or scenarios. 
         [0044]    Moreover, these temperatures will vary as the engine is exposed to differing altitudes and weather conditions. Therefore, the analysis process of the instant application allows a designer to predict such variations as the analysis process of the instant application accounts for such interdependencies which, in turn, allows the design to account for such variations. 
         [0045]    It is also contemplated that the number of subprocesses may be increased or decreased. In addition, the output and accordingly input pathways to and from each of the subprocesses may also be varied. Moreover, the number of output and input pathways may also be varied. 
         [0046]    Of course, the number of subprocesses and their interconnections is dependent upon the type of engineering analysis process being performed. For example, the instant application discusses one aspect of an aircraft engineering analysis process, however, the process of the instant application is not intended to be limited to the same and may be utilized with any design process. 
         [0047]    The integrated engineering analysis of the instant application provides accurate accounting and representation of the interdependent values. This results in high-quality predictions. For example, steady-state and transient temperature levels and distributions vary significantly and are dependent upon other values. The process of the instant application provides accurate predictions of the same which allows multiple interdependent outputs to be determined without having to rely on traditional “stand alone” calculations. 
         [0048]    This process provides a more streamlined analysis technique which permits more cases, scenarios or problems to be analyzed in less time and at less cost. 
         [0049]    There is also less opportunity for errors or miscalculations as the results of the various subprocesses are accounted for when calculating single values which in themselves vary. 
         [0050]    This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to make and use the invention. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.