With the demand of computing power from electronic chips on a constant rise, innovative methods are needed for effective and efficient thermal management. Forced convection cooling through an array of micro pin-fins acts not only as a heat sink, but also allows for the electrical interconnection between stacked layers of integrated circuits. This work performs a multi-objective optimization of three shapes of pin-fins to maximize the efficiency of this cooling system. An inverse design approach that allows for the design of cooling configurations without prior knowledge of thermal mapping was proposed and validated. The optimization study showed that pin-fin configurations are capable of containing heat flux levels of next generation electronic chips. It was also shown that even under these high heat fluxes the structural integrity is not compromised. The inverse approach showed that configurations exist that are capable of cooling heat fluxes beyond those of next generation chips. Thin film heat spreaders made of diamond and graphene nano-platelets were also investigated and showed that further reduction in maximum temperature, increase in temperature uniformity and reduction in thermal stresses are possible.

ABSTRACT Multidisciplinary Design Optimization of an Extreme Aspect Ratio HALE UAV Bryan J. Morrisey Development of High Altitude Long Endurance (HALE) aircraft systems is part of a vision for a low cost communications/surveillance capability. Applications of a multi payload aircraft operating for extended periods at stratospheric altitudes span military and civil genres and support battlefield operations, communications, atmospheric or agricultural monitoring, surveillance, and other disciplines that may currently require satellite-based infrastructure. Presently, several development efforts are underway in this field, including a project sponsored by DARPA that aims at producing an aircraft that can sustain flight for multiple years and act as a pseudo-satellite. Design of this type of air vehicle represents a substantial challenge because of the vast number of engineering disciplines required for analysis, and its residence at the frontier of energy technology. The central goal of this research was the development of a multidisciplinary tool for analysis, design, and optimization of HALE UAVs, facilitating the study of a novel configuration concept. Applying design ideas stemming from a unique WWII-era project, a “pinned wing” HALE aircraft would employ self-supporting wing segments assembled into one overall flying wing. The research effort began with the creation of a multidisciplinary analysis environment comprised of analysis modules, each providing information about a specific discipline. As the modules were created, attempts were made to validate and calibrate the processes against known data, culminating in a validation study of the fully integrated MDA environment. Using the NASA / AeroVironment Helios aircraft as a basis for comparison, the included MDA environment sized a vehicle to within 5% of the actual maximum gross weight for generalized Helios payload and mission data. When wrapped in an optimization routine, the same integrated design environment shows potential for a 17.3% reduction in weight when wing thickness to chord ratio, aspect ratio, wing loading, and power to weight ratio are included as optimizer-controlled design variables. Investigation of applying the sustained day/night mission requirement and improved technology factors to the design shows that there are potential benefits associated with a segmented or pinned wing. As expected, wing structural weight is reduced, but benefits diminish as higher numbers of wing segments are considered. For an aircraft consisting of six wing segments, a maximum of 14.2% reduction in gross weight over an advanced technology optimal baseline is predicted.

Current airspace regulations require the remote pilot-in-command of an unmanned aircraft systems (UAS) to maintain visual line of sight with the vehicle for situational awareness. The future of UAS will not have these constraints as technology improves and regulations are changed. An operational model for the future of UAS is proposed where a remote operator will monitor remote vehicles with the capability to intervene if needed. One challenge facing this future operational concept is the ability for a flight data system to effectively communicate flight status to the remote operator. A system architecture has been developed to facilitate the implementation of such a flight data system. Utilizing the system architecture framework, a Phase I prototype was designed and built for two vehicles in the Autonomous Flight Laboratory (AFL) at Cal Poly. The project will continue to build on the success of Phase I, culminating in a fully functional command and control system for remote UAS operational testing.

Multidisciplinary design optimization (MDO) can be used as an effective tool to improve the design of automotive structures. Large-scale MDO problems typically involve several groups who must work concurrently and autonomously for reasons of efficiency. When performing MDO, a large number of designs need to be rated. Detailed simulation models used to assess automotive design proposals are often computationally expensive to evaluate. A useful MDO process must distribute work to the groups involved and be computationally efficient. In this thesis, MDO methods are assessed in relation to the characteristics of automotive structural applications. Single-level optimization methods have a single optimizer, while multi-level optimization methods have a distributed optimization process. Collaborative optimization and analytical target cascading are possible choices of multi-level optimization methods for automotive structures. They distribute the design process, but are complex. One approach to handle the computationally demanding simulation models involves metamodel-based design optimization (MBDO), where metamodels are used as approximations of the detailed models during optimization studies. Metamodels can be created by individual groups prior to the optimization process, and therefore also offer a way of distributing work. A single-level optimization method in combination with metamodels is concluded to be the most straightforward way of implementing MDO into the development of automotive structures.

Les produits mécatroniques sont complexes et multidisciplinaires par nature. Les exigences pour les concevoir sont souvent contradictoires et doivent être validées par les différentes équipes d'ingénierie disciplinaire (ID). Pour répondre à cette complexité et réduire le temps de conception, les ingénieurs disciplinaires ont besoin de collaborer dynamiquement, de résoudre les conflits interdisciplinaires et de réutiliser les connaissances de projets antérieurs. De plus, ils ont besoin de collaborer en permanence avec l’équipe d’ingénierie systèmes (IS) pour avoir un accès direct aux exigences et l’équipe d’optimisation multidisciplinaire (OMD) pour valider le système dans sa globalité.Nous proposons d'utiliser des techniques de gestion des connaissances pour structurer les connaissances générées lors des activités de collaboration afin d'harmoniser le cycle de conception. Notre principale contribution est une approche d'unification qui explique comment IS, ID et OMD se complètent et peuvent être utilisés en synergie pour un cycle de conception intégré et continu. Notre méthodologie permet de centraliser les connaissances nécessaires à la collaboration et au suivi des exigences. Elle assure également la traçabilité des échanges entre les ingénieurs grâce à la théorie des graphes. Cette connaissance formalisée du processus de collaboration permet de définir automatiquement un problème OMD. / Mechatronic products are complex and multidisciplinary in nature. The requirements to design them are often contradictory and must be validated by the various disciplinary engineering (DE) teams. To address this complexity and reduce design time, disciplinary engineers need to collaborate dynamically, resolve interdisciplinary conflicts, and reuse knowledge from previous projects. In addition, they need to work seamlessly with the Systems Engineering (SE) team to have direct access to requirements and the Multidisciplinary Design Optimization (MDO) team for global validation. We propose to use Knowledge Management techniques to structure the knowledge generated during collaboration activities and harmonize the overall design cycle. Our primary contribution is a unification approach, elaborating how SE, DE, and MDO complement each-other and can be used in synergy for an integrated and continuous design cycle. Our methodology centralizes the product knowledge necessary for collaboration. It ensures traceability of the exchange between disciplinary engineers using graph theory. This formalized process knowledge facilitates MDO problem definition.

In order to enhance accessibility to microgravity research, the design process for experiments on the ISS must be streamlined and accessible to all scientific disciplines, not just aerospace engineers. Thus, a general design and analysis toolbox with accompanying best practices manual for microgravity liquid containment is proposed. The work presented in this thesis improves the design process by introducing a modular liquid tank design which can be filled, drained, or act as a passive liquid-gas separation device. It can also be pressurized, and used for aerosol spray. This tank can be modified to meet the design requirements of various experimental setups and liquids. Furthermore, rough simulations of this tank are presented and available to the user for modification. The simulation and design methodology for other general cases is discussed as well. After reading this thesis, the user should have a basic understanding of how liquids behave in microgravity. She will be able to run simple simulations, design, build, test, and fly a liquid management device which has been modified to suit the requirements of her specific experiment. The general tank design can be manufactured using 3-D printing, traditional CNC milling, or a combination thereof. The design methodology and best practices presented here have been used to design tanks used in experiments on the International Space Station for Budweiser and Lambda Vision. Both tanks functioned nominally on orbit. While the specific data from these experiments cannot be presented due to proprietary restrictions, using this thesis as a design guide for new experiments should yield favorable results when applied to new tank designs. If the reader has any questions or would like an updated design process, the author’s preferred contact information can be found using the Orcid iD: 0000-0002-2617-2957 .

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The Cal Poly Spacecraft Simulator is currently being developed for future testing and verifying theoretical control applications. This paper details the effort to balance the platform and remove undesired external torque from the system using System Identification technique developed by Patrick Healy. Since the relationship between the input and output of the system is linear, the least square method is proposed to identify the mass properties and location of center of mass of the system. The tests use four sine wave generators that are out of phase with different amplitudes as the inputs to excite various structural modes of the system. The outputs, angular rates of the platform, are measured by the newly implemented LN-200 Inertial Measurement Unit that helps reducing the measurement noise. Two test cases of 90o yaw rotations with the identified inertia were performed and validated against the computer simulation model; and the result shows that the test cases trajectories followed closely with the computer simulation model.