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This paper quantifies the potential of electric propulsion systems to reduce petroleum use and greenhouse gas (GHG) emissions in the 2030 U.S. light-duty vehicle fleet. The propulsion systems under consideration include gasoline hybrid-electric vehicles (HEVs), plug-in hybrid vehicles (PHEVs), fuel-cell hybrid vehicles (FCVs), and battery-electric vehicles (BEVs). The performance and cost of key enabling technologies were extrapolated over a 25-30 year time horizon. These results were integrated with software simulations to model vehicle performance and tank-to-wheel energy consumption. Well-to-wheel energy and GHG emissions of future vehicle technologies were estimated by integrating the vehicle technology evaluation with assessments of different fuel pathways. The results show that, if vehicle size and performance remain constant at present-day levels, these electric propulsion systems can reduce or eliminate the transport sector's reliance on petroleum.

The System Architecture Virtual Integration (SAVI) program is a collaboration of industry, government, and academic organizations within the Aerospace Vehicle System Institute (AVSI) with the goal of structuring a new integration process that relies on a “single-truth” architectural framework. The SAVI approach of “Integrate, then Build” provides a modern distributed development environment which arrests the propagation of requirements errors through the development life cycle. It does so by capturing design assumptions and shared properties of the system design in an authoritative, annotated architectural model. This reference model provides a common, analyzable framework for confirming that system requirements remain complete, consistent, and correct at all levels of system decomposition. Core concepts of SAVI include extensive use of model-based system engineering tools and use of a “single-truth” reference architectural model.

The Boeing Company has recently developed a portable positioning system based upon its patented flexible vacuum track technology, in support of its commitment to lean manufacturing techniques. The positioning system, referred to as Mini Flex Track, was initially developed as an inexpensive drilling system that minimizes machine setup time, does not require extensive operator training due to its simple user interface, is general purpose enough to be used in varying airplane applications, and meets strict accuracy requirements for aircraft manufacturing. The system consists of a variable length vacuum track that conforms to a range of contours, a two-axis numerically-controlled positioning carriage that controls machine motion, an additional rail perpendicular to the vacuum rail that provides transverse motion, and an end effector that can perform various tasks.

Security is a serious concern for all Internet users, and all the more so if the implications of security failure can potentially affect safety of flight or the public's perception of air travel. However, when designing networked aircraft and onboard systems, technical security features are only one aspect of the implementation that must be addressed. Given the unique operational, support, and regulatory environment of commercial air transports, careful consideration must also be given to both design and operational requirements in order to develop an aircraft that can be safely operated and maintained within the constraints of the existing infrastructure and personnel available. This paper addresses the unique Operational Considerations for Securing Airborne Networks in commercial air transport aircraft.

Increased emphasis on standardizing processes and controlling variability in production operations includes validating perishable tools used in daily operations. Even though dealing with reputable manufacturers, many factors including communication, custom specifications and personnel turnover can lead to the perpetuation of mistakes if errors are not discovered and corrective action implemented. However, inspection is costly and inspection costs far outweigh many item costs unless considering product defects. A beneficial balance may be obtained by employing statistical sampling techniques similar to ISO 2859 [1] to verify the quality of incoming tools.

This paper assesses the potential improvement of automotive powertrain technologies 25 years into the future. The powertrain types assessed include naturally-aspirated gasoline engines, turbocharged gasoline engines, diesel engines, gasoline-electric hybrids, and various advanced transmissions. Advancements in aerodynamics, vehicle weight reduction and tire rolling friction are also taken into account. The objective of the comparison is the potential of anticipated improvements in these powertrain technologies for reducing petroleum consumption and greenhouse gas emissions at the same level of performance as current vehicles in the U.S.A. The fuel consumption and performance of future vehicles was estimated using a combination of scaling laws and detailed vehicle simulations. The results indicate that there is significant potential for reduction of fuel consumption for all the powertrains examined.

The development of new commercial airliners is a very risky proposition. To get it right, airframe manufacturers must balance new technologies and manufacturing methods with global participation and business considerations. The 787 is Boeing's popular new wide body aircraft incorporating state of the art composites design and manufacturing methods. But new technology alone is not enough. A new logistics system was needed to integrate global partners in order to fully benefit from new technologies. The Boeing 747-400 Dreamlifter is a special purpose 747-400 modified to transport Boeing 787 airplane components through various stages of manufacturing.

This paper will describe the Efficient Assembly Integration and Test (EAIT) system level project operated as a partnership among Boeing business units, universities, and suppliers. The focus is on the successful implementation and sharing of technology solutions to develop a model based, multi-product pulsed line factory of the future. The EAIT philosophy presented in this paper focuses on a collaborative environment that is tightly woven with the Lean Initiatives at Boeing's satellite development center. The prototype is comprised of a platform that includes a wireless instrumentation system, rapid bonding materials and virtual test of guidance hardware there are examples of collaborative development in collaboration with suppliers. Wireless tools and information systems are also being developed across the Boeing Company. Virtual reality development will include university partners in the US and India.

An air quality simulation and assessment (AQSA) model was developed to simulate/evaluate the integrated system performance and obtain air quality characteristics and air contaminants inside the habitable compartments. This model applies both fixed control volume and quasi-steady-state approach for a multi-volume system to assess system performance, operating constraints, and capabilities. The model also integrates a state-of-the-art probabilistic analysis tool, UNIPASS, to compute failure probability due to the uncertainties of variables. In addition, this integrated model also predicts the most likely outcomes for analyzing risks and uncertainties as well as for quantitative toxicological evaluation. This model has been successfully and independently corrected/verified by NASA/JSC to be a very effective, reliable, and accurate tool, while providing savings in both the cost and time of the analysis.

NASA has long recognized the advantages of providing improved information interfaces to EVA astronauts and has pursued this goal through a number of development programs over the past decade. None of these activities or parallel efforts in industry and academia has so far resulted in the development of an operational system to replace or augment the current extravehicular mobility unit (EMU) Display and Controls Module (DCM) display and cuff checklist. Recent advances in display, communications, and information processing technologies offer exciting new opportunities for EVA information interfaces that can better serve the needs of a variety of NASA missions. Hamilton Sundstrand Space Systems International (HSSSI) has been collaborating with Simon Fraser University and others on the NASA Haughton Mars Project and with researchers at the Massachusetts Institute of Technology (MIT), Boeing, and Symbol Technologies in investigating these possibilities.

As part of the Sustaining Engineering program for the International Space Station (ISS), a ground simulator of the Internal Thermal Control System (ITCS) in the Lab Module was designed and built at the Marshall Space Flight Center (MSFC). To predict ITCS performance and address flight issues, this facility is operationally and functionally similar to the flight system and flight-like components were used when available. Flight software algorithms, implemented using the LabVIEW® programming language, were used for monitoring performance and controlling operation. Validation testing of the low temperature loop was completed prior to activation of the Lab module in 2001. Assembly of the moderate temperature loop was completed in 2002 and it was validated in 2003. Even before complete validation the facility was used to address flight issues, successfully demonstrating the ability to add silver biocide and to adjust the pH of the coolant.

Computer simulation of extravehicular activity (EVA) is increasingly being used in planning and training for EVA. A space suit model is an important, but often overlooked, component of an EVA simulation. Because of the inherent difficulties in collecting angle and torque data for space suit joints in realistic conditions, little data exists on the torques that a space suit’s wearer must provide in order to move in the space suit. A joint angle and torque database was compiled on the Extravehicular Maneuvering Unit (EMU), with a novel measurement technique that used both human test subjects and an instrumented robot. Using data collected in the experiment, a hysteresis modeling technique was used to predict EMU joint torques from joint angular positions. The hysteresis model was then applied to EVA operations by mapping out the reach and work envelopes for the EMU.

The US Air Force (USAF) has evolved a policy for the acquisition of fighter jet engines (FJE). In the 1970s and 1980s that policy placed a premium on FJE performance primarily measured by the metric: thrust/engine weight. In the 1990s, the USAF policy changed from an emphasis on performance to reduced life-cycle cost with a premium on sustainment. This paper reports the results of a study of how the USAF and Corporation Alpha (Alpha) have adapted their processes, practices, and policies to design, develop, manufacture, test, and sustain a family of FJEs. Each member of the family of FJEs is sequentially linked relative to insertion of technology designed to reduce sustainment costs. In addition to the technology linkages, the development of the family of FJEs selected for this case study is also tracked relative to US Department of Defense and USAF policy and industry design, build, and maintain processes, methods, and tools.

Defining a process for integrating human modeling within the design and verification activities of the International Space Station (ISS) has proven to be as important as the simulations themselves. The process developed (1) ensured configuration management of the required digital mockups, (2) provided consistent methodology for simulating and analyzing human tasks and hardware layout, (3) facilitated an efficient method of communicating design requirements and relaying satisfaction of contract requirements, and (4) provided substantial cost savings by reducing the amount of late redesign and expensive mockup tests. Human simulation is frequently the last step in the design process. Consequently, the influence it has on product design is minimal and oftentimes being used as a post-design verification tool.

The challenge of developing a robust, real-time driver gaze classification system is that it has to handle difficult edge cases that arise in real-world driving conditions: extreme lighting variations, eyeglass reflections, sunglasses and other occlusions. We propose a single-camera end-toend framework for classifying driver gaze into a discrete set of regions. This framework includes data collection, semi-automated annotation, offline classifier training, and an online real-time image processing pipeline that classifies the gaze region of the driver. We evaluate an implementation of each component on various subsets of a large onroad dataset. The key insight of our work is that robust driver gaze classification in real-world conditions is best approached by leveraging the power of supervised learning to generalize over the edge cases present in large annotated on-road datasets.

Currently, the Aviation industry uses traditional methods of communication, coordination, & human interaction to give disposition to resolve any kind of nonconformance occurrences which occur during manufacturing or operation of commercial or defense products. This involves increased in-person interaction and additional travel, especially to address the nonconformance issues arising at supplier plants or airports around the globe. During Covid and post-Covid environments, human interactions for the transfer of detailed information at different & distant manufacturing plant locations has been difficult, since support engineering teams (Example: Liaison, Product Review, Quality, Supplier Quality, and Manufacturing Engineering, and/or Service Engineering) have been working remotely.

Orbital hole drilling technology has shown a great deal of promise for cost savings on applications in the aerospace industry where burr free, high quality holes are a necessity. This presentation will show some of the basic research on orbital drilling development Boeing is doing with the Advanced Manufacturing Research Center at Sheffield University and the deployment of the technology into production programs within The Boeing Company.

To manage the function of a vehicle's engine, transmission, and related subsystems, almost all modern vehicles make use of one or more electronic controllers running embedded software, henceforth referred to as a Powertrain Controller System or PCS. Fully validating this PCS is a necessary step of vehicle development, and the validation process requires extensive amounts of testing. Within the automotive industry, more and more of this validation testing is being performed using Hardware-in-the-Loop (HIL) simulators to automate the extensive test sequences. A HIL simulation typically mates the physical PCS to a closed-loop real time computer simulation of a powertrain. Interfacing the physical PCS hardware to a powertrain simulation requires the HIL simulator to have extensive signal input/output (I/O) electronics and simulated actuator electrical loading.

Painting is the most expensive unit operation in automobile manufacturing and the source of over 90 percent of the air, water and solid waste emissions at the assembly plant. While innovative paint technologies such as waterborne or powder paints can potentially improve plant environmental performance, implementing these technologies often requires major capital investment. A process-based technical cost model was developed for examining the environmental and economic implications of automotive painting at the unit operation level. The tradeoffs between potential environmental benefits and their relative costs are evaluated for current and new technologies.

The Boeing Company is developing and implementing the tools for the 21st Century for product development with their Design Manufacturing and Producibility Simulation (DMAPS) program. DMAPS combines the best of people, hardware and software tools commercially available to develop product and process simulation applications. The DMAPS toolset enhances the process of preparing concept layouts, assembly layouts and build-to-packages. Comprised of an Integrated Product and Process Team (IPPT), DMAPS produces products faster and with higher quality. The result is a process that eliminates costly changes and rework, and provides all IPPT's the tools and training necessary to perform their tasks right the first time. Boeing applies DMAPS tools to a variety of existing and new programs to build more affordable products. Savings goals set forth by the program are shown in Figure 1.