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At least 235 records · Page 13

Real-Time Lifetime Prediction of Semiconductor Devices Using Hardware-in-the-Loop

This paper presents a unique approach to enable real-time lifespan prediction of semiconductor power modules using a Hardware-in-the-Loop (HIL) system. By integrating the module's overall loss characteristics-specifically switching and conduction losses-with a thermoelectric model of the thermal management system, this research demonstrates that the model can dynamically estimates the junction temperature profile of the semiconductor devices in response to a changing torque demand profile for the motor drive system. This capability enables continuous monitoring of the module's operational time and cumulative stress induced on the devices to compute accumulated remaining lifetime or time-to-failure (TTF). This study provides an architectural framework for the HIL system with high-fidelity component models of multiple physical domains, allowing simulation of dynamic behaviors of a closely-coupled motor drive system. The advanced real-time computation and measurement functionalities of the HIL system allow for both dynamic lifetime calculations based on simulated data and aggregate lifetime predictions utilizing historical data. Moreover, this paper details an algorithm that not only computes cumulative damage but also synthesizes these data into a comprehensive aggregated lifetime metric. This methodology can enhance the maintenance scheduling strategies and operational reliability of semiconductor devices in critical applications, ultimately extending their service life while optimizing performance.

hardware-in-the-loop (HIL)↗

Spatially Adaptive Tunable Lighting Control System with Expanded Wellness and Energy Saving Benefits

Lighting design is becoming increasingly complex, including active dimming for energy savings and spectral tuning for human wellbeing. Modern commercial lighting control systems are already difficult to use, and maintain, and even with so-called Smart Lighting, optimizing light settings is rapidly exceeding the capabilities of direct human control, limiting the adoption of lighting control systems. The growing importance of Occupancy Centric Controls (OCC) for advanced building management systems can be applied to the development of autonomous lighting system controls needed to drive the adoption of advanced lighting controls for improved adaptive “sculpted illumination” for both greater energy savings and broader human wellbeing perspectives. This project, led by Rensselaer Polytechnic Institute, entitled “Spatially adaptive tunable lighting control system with expanded wellness and energy saving benefits” will develop and test an entirely new platform for automated optimized lighting design and control that requires little or no human engagement, yet contours lighting profiles automatically to minimize lighting energy use. We call this approach to lighting control “dynamic light sculpting” since the right amount of illumination is automatically delivered to occupants in real time. Since the system uses new, privacy-preserving occupant position and pose detection technologies developed by Rensselaer for broad OCC building applications, the control system will analyze how to deliver the right amount of the right type of illumination only where and when it is needed based these OCC platforms. To create these powerful autonomous lighting control platforms, the project will integrate evolving augmented reality (AR) and virtual reality (VR) tools with sophisticated lighting and interior design toolkits to create interactive lighting design and control simulators. Using the quickly growing paradigm of digital twins, these tools will integrate light fixture properties, occupancy sensor data, interior design data, and lighting specifications to accurately visualize how various design concepts interact with simulated yet realistic human activities that occur in commercial office buildings of various types. These advanced digital twin design and simulation tools will be combined with a new class of digitally-programmable LED lighting fixtures that can dynamically change the spectral content and direction of light emission. When fully integrated, the new autonomous lighting control system will take all of the guesswork out of optimizing light quality while minimizing energy consumption. Digital twin tools will simplify the design, installation, commissioning, operation, and maintenance of future energy-efficient lighting systems. It should be possible to reduce lighting energy costs from 40% to 70% with OCC based dynamic light sculpting systems. The work will be led by the Center for Lighting Enabled Systems and Applications (LESA) and the Center for Architectural Science and Ecology (CASE), both at Renssealer Polytechnic Institute; Lumileds, a global leader in the development of advanced LED systems; and HKS, a leading global architecture design firm. This interdisciplinary project team’s experience includes all of the design simulation tools, VR/AR digital twin visualization technology, advanced occupancy sensing technology, and complex control system design capabilities that will revolutionize lighting design and control technology to autonomously deliver high-quality lighting that improves human health and wellbeing while simultaneously maximizing lighting energy savings.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Trajectory Design Strategies for the NGST L2 Libration Point Mission

The Origins' Next Generation Space Telescope (NGST) trajectory design is addressed in light of improved methods for attaining constrained orbit parameters and their control at the exterior collinear libration point, L2. The use of a dynamical systems approach, state-space equations for initial libration orbit control, and optimization to achieve constrained orbit parameters are emphasized. The NGST trajectory design encompasses a direct transfer and orbit maintenance under a constant acceleration. A dynamical systems approach can be used to provide a biased orbit and stationkeeping maintenance method that incorporates the constraint of a single axis correction scheme.

Folta, David↗

Analysis and Optimization of a Novel Hexagonal Waveguide Concentrator for Solar Thermal Applications

This paper analyzes a novel, cost-effective planar waveguide solar concentrator design that is inspired by cellular hexagonal structures in nature with the benefits of facile installation and low operation and maintenance cost. A coupled thermal and optical analysis of solar irradiation through an ideal hexagonal waveguide concentrator integrated with a linear receiver is presented, along with a cost analysis methodology, to establish the upper limit of performance. The techno-economic model, coupled with numerical optimization, is used to determine designs that maximized power density and minimized the cost of heat in the temperature range of 100–250 °C, which constitutes more than half of the industrial process heat demand. Depending on the incident solar irradiation and the application temperature, the cost of heat for the optimal design configuration ranged between 0.1–0.27 $/W and 0.075–0.18 $/W for waveguide made of ZK7 glass and polycarbonate, respectively. A techno-economic analysis showed the potential of the technology to achieve cost as low as 80 $/m2 and 61 $/m2 for waveguide made of ZK7 glass and polycarbonate material, respectively, which is less than half the cost of state-of-the-art parabolic trough concentrators. Overall, the hexagonal waveguide solar concentrator technology shows immense potential for decarbonizing the industrial process heat and thermal desalination sectors.

14 SOLAR ENERGY↗

General purpose optimization software for engineering design

The author has developed several general purpose optimization programs over the past twenty years. The earlier programs were developed as research codes and served that purpose reasonably well. However, in taking the formal step from research to industrial application programs, several important lessons have been learned. Among these are the importance of clear documentation, immediate user support, and consistent maintenance. Most important has been the issue of providing software that gives a good, or at least acceptable, design at minimum computational cost. Here, the basic issues developing optimization software for industrial applications are outlined and issues of convergence rate, reliability, and relative minima are discussed. Considerable feedback has been received from users, and new software is being developed to respond to identified needs. The basic capabilities of this software are outlined. A major motivation for the development of commercial grade software is ease of use and flexibility, and these issues are discussed with reference to general multidisciplinary applications. It is concluded that design productivity can be significantly enhanced by the more widespread use of optimization as an everyday design tool.

Vanderplaats, G. N.↗

Design and full core fuel performance assessment of high burnup cores for 4-loop PWRs

Increasing the fuel discharge burnup of current light water reactors (LWRs) promises reductions in fuel cycle and/or operations costs. By assuming a constant core power density, the economic gain is enabled by better fuel utilization and/or an increased capacity factor. In this effort to investigate greater than 62 MWd/kgU maximum rod average burnup for 110+ kW/l core power density, two core designs have been developed for a standard 17x17, 193 fuel assemblies pressurized water reactor (PWR). The levelized unit cost methodology is employed to evaluate fuel cycle, operation and maintenance, and capital cost impacts and to examine the economic viability of both core design pathways. Core design and optimization are performed using the commercial STUDSVIK code package. Fuel performance analysis is realized in full core configuration via auditing FRAPCON4.1, FAST1.2, and the high-fidelity code BISON. To provide a realistic assessment, the core design process takes into consideration best practices in current PWR core design. It features acceptable performance in terms of various core design constraints on maximum allowable peaking and boron concentration. Gadolinia (Gd2O3) is used as a burnable poison with a maximum of 9 wt% concentration while feeding 89 or 77 fuel assemblies in a 3-batch refueling scheme. Full core fuel performance simulation, which allows for characterization of relevant fuel temperatures, plenum pressures, stresses, and strains, is performed with respect to two bounding burnup levels. Such performance is potentially licensable for the 18-month high burnup core (<68 MWd/kgU peak pin), while it is more challenging for the 24-month high burnup core design pathway (<75 MWd/kgU peak pin). Maximum rod plenum pressure is identified as the most limiting fuel performance parameter. Here, while the scope of the present study focuses on the steady-state plus overpower conditions, the acceptability of the new discharge burnup has to be further assessed by considering uncertainties and impacts under accident scenarios in the future.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Lunar orbiting microwave beam power system

A microwave beam power system using lunar orbiting solar powered satellite(s) and surface rectenna(s) was investigated as a possible energy source for the Moon's surface. The concept has the potential of reduced system mass by placing the power source in orbit. This can greatly reduce and/or eliminate the 14 day energy storage requirement of a lunar surface solar system. Also propellants required to de-orbit to the surface are greatly reduced. To determine the practicality of the concept and the most important factors, a zero-th order feasibility analysis was performed. Three different operational scenarios employing state of the art technology and forecasts for two different sets of advanced technologies were investigated. To reduce the complexity of the problem, satellite(s) were assumed in circular equatorial orbits around the Moon, supplying continuous power to a single equatorial base through a fixed horizontal rectenna on the surface. State of the art technology yielded specific masses greater than 2500 kg/kw, well above projections for surface systems. Using advanced technologies the specific masses are on the order of 100 kg/kw which is within the range of projections for surface nuclear (20 kg/kw) and solar systems (500 kg/kw). Further studies examining optimization of the scenarios, other technologies such as lasers transmitters and nuclear sources, and operational issues such as logistics, maintenance and support are being carried out to support the Space Exploration Initiative (SEI) to the Moon and Mars.

Fay, Edgar H.↗

Lunar orbiting microwave beam power system

A microwave-beam power system using lunar orbiting solar-powered satellite(s) and surface rectenna(s) is investigated as a possible energy source for the moon's surface. The concept has the potential of achieving reduced system mass by placing the power source in orbit. This can greatly reduce and/or eliminate the 14-d energy storage requirement of a lunar surface solar system. Also, propellants required to de-orbit to the surface are greatly reduced. To determine the practicality of the concept and the most important factors, a zeroth-order feasibility analysis is performed. Three different operation scenarios employing state of the art technology and forecasts for two different sets of advanced technologies are investigated. To reduce the complexity of the problem, satellite(s) are assumed to be in circular equatorial orbits around the moon, supplying continuous power to a single equatorial base through a fixed horizontal rectenna on the surface. State of the art technology yields specific masses greater than 2500 kg/kw, well above projections for surface systems. The specific masses are on the order of 100 kg/kW using advanced technologies, which is within the range of projections for surface nuclear (20 kg/kW) and solar systems (500 kg/kW). Further studies examining optimization of the scenarios, other technologies, such as laser transmitters and nuclear sources, and operational issues, such as logistics, maintenance, and support, are being carried out to support the Space Exploration Initiative (SEI) to the moon and Mars.

Fay, Edgar H.↗

Fuzzy logic and neural network technologies

Applications of fuzzy logic technologies in NASA projects are reviewed to examine their advantages in the development of neural networks for aerospace and commercial expert systems and control. Examples of fuzzy-logic applications include a 6-DOF spacecraft controller, collision-avoidance systems, and reinforcement-learning techniques. The commercial applications examined include a fuzzy autofocusing system, an air conditioning system, and an automobile transmission application. The practical use of fuzzy logic is set in the theoretical context of artificial neural systems (ANSs) to give the background for an overview of ANS research programs at NASA. The research and application programs include the Network Execution and Training Simulator and faster training algorithms such as the Difference Optimized Training Scheme. The networks are well suited for pattern-recognition applications such as predicting sunspots, controlling posture maintenance, and conducting adaptive diagnoses.

Villarreal, James A.↗

High-Burnup BWR LOCA Burst Analysis Framework Development and Demonstration

Nuclear power currently contributes approximately 20% of total electricity generation in the United States and more than 10% globally. Given the increasing reliance on nuclear energy to achieve our nation’s goal of reaching net-zero carbon emissions by 2050, there is significant pressure on the existing nuclear industry to extend plant operational licenses and improve efficiency. This is crucial as the existing nuclear fleet serves as a vital bridge until new light water and advanced reactors can be developed and deployed, bolstering the supply of carbon-free energy to meet domestic demands. Operational costs primarily consist of plant operation and maintenance and fuel costs, influenced by materials and reactor core designs. These factors, coupled with heavily subsidized renewable energy markets, create a challenging economic environment for the existing light water reactor fleet, as well as for new build projects. To address these economic challenges, the nuclear industry has developed a strategic blueprint aimed at enhancing nuclear power’s economic sustainability. Past initiatives, such as efforts to eliminate fuel failures by 2010 and reduce operating costs by 30% before 2020, have laid the groundwork. Optimizing core design parameters, including burnup limits and enrichment levels, can lengthen cycles, reduce outages, reduce batch reload batch fractions and spent fuel storage requirements, and lower maintenance and operating expenses, thereby enhancing economic viability. In the United States, boiling water reactors (BWRs) comprise approximately one-third of the fleet, although much of the research and development focus has traditionally been on pressurized water reactors (PWRs). Advances in modeling and simulation, particularly through the Nuclear Energy Advanced Modeling and Simulation (NEAMS) program, are crucial to the long-term viability of BWRs, just as they are for PWRs. A key research area of the high burnup/increased enriched fuel initiative is focused on addressing loss-of-coolant-accident (LOCA)-related issues. NEAMS has dedicated significant effort to enhancing tools to better support BWRs, with a current focus on showcasing the BWR framework for high-burnup LOCA analysis. This high-fidelity work will demonstrate a best estimate pin-by-pin high-burnup BWR LOCA analysis to assess full-core cladding rupture behavior. This modeling capability will help with better understanding and realistic evaluation of fuel fragmentation, relocation, and dispersal (FFRD) phenomena at BWRs, which then could be used to prevent FFRD at BWRs without penalizing operational parameters. In addition, the results of this work will help identify strategies to identify additional margins or to potentially limit cladding rupture through core design optimizations.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Leverage modern artificial intelligence (AI) enabled systems for waste reduction

Manufacturing industries continue to face challenges in reducing waste, as upstream strategies such as source reduction and product redesign require a deeper understanding of processes compared to conventional recycling methods. Recent advancements in artificial intelligence (AI) and machine learning (ML) have opened new opportunities to integrate modern computational techniques with traditional waste minimization strategies. This paper explores AI-enabled approaches for product redesign, source reduction, and recycling that can significantly reduce waste generation while improving efficiency and sustainability. AI-driven material substitution and lightweighting in product design enable discovery of novel materials with optimized properties, reducing waste without compromising performance. Reinforcement learning models optimize process parameters, raw material specifications, and machine sequencing to minimize production losses, while Industrial Internet of Things (IIoT) systems paired with AI analytics enhance real-time waste tracking, predictive maintenance, and quality inspection. Furthermore, AI-based demand forecasting and production planning reduce overproduction and excess inventory, as demonstrated in industrial applications. In recycling, ML-powered pattern recognition and robotic sorting technologies achieve higher accuracy in waste segregation, directly improving recycling efficiency. Complementary solutions such as smart bins and AI-enabled waste pickup scheduling optimize collection logistics, reducing both costs and emissions. Although implementation requires upfront investment in infrastructure and training, the long-term benefits include higher material efficiency, reduced waste, improved product quality, and stronger sustainability outcomes across the supply chain. By leveraging AI-enabled systems, manufacturers can align waste minimization efforts with circular economy principles, creating scalable solutions for both industry and society.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Combustion Performance and Emissions Optimization through Integration of Miniaturized High Temperature Multi Process Monitoring System

The main objective of this research program is to design, manufacture, and demonstrate a miniaturized, multi-process, monitoring system (mMPMS) for boiler condition management and easy system deployment to obtain a higher spatial resolution. This system will facilitate a Condition-Based Maintenance (CBM) philosophy that actively monitors the health of assets to predict and prevent failures and maximize availability and generating capacity at a reduced cost. CBM systems can provide boiler data that the advanced process control (APC) system can utilize for plant performance optimization, which is increasingly relevant as coal power plants shift from predominantly base-load operation to predominantly transient operation involving large load swings. The mMPMS is based on an electrochemical sensor that provides a real-time indication of the risk of damage to key locations in the radiant or convective section of a coal-fired boiler such as metal loss rates, heat flux, metal surface temperature, and deposit thickness. These indications can be utilized to optimize boiler performance as well as improve boiler availability in conjunction with corresponding operating conditions. This monitoring system was developed and tested in the high-temperature regions of coal-fired utility boilers in this project but can be applied to many other industries and applications as well. The new sensor design, leveraging the existing electrochemical noise-based monitoring system, is small enough to be installed through the webbing of the waterwalls without the need for long shut-downs to bend tubes and to make it feasible to obtain high spatial resolution in the boiler. Data can be transferred to the plant distributed control system (DCS) and any other control system. The sensor body that houses the sensor assembly was designed to ensure good conductive contact with boiler tubes to ensure the sensor is held at an identical temperature to the tube surface temperature. The data acquisition and signal conditioning modules were redesigned into a small footprint with optimized cooling of the module. System software was developed specifically for the new signal conditioning module and is compatible with plant PLCs. After the preliminary testing at a pilot-scale facility, five mMPMS were installed at a full-scale pulverized coal-fired plant, Basin Electric Power Cooperative’s Leland Olds Unit 1. The systems were demonstrated over a 6-week period during typical operation. Sensor measurements of deposit thickness were validated during the demonstration and subsequently leveraged to determine sensor-based boiler cleaning strategies. These strategies have the benefit of reduced thermal stresses on boiler tubes from over-cleaning and improved boiler water management. At the end of the project, continued development of the sensor technology was carried out at PacifiCorp’s Hunter Station. REI leveraged the permanent installation of the mMPMS in Unit 3 made possible by DOE funding on a separate program. The work at Hunter Plant focused on application of machine learning and artificial intelligence-based models for integration of sensor signals into control and optimization of Hunter Unit 3 processes.

Advanced Sensors, Corrosion, Ash Deposition, Optim↗

Continuous Monitoring and Partial Water Softening for Cooling Tower Water Treatment

Cooling towers are an integral component of many refrigeration systems, providing comfort or process cooling across a broad range of applications. They are the point in the system where heat is dissipated to the atmosphere through the evaporative cooling process. Cooling towers are commonly found in industrial applications and are also often used in water-cooled chilled water plants in medium to large commercial buildings. Continuous monitoring and partial water softening for cooling towers used in medium to large commercial buildings are the focus of this paper. Cooling towers consume large amounts of water. Cooling tower-related water consumption is one of largest potable water loads within buildings in the United States, with substantial building water use associated with heating and cooling. Regional water shortages have highlighted a need to reduce water consumption; the U.S. General Services Administration (GSA) and Executive Order 13834 place priority on reducing water consumption. This priority has fueled interest in the identification, investigation, and potential broad deployment of cost-effective opportunities to reduce water use, such as alternative water treatment (AWT) technologies for cooling towers. Traditional water treatment approaches use chemicals to extend the ability of the water to hold scaling minerals in suspension, minimize corrosion, and prevent biological growth. This treatment protects the chillers and cooling tower equipment; however, even when chemicals are used regularly, a certain percentage of condenser water must be drained and made up with fresh water to maintain system water quality parameters. In addition, the use of chemicals sometimes creates a waste disposal issue and can cause building owners to incur additional fees, such as disposal or wastewater charges. To manage cooling tower water treatment, GSA typically contracts with a company specializing in conventional chemical maintenance for a fixed fee. While there are many types and vendors of AWT systems, this project assesses the effectiveness of one technology provided by Aqualogix. This system is a chilled water plant monitoring and control system aimed at optimizing system performance by reducing the blowdown occurrences used to remove mineral build-up. The technology consists of two components – continuous programmable logic control (PLC) monitoring and side-stream filtration with partial water softening. PLC monitoring calculates cycles of concentration (CoC) and determines the optimum amount of blowdown water required to satisfy all water chemistry requirements. Side-stream filtration removes suspended matter and improves biocide efficacy while precisely dispensing softened water to achieve optimal makeup water hardness. Unlike other AWT systems evaluated by GSA to date, this system does not replace the legacy treatment system but is used in addition to chemical water treatment. The vendor claims their technology will reduce water consumption, water discharge, and maintenance costs. The AWT system evaluated in this demonstration is a commercialized technology. Given its commercialized state, the system evaluated in this report is at a Technology Readiness Level 9 according to National Aeronautics and Space Administration (NASA) definitions.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

Combustion Performance and Emissions Optimization Through Integration of a Miniaturized High-Temperature Multi Process Monitoring System

The main objective of this research program is to design, manufacture, and demonstrate a miniaturized, multi-process, monitoring system (mMPMS) for boiler condition management and easy system deployment to obtain a higher spatial resolution. This system will facilitate a Condition-Based Maintenance (CBM) philosophy that actively monitors the health of assets to predict and prevent failures and maximize availability and generating capacity at a reduced cost. CBM systems can provide boiler data that the advanced process control (APC) system can utilize for plant performance optimization, which is increasingly relevant as coal power plants shift from predominantly base-load operation to predominantly transient operation involving large load swings. The mMPMS is based on an electrochemical sensor that provides a real-time indication of the risk of damage to key locations in the radiant or convective section of a coal-fired boiler such as metal loss rates, heat flux, metal surface temperature, and deposit thickness. These indications can be utilized to optimize boiler performance as well as improve boiler availability in conjunction with corresponding operating conditions. This monitoring system was developed and tested in the high-temperature regions of coal-fired utility boilers in this project but can be applied to many other industries and applications as well. The new sensor design, leveraging the existing electrochemical noise-based monitoring system, is small enough to be installed through the webbing of the waterwalls without the need for long shut-downs to bend tubes and to make it feasible to obtain high spatial resolution in the boiler. Data can be transferred to the plant distributed control system (DCS) and any other control system. The sensor body that houses the sensor assembly was designed to ensure good conductive contact with boiler tubes to ensure the sensor is held at an identical temperature to the tube surface temperature. The data acquisition and signal conditioning modules were redesigned into a small footprint with optimized cooling of the module. System software was developed specifically for the new signal conditioning module and is compatible with plant PLCs. After the preliminary testing at a pilot-scale facility, five mMPMS were installed at a full-scale pulverized coal-fired plant, Basin Electric Power Cooperative’s Leland Olds Unit 1. The systems were demonstrated over a 6-week period during typical operation. Sensor measurements of deposit thickness were validated during the demonstration and subsequently leveraged to determine sensor-based boiler cleaning strategies. These strategies have the benefit of reduced thermal stresses on boiler tubes from over-cleaning and improved boiler water management. At the end of the project, continued development of the sensor technology was carried out at PacifiCorp’s Hunter Station. REI leveraged the permanent installation of the mMPMS in Unit 3 made possible by DOE funding on a separate program. The work at Hunter Plant focused on application of machine learning and artificial intelligence-based models for integration of sensor signals into control and optimization of Hunter Unit 3 processes.

Advanced Sensors, Corrosion, Ash Deposition, Optim↗

Robust Scheduling of Networked Microgrids for Economics and Resilience Improvement

The benefits of networked microgrids in terms of economics and resilience are investigated and validated in this work. Considering the stochastic unintentional islanding conditions and conventional forecast errors of both renewable generation and loads, a two-stage adaptive robust optimization is proposed to minimize the total operating cost of networked microgrids in the worst scenario of the modeled uncertainties. By coordinating the dispatch of distributed energy resources (DERs) and responsive demand among networked microgrids, the total operating cost is minimized, which includes the start-up and shut-down cost of distributed generators (DGs), the operation and maintenance (O&M) cost of DGs, the cost of buying/selling power from/to the utility grid, the degradation cost of energy storage systems (ESSs), and the cost associated with load shedding. The proposed optimization is solved with the column and constraint generation (C&CG) algorithm. The results of case studies demonstrate the advantages of networked microgrids over independent microgrids in terms of reducing total operating cost and improving the resilience of power supply.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

Strategy Developed for Selecting Optimal Sensors for Monitoring Engine Health

Sensor indications during rocket engine operation are the primary means of assessing engine performance and health. Effective selection and location of sensors in the operating engine environment enables accurate real-time condition monitoring and rapid engine controller response to mitigate critical fault conditions. These capabilities are crucial to ensure crew safety and mission success. Effective sensor selection also facilitates postflight condition assessment, which contributes to efficient engine maintenance and reduced operating costs. Under the Next Generation Launch Technology program, the NASA Glenn Research Center, in partnership with Rocketdyne Propulsion and Power, has developed a model-based procedure for systematically selecting an optimal sensor suite for assessing rocket engine system health. This optimization process is termed the systematic sensor selection strategy. Engine health management (EHM) systems generally employ multiple diagnostic procedures including data validation, anomaly detection, fault-isolation, and information fusion. The effectiveness of each diagnostic component is affected by the quality, availability, and compatibility of sensor data. Therefore systematic sensor selection is an enabling technology for EHM. Information in three categories is required by the systematic sensor selection strategy. The first category consists of targeted engine fault information; including the description and estimated risk-reduction factor for each identified fault. Risk-reduction factors are used to define and rank the potential merit of timely fault diagnoses. The second category is composed of candidate sensor information; including type, location, and estimated variance in normal operation. The final category includes the definition of fault scenarios characteristic of each targeted engine fault. These scenarios are defined in terms of engine model hardware parameters. Values of these parameters define engine simulations that generate expected sensor values for targeted fault scenarios. Taken together, this information provides an efficient condensation of the engineering experience and engine flow physics needed for sensor selection. The systematic sensor selection strategy is composed of three primary algorithms. The core of the selection process is a genetic algorithm that iteratively improves a defined quality measure of selected sensor suites. A merit algorithm is employed to compute the quality measure for each test sensor suite presented by the selection process. The quality measure is based on the fidelity of fault detection and the level of fault source discrimination provided by the test sensor suite. An inverse engine model, whose function is to derive hardware performance parameters from sensor data, is an integral part of the merit algorithm. The final component is a statistical evaluation algorithm that characterizes the impact of interference effects, such as control-induced sensor variation and sensor noise, on the probability of fault detection and isolation for optimal and near-optimal sensor suites.

Source record↗

Spacecraft reliability/maintainability optimization.

Description of a procedure to develop a methodology to optimize man-serviced systems for reliability and maintainability. The spacecraft systems are analyzed using failure modes and effects analysis and maintenance analysis, component mean-time-between failure, duty cycle, type of redundancy, and cost information to develop parametric data on various time intervals. Included are crew time-to-repair, cost, weight, and volume effects of increasing subsystem reliability above the baseline. Results are presented for space systems using the existing data from a research and applications module. These results show the minimum cost of sustaining mission operations.

Sharmahd, J. N.↗

Global Radius of Curvature Estimation and Control for the Hobby-Eberly Telescope

A system, which estimates the global radius of curvature (GroC) and corrects for changes in GroC on a segmented primary mirror has been developed for and verified on McDonald Observatory's Hobby Eberly Telescope (HET). The GroC estimation and control system utilizes HET's primary mirror control (PMC) system and the Segment Alignment Maintenance System (SAMS), an inductive edge sensor system. A special set of boundary conditions is applied to the derivation of the optimal edge match control. The special boundary conditions allow the further derivation of an observer, which enables estimation and control of the Groc mode to within HET's specification. The magnitude of the GroC mode can then be controlled despite the inability of the SAMS edge sensor system, by itself, to observe or control the GroC mode. The observer can be extended to any segmented mirror telescope. It will be shown that the observer improves with accuracy as the number of segments increases. This paper presents the mathematical theory of the observer. Simulation results will demonstrate the inherent accuracy and robustness of the system. Performance verification data from the HET will be presented.

Rakoczy, John↗