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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 307 records · Page 17

Development and Manufacture of A Proof-of-Concept Magnetically-Geared Actuator for Use in Extremely Cold Lunar Environments

A magnetically-geared actuator is being developed for extremely cold space environments to avoid the wiring and significant efficiency penalty associated with heating grease-lubricated actuators as well as the stringent life and loading constraints imposed by dry film lubricated mechanical gears. This paper describes the lessons learned while designing, manufacturing, and assembling a proof-of-concept prototype similar to the preliminary design of the actuator.

lunar surface↗

Robotic Software Architecture for in-Space Outfitting Operations

Space exploration is expanding into longer missions, larger payloads, and more complex operations. To make these larger scale missions a reality, it is necessary to perform assembly, construction, and maintenance tasks via a robotic workforce in addition to crewed operations. While there has been significant research into in-space assembly and manufacturing, it is primarily focused on rigid structural elements, such as ISRU printing or truss construction. Outfitting tasks, such as cable routing, are a critical step to a fully operational in-space facility. This paper seeks to provide a reduced order state model and an optimized combination of state-of-the-art robotics algorithms applied to a cable routing scenario. Simulation results are expected to advance approaches to online autonomous robotic manipulation of non-rigid elements.

Amy M Quartaro↗

Trajectory Generation with Load Constraints for Robotic Manipulators

Future large spacecraft will utilize robotic manipulators for in-space servicing, assembly, and manufacturing. Due to launch mass constraints, such manipulators will be designed to be as lightweight as possible. Trajectory generation algorithms will need to factor in load constraints to avoid overexerting and damaging manipulators. This paper investigates an approach that combines optimal Rapidly-exploring Random Trees, spline interpolation, and Model Predictive Control to generate a manipulator trajectory which respects load constraints.

Manipulators↗

Design and Hardware Progress on a Magnetically-Geared Actuator for Extremely Cold Lunar Environments

Introduction: Under the Motors for Dusty and Extremely Cold Environments (MDECE) Project, NASA Glenn Research Center is developing a magnetically-geared actuator for extremely cold space environments to avoid the wiring and significant efficiency penalty associated with heating grease-lubricated actuators as well as the stringent life and loading constraints imposed by dry film lubricated mechanical gears. The heating penalty can be equivalent to up to a 90% efficiency reduction in permanently shadowed regions on the Moon. This poster or presentation will summarize the progress made over the past 6-12 months on designing the fully-functional actuator and building a proof-of-concept actuator and testing it in an ambient environment. Design Progress: A critical design review was successfully completed at the end of June 2023. This presentation will touch on the key highlights from that review in the areas of electro-magnetic design and optimization, bearing optimization, thermal analysis, structural analysis, and mechanical design and manufacturing. The predicted technical performance measures of the actuator will be mentioned. The team is currently finishing some actions from the review and finalizing the drawing package in preparation for hardware procurement. Hardware Progress: Despite some significant delays in receiving fabricated parts and magnetic subassemblies, progress was made in manufacturing and assembling a proof-of-concept version of both the actuator’s magnetically-geared motor (Fig. 1) and the actuator’s cycloidal-type output magnetic gear stage (Fig. 2) [3]. The presentation will mention key lessons learned to date from the fabrication, assembly, and testing of the proof of concept.

Lunar surface↗

Robotic Software Architecture for In-Space Outfitting Operations

Space exploration is expanding into longer missions, larger payloads, and more complex operations. To make these larger scale missions a reality, it is necessary to perform assembly, construction, and maintenance tasks via a robotic workforce in addition to crewed operations. While there has been significant research into in-space assembly and manufacturing, it is primarily focused on rigid structural elements, such as ISRU printing or truss construction. Outfitting tasks, such as cable routing, are a critical step to a fully operational in-space facility. This paper seeks to provide a reduced order state model and an optimized combination of state-of-the-art robotics algorithms applied to a cable routing scenario. Simulation results are expected to advance approaches to online autonomous robotic manipulation of non-rigid elements.

Amy Quartaro↗

Laser-Processed Condensing Heat Exchanger for Space Applications

In sizing a condensing heat exchanger for space life support systems, there is a limit to allowable pressure drop along with a required vapor recuperation rate. This sizing is performed by using known heat transfer and pressure drop correlations in a numerical model. Dimpling the surface of an air-liquid channeled heat exchanger increases the convective heat transfer rate however creates difficulties within the numerical model as the flat plate correlations are no longer accurate. To increase the fidelity of the numerical model used for sizing the heat exchanger Computational Fluid Dynamics (CFD) with an SST k-ω turbulence model was performed on a periodic portion of the heat exchanger. Through CFD modeling a heat flux and pressure drop was measured across the heat exchanger channel, this information was used to create a localized Nusselt number that was incorporated into the numerical model along with a more accurate pressure drop due to the dimpled surface. Additionally, through modeling the heat exchanger after manufacturing and assembly in Computer Aided Drafting (CAD) software there was an increase in the measurement accuracy of geometric features which was incorporated into the numerical model for further increase in fidelity.

heat exchanger↗

The Space Superhighway: Enabling Active Debris Remediation Through an In-Space Logistics Infrastructure

The Space Superhighway is a future space infrastructure concept intended to support civil, commercial, and national security space interests by providing In-Space Servicing, Assembly, and Manufacturing (ISAM) services across low Earth orbit (LEO), geosynchronous orbit (GEO), and cislunar space. This concept was originally developed by an interagency working group and commissioned by the Executive Office of the President. The Space Superhighway is comprised of three primary components: regional hubs, a sustainable transportation network, and Earth-to-orbit logistics. This study establishes methods which may be used to quantify the cost-savings from use of the Space Superhighway infrastructure and interrogates the effects of the use of this logistics network on a specific use case – removal of 26 pieces of large space debris within LEO. Through application of the established methods and assuming an emplaced Space Superhighway infrastructure with no cost implications related to deployment of infrastructure-related spacecraft, this study found that the cost to use an established Space Superhighway infrastructure to remove the targeted debris may be cheaper than removal of the targeted debris through traditional methods when the ΔV between a regional hub hosting propellant and the debris field is less than 1500 m/s. Through determining optimized locations of regional hubs within LEO, this study estimates that such a ΔV is within expectations for a LEO environment supported by a fully evolved Space Superhighway logistics infrastructure. This study provides a blueprint for future Space Superhighway value proposition studies for other use cases which, when combined, may provide the ultimate benefit and justification for the proliferation of an interconnected Space Superhighway.

Space Superhighway↗

Robotic Manipulation Testbeds with HPSC

Interoperability and scalability of robotic manipulators will be key to develop and sustain a lunar surface and cislunar ecosystem. From in-space servicing, assembly, and manufacturing (ISAM) to logistics, maintenance, and science operations, robotic manipulation is a critical NASA capability need and the demand for high-performance spaceflight computing will only rise as robotic tasks become more autonomous. With increased complexity, testbeds for research, feasibility studies, and technology demonstrations will be essential. The Dexterous Robotics Team at NASA Johnson Space Center has established multiple robotic manipulation testbeds taking a supervised autonomous remote operations approach and plans to infuse High-Performance Spaceflight Computing (HPSC) to emulate the flight environment and close the gap between space technology development and flight operations.

Alex Sowell↗

The Space Superhighway: Enabling Active Debris Remediation Through an In-Space Logistics Infrastructure

The Space Superhighway is a future space infrastructure concept intended to support civil, commercial, and national security space interests by providing In-Space Servicing, Assembly, and Manufacturing (ISAM) services across low Earth orbit (LEO), geosynchronous orbit (GEO), and cislunar space. This concept was originally developed by an interagency working group and commissioned by the Executive Office of the President. The Space Superhighway is comprised of three primary components: regional hubs, a sustainable transportation network, and Earth-to-orbit logistics. This study establishes methods which may be used to quantify the cost-savings from use of the Space Superhighway infrastructure and interrogates the effects of the use of this logistics network on a specific use case – removal of 26 pieces of large space debris within LEO. Through application of the established methods and assuming an emplaced Space Superhighway infrastructure with no cost implications related to deployment of infrastructure-related spacecraft, this study found that the cost to use an established Space Superhighway infrastructure to remove the targeted debris may be cheaper than removal of the targeted debris through traditional methods when the ΔV between a regional hub hosting propellant and the debris field is less than 1500 m/s. Through determining optimized locations of regional hubs within LEO, this study estimates that such a ΔV is within expectations for a LEO environment supported by a fully evolved Space Superhighway logistics infrastructure. This study provides a blueprint for future Space Superhighway value proposition studies for other use cases which, when combined, may provide the ultimate benefit and justification for the proliferation of an interconnected Space Superhighway.

Space Superhighway↗

Additively Manufactured Plastic Plasma Spectrometer

We report results in development and testing of a low resource top hat electrostatic analyzer (ESA) for space plasma measurements. This device has been additively manufactured (3D-printed) using fused deposition modeling. The classic top hat design is composed of four plastic pieces, without any surface coatings. The three conducting electrodes are printed from carbon nanotube infused polyether ether ketone (CNT-PEEK). The fourth piece, an insulating electrode support, uses pure PEEK. This ESA is designed to detect electrons in space from 10eV up to 30 keV. We demonstrate that the printed CNT-PEEK is sufficiently electrically conductive to support the fast high voltage slewing often required for high time resolution measurements. The plastic ESA has been successfully vibrated beyond standard pre-flight levels, tested under keV electron beam illumination over a wide range of temperatures, and tested under UV illumination, simulating the solar Ly-α flux. In comparison with an identical machined aluminum ESA, our CNT-PEEK ESA provides nominal energy/angle band passes, closely matching simulation. These band passes imply minimal impact from surface charging at beam energies of 2-3 keV, although more investigation is needed. We also find that the CNT-PEEK ESA provides far superior out-of-band electron rejection and UV photon rejection compared to the machined aluminum ESA. We do not detect any problems with trapped gases or outgassing. This development offers potential for significant mass savings, implementation of otherwise unattainable geometric configurations, and dramatic simplification in manufacturing and assembly processes required for development of space plasma instruments.

Quetzal Larrick↗

Integrating Energy Efficiency Strategies with Industrialized Construction for Our Clean Energy Future: Preprint

NREL’s Industrialized Construction Innovation Team has developed an ambitious plan to accelerate the integration of energy efficiency (EE) strategies with Industrialized Construction (IC). The United States (U.S.) construction industry is beginning to use IC methods to build multifamily apartment buildings to address affordability and labor shortages. Apart from reducing cost of construction and delivery times, the IC method of permanent modular construction has the potential to facilitate the integration of a wide range of EE strategies and advanced controls into such buildings. While there may be unintended EE benefits to IC such as a tighter envelope due to higher construction quality, the process has not been leveraged specifically to enhance EE. NREL aims to claim this missed opportunity and integrate IC benefits with EE as well as advanced controls, distributed energy resources, and grid-friendly design strategies. The paper proposes an ‘IC Assessment Framework’ to achieve affordable zero-energy modular multifamily buildings. Through the selection criteria of Design for Manufacturing and Assembly, the framework aims to distill a broad range of proven EE strategies for site-built into a set of strategies that qualify as easy to integrate for off-site. The output is a Factory Information Model (FIM) that represents a process-based digital twin to enable advanced time-and-motion study, plugs into open source building energy modeling platform (EnergyPlus), and serves as a vital tool facilitating wider adoption of EE integration. Conclusively, the paper delineates next steps for upcoming pilots with NREL’s IC partners towards developing a transformational pathway for our Clean Energy Future.

30 DIRECT ENERGY CONVERSION↗

Optoelectronic device with a support member

Optoelectronic devices with a support member and methods of manufacturing or assembling the same are provided. An example of an optoelectronic device according to the present disclosure includes a substrate and an optical component and an electronic component disposed thereon or therein. The optoelectronic device further includes a ferrule coupled to the optical fiber and an optical socket receiving the ferrule therein. The optoelectronic device includes a support member disposed between the substrate and the optical socket such that the optical socket is spaced from the substrate by the support member.

42 ENGINEERING↗

Optoelectronic system with a wedge-shaped adapter

Optoelectronic systems with an adapter and methods of manufacturing or assembling the same are provided. An example of an optoelectronic system according to the present disclosure includes a substrate, an interposer, an electronic component disposed on the interposer, and an optical component. The optoelectronic system includes a ferrule and an optical fiber coupled to the ferrule. The optoelectronic system also includes an optical socket configured to receive the ferrule therein. The optoelectronic system further includes an adapter positioned between the interposer and the optical socket. The adapter has a wedge-shaped configuration such that the ferrule is disposed at a non-zero angle relative to the interposer when the ferrule is received in the optical socket and the optical socket is coupled to the adapter.

Mathai, Sagi Varghese↗

Sampling Size Optimization for Bioburden Density Estimation in Planetary Protection

Planetary protection (PP) is a discipline that focuses on minimizing the biological contamination of spacecraft to ensure compliance with international policy. Precise estimation of bioburden - the total number of microbes in or on spacecraft hardware – and the bioburden density are of utmost importance for PP. Such estimation is the way concordance with requirements is demonstrated, and it is critical for quantifying the potential risk of inadvertently contaminating other planetary bodies. Although a suite of molecular techniques have been used to thoroughly characterize and profile the microbiome of various cleanroom environments and spacecraft, the gold standard remains the physical enumeration of microbes via culturing of samples directly taken from spacecraft and associated surfaces. However, due to technical, budgetary, and programmatic constraints, only a manageable portion (around 10%) of the entire spacecraft surface is directly sampled with cotton swabs or wipes. To generate the bioburden current best estimate (CBE) for components not directly verifiable, the accepted approach is to apply a NASA-defined bioburden estimate based on the components’ manufacturing or assembly environment. This approach utilizes a prespecified bioburden density estimation that applies a maximum value across the total surface area of the specified component. For hardware components that underwent similar assembly processes, an implied bioburden is adopted for all components, based on a direct verification of a representative component within the same lot. Once all components have a CBE, the bioburden estimates are generated. In previous publication [ 1], we have shown that statistical risks quantifying the accuracy of the estimates for sampled, prespecified, and implied components can be derived and ranked. For mean squared error (MSE) function, the risks are available analytically and hence a cost function can be obtained to optimize the risks with respect to the sampling area and sampling cost. Since the sampling area and sampling cost are two complimentary variables, their sum will have a well-defined minimum. This paper presents the multivariate optimization of the integrated risk of an empirical Bayes estimator to determine the optimal sampling schedule for a given number of components. It is assumed that given a number of components, N, the bioburden density for each component can either be sampled, implied, or prespecified. The multivariate optimization searches through different options to sample, imply or prespecify the bioburden density for a component, and account for the component’s surface area and cost of sampling. The idea of the optimization is based on the observation that the statistical risk of using an estimator is a monotonically decreasing function of the sampled area. The larger the sampled area, the lower the risk of using the estimator as the estimator becomes more and more accurate as the sampling area increases. On the other hand, the cost of sampling is monotonically increasing as the sampled surface grows. This makes the risk and total cost of sampling complimentary variables which can be counterbalanced to achieve an optimal overall value with respect to the sampled surface. In this paper, the integrated risk has been used to quantify the accuracy of the estimator. This risk has been selected because it depends on neither the true value of the parameter nor on the collected data. The cost of each sample was also available to obtain the total cost of sampling of N components. The paper will present the results based on computer-simulated data as well as the data collected during the InSight mission. The computer-simulated data have N components with randomly generated total areas and each component assigned to one of the three categories according to the method of estimating of bioburden density: sampled, implied, or prespecified. The cost of sampling is also available. The cost of sampling is estimated based on a cost model provided by the planetary protection group at JPL. For this paper, the overall cost was assumed to be a linear function of exposure. The optimization process finds the allocation of the components to the three categories that minimizes the tradeoff between integrated risk and total cost. For the InSight data, a set of components is selected representing all three categories, and optimization is performed to determine if the performed allocation was optimal or if a better allocation could have been obtained. To the best of our knowledge, this work is the first attempt not only perform an accurate estimation of bioburden density but also do it in an optimal way.

97 - MATHEMATICS AND COMPUTING↗

Restructuring and Optimizing Reactor Building Lifting Processes & Designing a Solution for an Overhead Door Handling Forklift Attachment

This poster presents two innovative projects aimed at enhancing operational efficiency and safety at the Advanced Test Reactor (ATR) Complex. The first project focuses on restructuring the existing lift book used for hoisting operations within the ATR Reactor Building. The current lift book, a cumbersome 150+ page document, is being transformed into a more efficient format using charts that allow for quick identification of maximum lift heights based on object footprint and weight. This new method also considers various parameters such as floor integrity and reactor status, dividing entries into four distinct charts to improve usability and safety during lifts. The second project involves designing a specialized forklift attachment for handling an overhead door at the ATR Reactor Building. The attachment is engineered to securely lift and lower a 1200lb, 14ft long door, ensuring safe replacement operations. The design process included research on forklift attachment codes, modeling in Autodesk Inventor, and testing through Finite Element Analysis (FEA) and hand calculations to confirm the attachment's structural integrity. Future work includes completing detailed drawings and an Engineering Calculations Analysis and Review (ECAR) document to proceed with manufacturing and assembly. Together, these projects demonstrate a commitment to optimizing reactor building operations through innovative engineering solutions and safety considerations.

42 - ENGINEERING↗

Lightweight Thrust Chamber Assemblies using Multi-Alloy Additive Manufacturing and Composite Overwrap

Additive Manufacturing (AM) has brought significant design and fabrication opportunities for complex components with internal features such as liquid rocket engine thrust chambers not previously possible. This technology allows for significant cost savings and schedule reductions in addition to new performance optimization through weight reduction and increased margins. Specific to regeneratively-cooled combustion chambers and nozzles for liquid rocket engines, additive manufacturing offers the ability to form the complex internal coolant channels and the closeout of the channels to contain the high pressure liquid propellants with a single operation. Much of additive manufacturing development has focused on monolithic alloys using Laser Powder Bed Fusion (L-PBF), which do not allow for complete optimization of the structure. The National Aeronautics and Space Administration (NASA) completed feasibility of an AM bimetallic L-PBF GRCop-84 copper-alloy combustion chamber with an AM electron beam freeform Inconel 625 structural jacket under the Low Cost Upper Stage Propulsion (LCUSP) Project. A follow-on project called Rapid Analysis and Manufacturing Propulsion Technology (RAMPT) is under development to further expand large-scale multi-alloy thrust chambers while maturing composite overwrap technology for significant weight savings opportunities. The RAMPT project has three primary objectives: 1) Advancing blown powder Directed Energy Deposition (DED) to fabricate integral-channel large scale nozzles, 2) Develop composite overwrap technology to reduce weight and provide structural capability for thrust chamber assemblies, and 3) Develop bimetallic and multi-metallic additively manufactured radial and axial joints to optimize material performance. In addition to these primary manufacturing developments, analytical modeling efforts compliment the process development to simulate the AM processes to reduce build failures and distortions. The RAMPT project is also maturing the supply chain for various manufacturing processes described above in addition to L-PBF of GRCop-42. This paper will present an overview of the RAMPT project, the process development and hardware progress to date, material and hot-fire testing results, along with future developments.

Additive Manufacturing↗

Statistical Tolerance and Clearance Analysis for Assembly

Tolerance is inevitable because manufacturing exactly equal parts is known to be impossible. Furthermore, the specification of tolerances is an integral part of product design since tolerances directly affect the assemblability, functionality, manufacturability, and cost effectiveness of a product. In this paper, we present statistical tolerance and clearance analysis for the assembly. Our proposed work is expected to make the following contributions: (i) to help the designers to evaluate products for assemblability, (ii) to provide a new perspective to tolerance problems, and (iii) to provide a tolerance analysis tool which can be incorporated into a CAD or solid modeling system.

statistical tolerance clearance analysis Monte-Car↗