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At least 361 records · Page 20

Software Tools for Developing and Simulating the NASA LaRC CMF Motion Base

The NASA Langley Research Center (LaRC) Cockpit Motion Facility (CMF) motion base has provided many design and analysis challenges. In the process of addressing these challenges, a comprehensive suite of software tools was developed. The software tools development began with a detailed MATLAB/Simulink model of the motion base which was used primarily for safety loads prediction, design of the closed loop compensator and development of the motion base safety systems1. A Simulink model of the digital control law, from which a portion of the embedded code is directly generated, was later added to this model to form a closed loop system model. Concurrently, software that runs on a PC was created to display and record motion base parameters. It includes a user interface for controlling time history displays, strip chart displays, data storage, and initializing of function generators used during motion base testing. Finally, a software tool was developed for kinematic analysis and prediction of mechanical clearances for the motion system. These tools work together in an integrated package to support normal operations of the motion base, simulate the end to end operation of the motion base system providing facilities for software-in-the-loop testing, mechanical geometry and sensor data visualizations, and function generator setup and evaluation.

Bryant, Richard B., Jr.↗

Multifunctional, High-Temperature Nanocomposites

In experiments conducted as part of a continuing effort to incorporate multifunctionality into advanced composite materials, blends of multi-walled carbon nanotubes and a resin denoted gPETI-330 h (wherein gPETI h is an abbreviation for gphenylethynyl-terminated imide h) were prepared, characterized, and fabricated into moldings. PETI-330 was selected as the matrix resin in these experiments because of its low melt viscosity (<10 poise at a temperature of 280 C), excellent melt stability (lifetime >2 hours at 280 C), and high temperature performance (>1,000 hours at 288 C). The multi-walled carbon nanotubes (MWCNTs), obtained from the University of Kentucky, were selected because of their electrical and thermal conductivity and their small diameters. The purpose of these experiments was to determine the combination of thermal, electrical, and mechanical properties achievable while still maintaining melt processability. The PETI-330/MWCNT mixtures were prepared at concentrations ranging from 3 to 25 weight-percent of MWCNTs by dry mixing of the constituents in a ball mill using zirconia beads. The resulting powders were characterized for degree of mixing and thermal and rheological properties. The neat resin was found to have melt viscosity between 5 and 10 poise. At 280 C and a fixed strain rate, the viscosity was found to increase with time. At this temperature, the phenylethynyl groups do not readily react and so no significant curing of the resin occurred. For MWCNT-filled samples, melt viscosity was reasonably steady at 280 C and was greater in samples containing greater proportions of MWCNTs. The melt viscosity for 20 weightpercent of MWCNTs was found to be .28,000 poise, which is lower than the initial estimated allowable maximum value of 60,000 poise for injection molding. Hence, MWCNT loadings of as much as 20 percent were deemed to be suitable compositions for scale-up. High-resolution scanning electron microscopy (HRSEM) showed the MWCNTs to be well dispersed in the polymer matrices, while high-resolution transmission electron microscopy shows splits in the walls of the MWCNTs but no catastrophic breakage of tubes. To further assess processing characteristics prior to scale-up, samples containing 10, 15, and 20 weight-percent of MWCNTs were processed through a laboratory melting extruder. HRSEM of the extruded fibers shows significant alignment of MWCNTs in the flow direction (see figure). For the samples containing 20 weight-percent of MWCNTs, difficulties were encountered during feeding, and the temperature of a rotor in the extruder rose to 245 C because of buildup of frictional heat; this indicates that materials of this type having MWCNT concentrations .20 weight- percent may not be melt-processable. On the basis of the results from the foregoing characterizations, samples containing 10, 15, and 20 weight-percent of MWCNTs were scaled up to masses of .300 g and used to make specimens having dimensions of 10.2 by 15.2 by 0.32 cm. These specimens were molded by (1) injecting the mixtures, at temperatures between 260 and 280 C, into a tool made of the low-thermal-expansion alloy InvarR and then (2) curing for 1 hour at 371 C. The tool was designed to impart shear during the injection process in an attempt to achieve some alignment of the MWCNTs in the flow direction.

Connell, John W.↗

Manufacturing Process Simulation of Large-Scale Cryotanks

NASA's Space Launch Initiative (SLI) is an effort to research and develop the technologies needed to build a second-generation reusable launch vehicle. It is required that this new launch vehicle be 100 times safer and 10 times cheaper to operate than current launch vehicles. Part of the SLI includes the development of reusable composite and metallic cryotanks. The size of these reusable tanks is far greater than anything ever developed and exceeds the design limits of current manufacturing tools. Several design and manufacturing approaches have been formulated, but many factors must be weighed during the selection process. Among these factors are tooling reachability, cycle times, feasibility, and facility impacts. The manufacturing process simulation capabilities available at NASA.s Marshall Space Flight Center have played a key role in down selecting between the various manufacturing approaches. By creating 3-D manufacturing process simulations, the varying approaches can be analyzed in a virtual world before any hardware or infrastructure is built. This analysis can detect and eliminate costly flaws in the various manufacturing approaches. The simulations check for collisions between devices, verify that design limits on joints are not exceeded, and provide cycle times which aide in the development of an optimized process flow. In addition, new ideas and concerns are often raised after seeing the visual representation of a manufacturing process flow. The output of the manufacturing process simulations allows for cost and safety comparisons to be performed between the various manufacturing approaches. This output helps determine which manufacturing process options reach the safety and cost goals of the SLI. As part of the SLI, The Boeing Company was awarded a basic period contract to research and propose options for both a metallic and a composite cryotank. Boeing then entered into a task agreement with the Marshall Space Flight Center to provide manufacturing simulation support. This paper highlights the accomplishments of this task agreement, while also introducing the capabilities of simulation software.

Babai, Majid↗

Manufacturing Process Simulation of Large-Scale Cryotanks

NASA's Space Launch Initiative (SLI) is an effort to research and develop the technologies needed to build a second-generation reusable launch vehicle. It is required that this new launch vehicle be 100 times safer and 10 times cheaper to operate than current launch vehicles. Part of the SLI includes the development of reusable composite and metallic cryotanks. The size of these reusable tanks is far greater than anything ever developed and exceeds the design limits of current manufacturing tools. Several design and manufacturing approaches have been formulated, but many factors must be weighed during the selection process. Among these factors are tooling reachability, cycle times, feasibility, and facility impacts. The manufacturing process simulation capabilities available at NASA's Marshall Space Flight Center have played a key role in down selecting between the various manufacturing approaches. By creating 3-D manufacturing process simulations, the varying approaches can be analyzed in a virtual world before any hardware or infrastructure is built. This analysis can detect and eliminate costly flaws in the various manufacturing approaches. The simulations check for collisions between devices, verify that design limits on joints are not exceeded, and provide cycle times which aid in the development of an optimized process flow. In addition, new ideas and concerns are often raised after seeing the visual representation of a manufacturing process flow. The output of the manufacturing process simulations allows for cost and safety comparisons to be performed between the various manufacturing approaches. This output helps determine which manufacturing process options reach the safety and cost goals of the SLI.

Babai, Majid↗

CFD Process Pre- and Post-processing Automation in Support of Space Propulsion

The use of Computational Fluid Dynamics or CFD has become standard practice in the design and analysis of the major components used for space propulsion. In an attempt to standardize and improve the CFD process a series of automated tools have been developed. Through the use of these automated tools the application of CFD to the design cycle has been improved and streamlined. This paper presents a series of applications in which deficiencies were identified in the CFD process and corrected through the development of automated tools.

Dorney, Suzanne M.↗

Lightweight solar array blanket tooling, laser welding and cover process technology

A two phase technology investigation was performed to demonstrate effective methods for integrating 50 micrometer thin solar cells into ultralightweight module designs. During the first phase, innovative tooling was developed which allows lightweight blankets to be fabricated in a manufacturing environment with acceptable yields. During the second phase, the tooling was improved and the feasibility of laser processing of lightweight arrays was confirmed. The development of the cell/interconnect registration tool and interconnect bonding by laser welding is described.

Dillard, P. A.↗

Building the Case for Hybrid Energy Developments: Webinar Recording Day 1

INL, PNNL, and NREL, with support from our academic and industry partners, hosted a 2-day webinar to learn more about the benefits of hybrid energy systems, considerations for designing the right system for communities, and practical tools that can help with the design and development process. In Day 1 of this webinar, the focus was on why users might want to consider hybrid energy systems, and frameworks that could help inform design decisions for hybrid systems, including a valuation framework, resilience framework, and hybrid system design optimization framework.

14 SOLAR ENERGY↗

Model Inputs, Outputs, and Scripts associated with: “Spatial microbial respiration variations in the hyporheic zones within the Columbia River Basin”

This data package is associated with the publication “Spatial microbial respiration variations in the hyporheic zones within the Columbia River Basin” published in the Journal of Geophysical Research: Biogeosciences (Son et al. 2022) available at doi: 10.1029/2021JG006654. This data package includes the key model inputs/outputs of the river corridor model for the Columbia River Basin (CRB) and the model source codes, which were used in the manuscript. The model is a carbon-nitrogen-coupled river corridor model (RCM), and the model is used to quantify hyporheic zone (HZ) aerobic and anaerobic respiration at the NHDPLUS stream reach scales. The RCM used in this study combines empirical substrate models derived from observations and three microbially driven reactions to compute respiration of the HZ for each National Hydrography Dataset (NHD) reach within the CRB. The reactions in HZs of each NHD reach include anaerobic respiration and two-step anaerobic respiration via denitrification. Our HZ respiration estimates are limited to the lotic (or flowing) stream/river systems, and do not account for the respiration process in water column. Note that the RCM only simulates the HZ’s contribution to the dissolved carbon dioxide (CO2) concentrations in the streams, and the CO2 emissions to the atmosphere are not modelled. The model computes at hourly timesteps because of the fast reaction rates. The key input data of the model are exchange flux, residence time, and stream solute (dissolved organic carbon (DOC), dissolved oxygen (DO), and nitrate concentrations). These inputs are constant over time and represent long-term averaged values.This modeling framework successfully quantified HZ respiration components over multiple scales. It revealed key mechanisms driving the spatial variation of HZ aerobic and anaerobic respiration in reaches with varying hydrologic and substrate conditions. Thus, this modeling study offers a testing hypothesis in different river system (e.g., climate and biomes) for the HZ respiration processes, and can be used as a sampling design tool for large-scale HZ experimental studies.This dataset contains five folders: (1) model_inputs, (2) model_outputs, (3) Rscripts, (4) figures, and (5) model_codes. It also contains a readme, file level metadata (FLMD), and data dictionary (dd). Please see the FLMD for a list of all the files contained in this data package and descriptions for each. The model_inputs folder contains the model inputs used to drive the model simulations. The model_outputs folder contains key model output files from the river corridor model. The Rscripts folder contains the Rscripts for pre- and post- processing model results. The figures folder contains the raw figures associated with the manuscript. The model_codes folder includes key model source codes/input files. All files are .jpg, .jpeg, .out, .e, .od, .dat, .sub, .F90, .0, .R, .sbx, .cpg, .sbn, .shx, .shp, .dbf, .prj, .tfw, .tif, .xml, .pdf, or .csv.

54 ENVIRONMENTAL SCIENCES↗

Application of the Tool for Turbine Engine Closed-Loop Transient Analysis (TTECTrA) for Dynamic Systems Analysis

The aircraft engine design process seeks to achieve the best overall system-level performance, weight, and cost for a given engine design. This is achieved by a complex process known as systems analysis, where steady-state simulations are used to identify trade-offs that should be balanced to optimize the system. The steady-state simulations and data on which systems analysis relies may not adequately capture the true performance trade-offs that exist during transient operation. Dynamic Systems Analysis provides the capability for assessing these trade-offs at an earlier stage of the engine design process. The concept of dynamic systems analysis and the type of information available from this analysis are presented in this paper. To provide this capability, the Tool for Turbine Engine Closed-loop Transient Analysis (TTECTrA) was developed. This tool aids a user in the design of a power management controller to regulate thrust, and a transient limiter to protect the engine model from surge at a single flight condition (defined by an altitude and Mach number). Results from simulation of the closed-loop system may be used to estimate the dynamic performance of the model. This enables evaluation of the trade-off between performance and operability, or safety, in the engine, which could not be done with steady-state data alone. A design study is presented to compare the dynamic performance of two different engine models integrated with the TTECTrA software.

systems analysis↗

Human Systems Intergration & Engineering: HSI & E Design Influence

The design of space systems is a long and complicated process where changes to the design increase cost and schedule as the design progresses into implementation. Human Systems Integration uses tools such as mockups, Virtual Reality, Augmented Reality and human simulations early in the design process to evaluate designs for usability, operability, and maintainability. This early design influence provides cost and schedule savings during manufacturing and operations. Examples of how MSFC EV74 Human Systems Integration Team have used these tools to evaluate hardware designs will be discussed.

Tanya Andrews↗

Proof of Concept Study of Trade Space Configuration Tool for Spacecraft Design

Spacecraft design is a very difficult and time consuming process because requirements and criteria are often changed or modified as the design is refined. Accounting for these adjustments in the design constraints plays a significant role in furthering the overall progress. There are numerous aspects and variables that hold significant influence on various characteristics of the design. This can be especially frustrating when attempting to conduct rapid trade space analysis on system configurations. Currently, the data and designs considered for trade space evaluations can only be displayed by using the traditional interfaces of Excel spreadsheets or CAD (Computer Aided Design) models. While helpful, these methods of analyzing the data from a systems engineering approach can be rather complicated and overwhelming. As a result, a proof of concept was conducted on a dynamic data visualization software called Thinkmap SDK (Software Developer Kit) to allow for better organization and understanding of the relationships between the various aspects that make up an entire design. The Orion Crew Module Aft Bay Subsystem was used as the test case for this study because the design and layout of many of the subsystem components will be significant in ensuring the overall center of gravity of the capsule is correct. A simplified model of this subsystem was created and programmed using Thinkmap SDK to create a preliminary prototype application of a Trade Space Configuration Tool. The completed application ensures that the core requirements for the Tool can be met. Further development is strongly suggested to produce a full prototype application to allow final evaluations and recommendations of the software capabilities.

Glidden, Geoffrey L.↗

Managing the Digital Thread for Structural Applications With Fit for Purpose Materials

With the increased emphasis on reducing the cost and time to market of new materials, the need for analytical tools that enable the virtual design and optimization of materials throughout their processing - internal structure - property - performance envelope, along with the capturing and storing of the associated material and model information across its lifecycle, has become critical. This need is also fueled by the demands for higher efficiency in material testing; consistency, quality and traceability of data; product design; engineering analysis; as well as control of access to proprietary or sensitive information. Consequently, at NASA Glenn Research Center a robust information management system that manages the digital thread across the full material life (i.e., capture, analysis, maintenance, and dissemination of data) cycle directed at the design of ‘fit-for-purpose materials’ is under development. To this end the Application Table has been incorporated within NASA Glenn Research Center’s ICME Information Management framework within the ANSYS Granta MI tool. The Application Table provides a place where material and structural application information/requirements can be linked to marry the “design-the-material” (structural engineering) and the “design-with-material” (material science) paradigms and thereby enable application-driven design and optimization of materials and structures. In additional several associated toolsets, specifically: AIMAOS (Automated Information Management Across Organizations and Scales), Py MILab, and JARIMIS (Just A Rather Intelligent Material Interrogation System) are also under development to assist in the judicious automation of this process. AIMOAS offers users an interactive graphical user interface for connecting material information management systems with both commercial and in-house simulation tools at various length scales to enable such automation in the handoff across scales and maintenance of material digital twins and the digital thread. Py MILab, is an automatic framework for the capture, analysis, maintenance, and storage of material test data. Py MILab uses a modular approach for capturing raw data, analyzing the data, and storing the data in a database, interfaced by neutral file structures, to promote plug-and-play capabilities for various analysis types. Finally, JARIMIS is an expert system that integrates various materials informatics tools (e.g., MicroNet, Surrogate ML models, ANSYS Granta MI, etc.) to enable inverse design of materials and facilitate the application of machine learning (ML) and data science with human in the loop decision making to rapidly discover and optimize new materials.

Digital Transformation↗

Impact of Timing in the Design Process on Students’ Application of Design for Additive Manufacturing Heuristics

The goal of this work is to study the way student designers use design for additive manufacturing (DfAM) rules or heuristics. It can be challenging for novice designers to create successful designs for additive manufacturing (AM), due to its recent surge in popularity and lack of formal education or training. A study was carried out to investigate the way novices apply DfAM heuristics when they receive them at different points in the design process. A design problem was presented to students, and three different groups of student participants were given a lecture on DfAM heuristics at three different points in the design process: before the initial design, between the initial design and redesign, and after the redesign. The novelty and quality of each of the resulting designs were evaluated. Results indicate that although the DfAM heuristics lecture had no impact on the overall quality of the designs generated, participants who were given the heuristics lecture after the initial design session produced designs that were better-suited for 3D printing in the second phase of the design activity. However, receiving this additional information appears to prevent students from creatively iterating upon their initial designs, as participants who received heuristic information between the design sessions experienced a decrease in novelty between the two sessions. Additionally, receiving the heuristics lecture increased all students’ perceptions of their ability to perform DfAM-related tasks. Furthermore, these results validate the practicality of design heuristics in lecture form as AM training tools while also emphasizing the importance of iteration in the design process.

computer-aided design↗

An Overview of the Risk Assessment Information System

This technical memorandum (TM) presents an overview of the Risk Assessment Information System (RAIS), a collection of web-based tools designed to assist with the environmental risk assessment process. The objective of the RAIS is to be a single resource for the risk assessment process, providing guidance when planning and performing the steps: data assessment, exposure assessment, toxicity assessment, and risk characterization. The RAIS evolved as a result of the initial remediation efforts at various United States (U.S.) Department of Energy (DOE) facilities. The goal was to increase the efficiency and transparency of the human health and ecological assessments being performed by DOE’s Office of Environmental Management, Oak Ridge Operations (ORO) office by providing a repository for toxicity information, physicochemical data, risk assessment procedures, standardized risk calculation methods, and web-based tools. Since the initial launch in 1996, the RAIS has expanded its user base outside of the federal government and now has users from over 100 countries, universities, states, and local governments. What sets the RAIS apart from other risk assessment sites are the publicly available, searchable toxicity and physicochemical databases and the wide range of chemical and radionuclide risk calculation tools. The purpose of this TM is to present the RAIS tools in order of the website menus and explain how they fit in the risk assessment process. In addition, this TM describes differences between the chemical and radionuclide tools of the RAIS. Screening level equations, chronic daily intake equations, and default exposure factors used in the chemical and radionuclide calculators are included in the appendices of this TM. This TM is not intended to be a detailed guide to risk assessment or the RAIS tools. The tools on the RAIS can be used to comply with procedures from multiple agencies, including but not limited to DOE, U.S. Environmental Protection Agency (EPA), U.S. Department of Defense (DoD), and many state governments. Further information on the RAIS tools can be found in the user guides and tutorials available on the webpage.

38 RADIATION CHEMISTRY, RADIOCHEMISTRY, AND NUCLEA↗

NextGen Operational Improvements: Will they Improve Human Performance

Modernization of the National Airspace System depends critically on the development of advanced technology, including cutting-edge automation, controller decision-support tools and integrated on-demand information. The Next Generation Air Transportation System national plan envisions air traffic control tower automation that proposes solutions for seven problems: 1) departure metering, 2) taxi routing, 3) taxi and runway scheduling, 4) departure runway assignments, 5) departure flow management, 6) integrated arrival and departure scheduling and 7) runway configuration management. Government, academia and industry are simultaneously pursuing the development of these tools. For each tool, the development process typically begins by assessing its potential benefits, and then progresses to designing preliminary versions of the tool, followed by testing the tool's strengths and weaknesses using computational modeling, human-in-the-loop simulation and/or field tests. We compiled the literature, evaluated the methodological rigor of the studies and served as referee for partisan conclusions that were sometimes overly optimistic. Here we provide the results of this review.

Beard, Bettina L.↗

EVA-Compatible Microbial Swab Tool

When we send humans to search for life on Mars, we'll need to know what we brought with us versus what may already be there. To ensure our crewed spacecraft meet planetary protection requirements—and to protect our science from human contamination—we'll need to know whether micro-organisms are leaking/venting from our ships and spacesuits. This is easily done by swabbing external vents and suit surfaces for analysis, but requires a specialized tool for the job. Engineers at the National Aeronautics and Space Administration (NASA) recently developed an Extravehicular Activity (EVA)-compatible swab tool that can be used to sample current space suits and life support systems. Data collected now will influence Mars life support and EVA hardware early in the planning process, before design changes become difficult and expensive.NASA’s EVA swab tool pairs a Space Shuttle-era tool handle with a commercially available swab tip mounted into a custom-designed end effector. A glove-compatible release mechanism allows the handle to quickly switch between swab tips, much like a shaving razor handle can snap onto a disposable blade cartridge. Swab tips are stowed inside individual sterile containers, each fitted with a microbial filter that allows the container to equalize atmospheric pressure, but prevents cabin contaminants from rushing into the container when passing from the EVA environment into a pressurized cabin. A bank of containers arrayed inside a tool caddy allows up to six individual samples to be collected during a given spacewalk.NASA plans to use the tool in 2016 to collect samples from various spacesuits during ground testing to determine what (if any) human-borne microbial contamination leaks from the suit under simulated thermal vacuum conditions. Next, the tool will be used on board the International Space Station to assess the types of microbial contaminants found on external environmental control and life support system vents. Data will support advanced EVA and life support system maturation studies, helping to answer questions such as “how close can an EVA-suited crew member approach an area of scientific interest without compromising the science?”

Rucker, Michelle A.↗

A Survey of Applications and Research in Integrated Design Systems Technology

The initial part of the study was begun with a combination of literature searches, World Wide Web searches, and contacts with individuals and companies who were known to members of our team to have an interest in topics that seemed to be related to our study. There is a long list of such topics, such as concurrent engineering, design for manufacture, life-cycle engineering, systems engineering, systems integration, systems design, design systems, integrated product and process approaches, enterprise integration, integrated product realization, and similar terms. These all capture, at least in part, the flavor of what we describe here as integrated design systems. An inhibiting factor in this inquiry was the absence of agreed terminology for the study of integrated design systems. It is common for the term to be applied to what are essentially augmented Computer-Aided Design (CAD) systems, which are integrated only to the extent that agreements have been reached to attach proprietary extensions to proprietary CAD programs. It is also common for some to use the term integrated design systems to mean a system that applies only, or mainly, to the design phase of a product life cycle. It is likewise common for many of the terms listed earlier to be used as synonyms for integrated design systems. We tried to avoid this ambiguity by adopting the definition of integrated design systems that is implied in the introductory notes that we provided to our contacts, cited earlier. We thus arrived at this definition: Integrated Design Systems refers to the integration of the different tools and processes that comprise the engineering, of complex systems. It takes a broad view of the engineering of systems, to include consideration of the entire product realization process and the product life cycle. An important aspect of integrated design systems is the extent to which they integrate existing, "islands of automation" into a comprehensive design and product realization environment. As the study progressed, we relied increasingly upon a networking approach to lead us to new information. The departure point for such searches often was a government-sponsored project or a company initiative. The advantage of this approach was that short conversations with knowledgeable persons would usually cut through confusion over differences of terminology, thereby somewhat reducing the search space of the study. Even so, it was not until late in our eight-month inquiry that we began to see signs of convergence of the search, in the sense that a number of the latest inquiries began to turn up references to earlier contacts. As suggested above, this convergence often occurred with respect to particular government or company projects.

Source record↗

Real-time graphic simulation for space telerobotics applications

Designing space-based telerobotic systems presents many problems unique to telerobotics and the space environment, but it also shares many common hardware and software design problems with Earth-based industrial robot applications. Such problems include manipulator design and placement, grapple-fixture design, and of course the development of effective and reliable control algorithms. Since first being applied to industrial robotics just a few years ago, interactive graphic simulation has proven to be a powerful tool for anticipating and solving problems in the design of Earth-based robotic systems and processes. Where similar problems are encountered in the design of space-based robotic mechanisms, the same graphic simulation tools may also be of assistance. The capabilities of PLACE, a commercially available interactive graphic system for the design and simulation of robotic systems and processes is described. A space-telerobotics application of the system is presented and discussed. Potential future enhancements are described.

Baumann, E. W.↗