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All sources NASA NTRS DOE OSTI

DOE OSTI2022

The BREKTRIA 500 – A Breakthrough in Technology and Power Density for an Advanced 500kW Utility-Scale String Inverter (Final Technical Report)

The primary goal of this development project, planned to be 36 months in duration, was to create a 500kW utility-scale string inverter, demonstrating an advanced hybrid architecture that would achieve unprecedented high power density, and bring the inverter to the stage of production readiness. Specific key objectives for the 500kW utility-scale string inverter were: Create a 500kW 3-phase 600Vac inverter that was similar in overall size to the existing 250kW string inverters in the market, thereby demonstrating dramatically increased power density; Achieve a cost of goods, including all manufacturing-related costs and overheads, at or below 2.5¢/Wac ($12,500); Demonstrate full-power operation at a 45-50C ambient temperature with no power de-rating; Accommodate a PV array DC input of up to 1MWdc, aka a DC/AC Ratio of 2.0; Demonstrate peak efficiency greater than 99% at any operating dc voltage, and a CEC weighted average efficiency greater than or equal to 98.5%. The motivation for this project was to leapfrog the competition by creating the world’s most powerful string inverter, utilizing an innovative topology and achieving a step change increase in power density. Achieving the goals of the project would have enabled Yaskawa Solectria Solar to demonstrate its technology leadership, manufacture the utility-scale string inverter in the company’s facilities in Illinois, and bring to the market a highly-differentiated and compelling product to help the company grow its share in the large and growing utility market segment. During the course of this project, BREK Electronics’ hybrid architecture inverter was taken from an early-stage 125kW prototype, to a more mature and successfully demonstrated power stage at twice the power. Two 250kW power stages were planned to build the 500kW inverter. Significant progress was made in the inverter controls, achieving a clean AC sinewave and closed-loop operation into the grid, and improved efficiency by control of the high-speed switching. Further, the updated 250kW power stage was on track to achieve full power operation at an ambient temperature of 50C. At the time of the project’s closure in September 2022, global semiconductor supply remained limited, with shortages creating dramatic swings in both availability and price. Given this situation, our ability to predict cost-of-goods two years out with any accuracy or confidence was limited. As a result, the probability of attaining the target cost of 2.5¢/Wac for the 500kW inverter remained uncertain at the closure of the project. This project successfully demonstrated the potential for the advanced hybrid architecture inverter that emerged from a decade of university research on Si IGBTs and SiC mosfets, leading to this unique inverter topology. The team has taken the first steps toward an evolutionary advancement in inverter technology that remains to be fully realized.

14 SOLAR ENERGY↗

DOE OSTI2025

Status of the Proton EDM Experiment (pEDM)

The Proton EDM Experiment (pEDM) is the first direct search for the proton electric dipole moment (EDM) with the aim of being the first experiment to probe the Standard Model (SM) prediction of any particle EDM. Phase-I of pEDM will achieve $10^{-29} e\cdot$cm, improving current indirect limits by four orders of magnitude. This will establish a new standard of precision in nucleon EDM searches and offer a unique sensitivity to better understand the Strong CP problem. The experiment is ideally positioned to explore physics beyond the Standard Model (BSM), with sensitivity to axionic dark matter via the signal of an oscillating proton EDM and across a wide mass range of BSM models from $\mathcal{O}(1\text{GeV})$ to $\mathcal{O}(10^3\text{TeV})$. Utilizing the frozen-spin technique in a highly symmetric storage ring that leverages existing infrastructure at Brookhaven National Laboratory (BNL), pEDM builds upon the technological foundation and experimental expertise of the highly successful Muon $g$$-$$2$ Experiments. With significant R&D and prototyping already underway, pEDM is preparing a conceptual design report (CDR) to offer a cost-effective, high-impact path to discovering new sources of CP violation and advancing our understanding of fundamental physics. It will play a vital role in complementing the physics goals of the next-generation collider while simultaneously contributing to sustaining particle physics research and training early-career researchers during gaps between major collider operations.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗

NASA NTRS1992

Geometric modeling for computer aided design

The goal was the design and implementation of software to be used in the conceptual design of aerospace vehicles. Several packages and design studies were completed, including two software tools currently used in the conceptual level design of aerospace vehicles. These tools are the Solid Modeling Aerospace Research Tool (SMART) and the Environment for Software Integration and Execution (EASIE). SMART provides conceptual designers with a rapid prototyping capability and additionally provides initial mass property analysis. EASIE provides a set of interactive utilities that simplify the task of building and executing computer aided design systems consisting of diverse, stand alone analysis codes that result in the streamlining of the exchange of data between programs, reducing errors and improving efficiency.

Schwing, James L.↗

NASA NTRS1990

A dynamic satellite simulation testbed based on CLIPS and CLIPS-derived tools

We were motivated to define and build a sophisticated satellite simulation capability for the evaluation at a satellite operations automated environment called IntelliSTAR. This architecture, and associated prototype, addresses the entire spacecraft operations cycle including planning, scheduling, task execution, and analysis. It is aimed at increasing the autonomous capability of current and future spacecraft. It utilizes advanced software techniques to address incomplete and conflicting data for making decisions. It also encompasses critical response time requirements, complex relationships among multiple systems, and dynamically changing objectives. Given the extreme scope of activities that are targeted, a sophisticated, flexible, and dynamic simulation environment was required to drive this prototype. In particular the derived requirements for evaluating the IntelliSTAR prototype include realistic and dynamic environment, easily reconfigurable, and multiple levels of fidelity.

Gathmann, Thomas P.↗

NASA NTRS2009

Prototype Common Bus Spacecraft: Hover Test Implementation and Results

In order to develop the capability to evaluate control system technologies, NASA Ames Research Center (Ames) began a test program to build a Hover Test Vehicle (HTV) - a ground-based simulated flight vehicle. The HTV would integrate simulated propulsion, avionics, and sensors into a simulated flight structure, and fly that test vehicle in terrestrial conditions intended to simulate a flight environment, in particular for attitude control. The ultimate purpose of the effort at Ames is to determine whether the low-cost hardware and flight software techniques are viable for future low cost missions. To enable these engineering goals, the project sought to develop a team, processes and procedures capable of developing, building and operating a fully functioning vehicle including propulsion, GN&C, structure, power and diagnostic sub-systems, through the development of the simulated vehicle.

Hine, Butler Preston↗

NASA NTRS2015

Tracking Three-Dimensional Fish Behavior with a New Marine Acoustic Telemetry System

The persistent monitoring capability provided by acoustic telemetry systems allows us to study behavior, movement, and resource selection of mobile marine animals. Current marine acoustic telemetry systems are challenged by localization errors and limits in the number of animals that can be tracked simultaneously. We designed a new system to provide detection ranges of up to 1 km, to reduce localization errors to less than 1 m, and to increase to 500 the number of unique tags simultaneously tracked. The design builds on HTIs experience of more than a decade developing acoustic telemetry systems for freshwater environments. A field trial of the prototype system was conducted at the University of Washingtons Friday Harbor Marine Laboratory (Friday Harbor, WA). Copper rockfish (Sebastes caurinus) were selected for field trials of this new system because their high site-fidelity and small home ranges provide ample opportunity to track individual fish behavior while testing our ability to characterize the movements of a species of interest to management authorities.

acoustic telemetry↗

NASA NTRS2020

Verification of the Convection-Allowing Ensemble System over the Hindu Kush Himalaya Region During the 2018 and 2019 Pre-Monsoon Severe Thunderstorm Seasons

Some of the most intense thunderstorms on the planet occur in the Hindu Kush Himalaya (HKH) region of South-Central Asia. NASA/SERVIR Applied Sciences Team competitive project to develop capacity of severe thunderstorm monitoring and forecasting tool for HKH. Project Goal: Use [NASA] modeling and remote-sensing assets to build early warning capabilities and facilitate timely disaster response for high impact weather events in the HKH region. Specific objectives: 1. Prototype and transition High-Impact Weather Assessment Toolkit (HIWAT) 2. Jointly develop HIWAT capabilities & training with SERVIR’s hub in Kathmandu, Nepal: International Centre for Integrated Mountain Development (ICIMOD) 3. Demonstrate capacity in end-user environment 4. Transition HIWAT system to ICIMOD for future maintenance.

Case, Jonathan L.↗

NASA NTRS2023

MMIC-I: A Robotic Platform for Assembly Integration and Internal Locomotion through Mechanical Meta-Material Structures

In-space assembly is crucial to creating large-scale space structures and enabling long term space missions. Natural limitations in the size of transportation vehicles and ISRU production facilities necessitate an additive strategy with the size of the typical structural unit being essentially fixed and inversely proportional to the final assembly size. In prior robotic and space assembly examples, reversible mechanical integration of structural modules is typically achieved with actuated alignment and fastening mechanisms onboard every structural module. Additive assembly or manufacturing planning approaches often feature a “build front” that receives new materials or parts and progresses gradually across the target geometry. The system we describe here places much of the alignment and fastener actuation systems onboard a mobile robot that can operate at a build front while companion robots (Scaling Omni-directional Lattice Locomoting Explorer, SOLLE) provide part or material transportation. The design and evaluation of this Mobile Meta-Material Interior Co-Integrator (MMIC-I), an inchworm-style locomoting robotic assembler, is described here with an emphasis on ease of assembly and a low number of unique parts for a simple design. It is designed to assist in alignment of cuboctahedron structural unit cells with captive fasteners, defining the build front in operation. Adjacent structural unit cells are locked together with specified axial and rotational actuation of the fasteners. Hardware prototypes show that the robot is able to successfully locomote to any indexed location within a lattice structure and bolt together each set of fasteners on any interface.

Robotics↗

NASA NTRSDate not supplied

An Analytic Collaborative Framework for the Earth System Observatory

NASA's Earth System Observatory groundbreaking observations will provide critical measurements to address societal relevant problems in climate change, natural hazard mitigation, fighting forest fires, and improving real-time agricultural processes. Central to the ESO vision is the notion of Open-Source Science (OSS), a collaborative culture enabled by technology that promotes the open sharing of data, information, and knowledge aiming to facilitate and accelerate scientific understanding, and the agile development of applications for the benefit of society. The larger vision of an Earth System Digital Twin (ESDT) calls for integrated Earth science frameworks that mirror the Earth by a proxy digital construct that includes km-scale resolution Earth system models and data assimilation systems along with an integrated set of analytic tools to enable the next generation of science discoveries and evidence-based decision making. The goal of this project is to develop an Analytic Collaborative Framework for ESO missions, based on realistic, science-based observing system simulations and the Program of Record (PoR). Tying it all together is a cloud-based cyberinfrastructure that will enable each uniquely designed satellite in the Earth System Observatory to work in tandem to create a 3D, holistic view of Earth. In this presentation, we lay the technological groundwork for enabling such a vision. Our approach consists of the 3 main interconnected building blocks: 1. Cloud-optimized representative datasets for ESO missions and the PoR to serve as basis for developing and prototyping an Analytic Collaborative Framework. 2. An Algorithm Workbench for enabling experimentation and exploration of synergistic algorithms not only for instruments within a mission, but also including the PoR and other ESO missions. 3. A series of concrete Open-Source Science demonstrations including use cases that span science discovery and end-user applications with direct societal impact. While our ultimate goal is to include all of the main missions comprising the Earth System Observatory, in our initial 2 years we will focus on AOS and SBG, two missions for which specific synergisms have been identified in a recent workshop. In this presentation we will describe our approach and discuss some illustrative examples of our framework.

Arlindo da SIlva↗

NASA NTRSDate not supplied

An Analytic Collaborative Framework for the Earth System Observatory

Arlindo da SIlva↗

DOE OSTI2022

High Temperature Anode Recycle Blower for Solid Oxide Fuel Cell, Phase II (Final Report)

Broad commercialization of solid oxide fuel cells (SOFCs) requires anode offgas recycle blowers (ARCB) that are specifically designed for handling the challenging operating conditions presented by the SOFC process gases. Otherwise, they can be susceptible to frequent maintenance, low reliability, and short life. This report presents details of a DOE-funded Phase II effort conducted by Mohawk Innovative Technology, Inc. (MiTi®) for the development and testing of an oil-free, low cost, high-temperature centrifugal ARCB based on compliant foil bearing (CFB) technology for support of a 100 kW solid oxide fuel cell power plant. This Phase II builds on the results of a successful Phase I development project that resulted in the demonstration of a low TRL-6 prototype, shown in Figure 1. This Phase II final report presents design improvements over the Phase I prototype, presents the assembled test ARCBs, and discusses the advantages of this novel technology, particularly its long life and maintenance-free operation, which are derived from the use of CFBs. Also included are preliminary techno-economic analysis considerations for cost-effective deployment of the technology. The specific objectives of this project, as stated in the statement of program objectives (SOPO) were 1) to follow the methodology of design for manufacturing (or manufacturability) and assembly for implementing improvements identified as part of the Phase I effort with the purpose of reducing cost, enabling mass production, and facilitating the commercialization of a revised ARCB design, and 2) to fabricate four complete ARCB units based on the revised design and demonstrating their performance in both a laboratory setting and in an actual SOFC power plant. Execution of this SOPO would be supported by a number of technical tasks resulting in the fabrication and testing of the prototypes. To this end, MiTi continued the teaming relationship started during Phase I of the program with subcontracting partner FuelCell Energy, Inc. (FCE), which integrated (under a parallel effort funded by DOE Award DE-FE0026199) a modular 200 kWe SOFC power plant. MiTi and FCE coordinated to ultimately incorporate one of MiTi’s ARCB prototypes into one of the 100 kWe SOFC Modular Power Blocks (MPB) that constitute the core of FCE’s SOFC power plant for in-situ long-duration testing. Additionally, MiTi would explore the scalability and extendibility of the technology to other applications, as well as conduct a basic techno-economic analysis.

03 NATURAL GAS↗

DOE OSTI2026

Lab-Scale Cable-Driven Parallel Robot Prototype for Automated Prefabricated Component Manipulation

This paper presents the design and evaluation of a lab-scale cable-driven parallel robot (CDPR) developed as a flexible platform for automated installation of prefabricated components onto exterior building envelopes. Traditional manual installation methods for prefabricated components, which depend on scaffolding, cranes, cherry pickers, and verbal coordination, are not only labor-intensive and error-prone but also face significant limitations in dense urban environments due to site access constraints. To address these challenges, we developed a lab-scale CDPR platform capable of autonomously transporting building envelope components from a designated pickup zone to their target installation location, minimizing the need for human intervention. This study describes the system’s mechanical design, actuation architecture, real-time feedback system, and control strategy of the CDPR, and evaluates its performance in a laboratory environment. The robot’s actuation system uses torque control for end-effector manipulation. The robot’s real-time pose feedback comes from a construction-grade total station and a wireless inertial measurement unit (IMU), which together support precise end-effector control. Experimental results demonstrate the successful integration of the hardware, sensing, state estimation, and control subsystems. Preliminary tests showed that our lab-scale prototype can position the end effector with an error of less than 3 mm, which is a level of precision not previously achieved by existing CDPRs in construction applications. The key findings are twofold: (1) torque-only control is necessary but not sufficient for minimizing final pose error, and (2) incorporating real-time pose feedback can achieve the desired placement accuracy.

Liu, Yifang [Oak Ridge National Laboratory (ORNL),↗

DOE OSTI2023

Dynamic Thermal Performance Analysis of PCM Products Used for Energy Efficiency and Internal Climate Control in Buildings

PCMs are attractive for the future generation of buildings, where energy efficiency targets and thermal comfort expectations are increasingly prioritized. Experimental analysis of local thermal processes in these dynamic components and whole-building energy consumption predictions are essential for the proper implementation of PCMs in buildings. This paper discusses the experimental analysis of the thermophysical characteristics of both a latent heat storage material (PCM) and a product containing this PCM. The prototype product under investigation is a panelized PCM technology containing inorganic, salt-hydrate-based PCM. The thermal analysis includes studies of melting and freezing temperatures, enthalpy changes during phase change processes, nucleation intensity, sub-cooling effects, and PCM stability. The PCM’s stability is also investigated, as is the ability of PCM products to control local temperatures and peak load transmission times. Two inorganic PCM formulations based on calcium chloride hexahydrate (CaCl 2 .6H 2 O) were prepared and tested in laboratory conditions. Material-scale testing results were compared with outcomes from the system-scale analysis, using both laboratory test methods as well as field exposure in test huts. This work demonstrates that PCM technologies used in buildings can effectively control both the magnitude of thermal storage capacity as well as the time of the peak thermal load. It was found that commonly used material-scale testing methods may not always be beneficial in assessing the dynamic thermal performance characteristics of building technologies containing PCMs.

42 ENGINEERING↗

NASA NTRS1991

A prototype power assist EVA glove

The most recent generation of space suit EVA gloves has addressed the problem of loose fit and stiffness in the fingers, but it remains difficult to build a glove assembly with low metacarpophalangeal joint stiffness. Fatigue due to constantly displacing the glove from a neutral position has been reported as the limiting factor in some EVA activities. This paper outlines an actuation system that uses gas filled bladders attached to the back of the EVA glove to provide the necessary force to bend the glove at the metacarpal joint, thus providing greater endurance during finger grasping tasks. A simple on-off controller senses hand movement through small pressure sensors between the finger and the glove restraint. The controller then fills or exhausts the bladders on the back of the glove to effectively move the neutral position of the glove as the hand inside moves.

Main, John A.↗

DOE OSTI2023

Gas-phase formation of the resonantly stabilized 1-indenyl (C 9 H 7 • ) radical in the interstellar medium

The 1-indenyl (C 9 H 7 • ) radical, a prototype aromatic and resonantly stabilized free radical carrying a six- and a five-membered ring, has emerged as a fundamental molecular building block of nonplanar polycyclic aromatic hydrocarbons (PAHs) and carbonaceous nanostructures in deep space and combustion systems. However, the underlying formation mechanisms have remained elusive. Here, we reveal an unconventional low-temperature gas-phase formation of 1-indenyl via barrierless ring annulation involving reactions of atomic carbon [C( 3 P)] with styrene (C 6 H 5 C 2 H 3 ) and propargyl (C 3 H 3 • ) with phenyl (C 6 H 5 • ). Macroscopic environments like molecular clouds act as natural low-temperature laboratories, where rapid molecular mass growth to 1-indenyl and subsequently complex PAHs involving vinyl side-chained aromatics and aryl radicals can occur. These reactions may account for the formation of PAHs and their derivatives in the interstellar medium and carbonaceous chondrites and could close the gap of timescales of their production and destruction in our carbonaceous universe.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2021

Methane Mitigation Thermoelectric Generator (MMTEG) (Final Scientific/ Technical Report)

Gas Technology Institute (GTI) has completed a $1.815M (plus $500K cost share), 54-month Co-operative agreement with the Department of Energy’s National Energy Technology Laboratory to develop a Methane Mitigation Thermoelectric Generator (MMTEG) system for gas field applications. This novel system uses fugitive gas to produce electrical power and consists of Thermoelectric Generators (TEG) driven by a linear burner, an air compressor, an accumulator, valves, batteries, and power electronics. The electrical power generated by the system is used to compress air and, in turn, the air is used to operate the pneumatic valves at the well site instead of using natural gas (NG) which would then be vented. The team completed the project objectives which included (1) Design, fabricate and test an integrated 6We nominal MMTEG prototype system, (2) Design a “retrofit kit” MMTEG system capable of being field tested at a gas well production site, and (3) build and test the field MMTEG system in a laboratory environment. Multiple system options were developed prior to selecting a “Passive” system which meets cost, NG savings, and greenhouse gas (GHG) reduction targets although not as efficient as initially planned. The MMTEG system is built primarily from commercial off-the-shelf parts (in some cases re-purposed) including the heat exchanger, heat rejection, electronic components, and also the TEGs. The team developed and implemented a novel system including the control system developed by Morrison Applied Sciences (MAS). The team completed incremental demonstrations of the hardware prior to the MMTEG system demonstration. A one-year simulation of the air delivery and battery charging subsystems was completed prior to the integration into the MMTEG system. In addition, the team simulated two-years of thermal cycles for integrated Burner/TEG/heat rejection subsystem. Finally, the entire MMTEG system was assembled, and troubleshooting was completed over a two-week period. Next, the MMTEG system was tested to simulate over 15 weeks of entire system operation over approximately four weeks in an accelerated test fashion with minimal intervention (such as changing fuel tanks). The MMTEG system met the key goals of a unit cost of under $1500 while saving 97% of NG expended today (including leakage) on average by pneumatic systems venting to the atmosphere. The MMTEG system reduced GHG emissions by 1000X (using the methane intensification factor of 28 relative to CO2). GTI is currently pursuing a field test of the MMTEG system. Interfacing with producers has provided additional insight into system improvements. Planned improvements include additional weather protection and control system improvements including the implementation of a long- range radio capability to notify operators if there is a fault.

03 NATURAL GAS↗

NASA NTRS1974

Experimental feasibility study of the application of magnetic suspension techniques to large-scale aerodynamic test facilities

Based on the premises that (1) magnetic suspension techniques can play a useful role in large-scale aerodynamic testing and (2) superconductor technology offers the only practical hope for building large-scale magnetic suspensions, an all-superconductor three-component magnetic suspension and balance facility was built as a prototype and was tested successfully. Quantitative extrapolations of design and performance characteristics of this prototype system to larger systems compatible with existing and planned high Reynolds number facilities have been made and show that this experimental technique should be particularly attractive when used in conjunction with large cryogenic wind tunnels.

Zapata, R. N.↗

NASA NTRS2003

NASA Helps Keep the Light Burning for the Saturn Car Company

The Saturn Electronics & Engineering, Inc. (Saturn) facility in Marks, Miss., that produces lamp assemblies was experiencing itermittent problems with its automotive under the hood lamps. After numerous testing and engineering efforts, technicians could not pin down the root of the problem. So Saturn contacted the NASA Technology Assistance Program (TAP) at Stennis Space Center. The Marks production facility had been experiencing intermittent problems with under the hood lamp assemblies for some time. The failure rate, at 2 percent, was unacceptable. Every effort was made to identify the problem so that corrective action could be put in place. The problem was investigated and researched by Saturn's engineering department. In addition, Saturn brought in several independent testing laboratories. Other measures included examining the switch component suppliers and auditing them for compliance to the design specifications and for surface contaminants. All attempts to identify the factors responsible for the failures were inconclusive. In an effort to get to the root of the problem, and at the recommendation of the Mississippi Department of Economic Development, Saturn contacted the NASA TAP at Stennis. The NASA Materials and Contamination Laboratory, with assistance from the Stennis Prototype Laboratory, conducted a materials evaluation study on the switch components. The laboratory findings showed the failures were caused by a build-up of carbon-based contaminants on the switch components. Saturn Electronics & Engineering, Inc., is a minority-owned provider of contract manufacturing services to a diverse global marketplace. Saturn operates manufacturing facilities globally serving the North American, European, and Asian markets. Saturn's production facility in Marks, Mississippi, produces more than 1,000,000 lamps and switches monthly. "Since the NASA recommendations were implemented, our internal failure rate for intermittency has dropped to less than .02 percent. Most importantly, we restored our high-level of customer satisfaction. Stennis provided an invaluable service to our business," Patrick said. Both NASA and Saturn were pleased with the results form this technical assistance project. The Technology Assistance Program at Stennis makes available to the public NASA technical expertise and access to lab facilities. This project provided both services with a positive outcome.

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