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All sources NASA NTRS DOE OSTI

NASA NTRS2002

Microwave-Driven Multifunctional Capability of Membrane Structures

A large, ultra lightweight space structure, such as solar sails and Gossamer spacecrafts, requires a distributed power source to alleviate wire networks, unlike the localized on-board power infrastructures typically found in most small spacecrafts. The concept of microwave-driven multifunctional capability for membrane structures is envisioned as the best option to alleviate the complexity associated with hard-wired control circuitry and on-board power infrastructures. A rectenna array based on a patch configuration for high voltage output was developed to drive membrane actuators, sensors, probes, or other devices. Networked patch rectenna array receives and converts microwave power into a DC power for an array of smart actuators. To use microwave power effectively, the concept of a power allocation and distribution (PAD) circuit is adopted for networking a rectenna/actuator patch array. The use of patch rectennas adds a significant amount of rigidity to membrane flexibility and they are relatively heavy. A dipole rectenna array (DRA) appears to be ideal for thin-film membrane structures, since DRA is flexible and light. Preliminary design and fabrication of PAD circuitry that consists of a few nodal elements were made for laboratory testing. The networked actuators were tested to correlate the network coupling effect, power allocation and distribution, and response time.

Choi, Sang H.↗

NASA NTRS2004

Prototype Morphing Fan Nozzle Demonstrated

Ongoing research in NASA Glenn Research Center's Structural Mechanics and Dynamics Branch to develop smart materials technologies for aeropropulsion structural components has resulted in the design of the prototype morphing fan nozzle shown in the photograph. This prototype exploits the potential of smart materials to significantly improve the performance of existing aircraft engines by introducing new inherent capabilities for shape control, vibration damping, noise reduction, health monitoring, and flow manipulation. The novel design employs two different smart materials, a shape-memory alloy and magnetorheological fluids, to reduce the nozzle area by up to 30 percent. The prototype of the variable-area fan nozzle implements an overlapping spring leaf assembly to simplify the initial design and to provide ease of structural control. A single bundle of shape memory alloy wire actuators is used to reduce the nozzle geometry. The nozzle is subsequently held in the reduced-area configuration by using magnetorheological fluid brakes. This prototype uses the inherent advantages of shape memory alloys in providing large induced strains and of magnetorheological fluids in generating large resistive forces. In addition, the spring leaf design also functions as a return spring, once the magnetorheological fluid brakes are released, to help force the shape memory alloy wires to return to their original position. A computerized real-time control system uses the derivative-gain and proportional-gain algorithms to operate the system. This design represents a novel approach to the active control of high-bypass-ratio turbofan engines. Researchers have estimated that such engines will reduce thrust specific fuel consumption by 9 percent over that of fixed-geometry fan nozzles. This research was conducted under a cooperative agreement (NCC3-839) at the University of Akron.

Lee, Ho-Jun↗

NASA NTRS2002

A Data Management System for International Space Station Simulation Tools

Groups associated with the design, operational, and training aspects of the International Space Station make extensive use of modeling and simulation tools. Users of these tools often need to access and manipulate large quantities of data associated with the station, ranging from design documents to wiring diagrams. Retrieving and manipulating this data directly within the simulation and modeling environment can provide substantial benefit to users. An approach for providing these kinds of data management services, including a database schema and class structure, is presented. Implementation details are also provided as a data management system is integrated into the Intelligent Virtual Station, a modeling and simulation tool developed by the NASA Ames Smart Systems Research Laboratory. One use of the Intelligent Virtual Station is generating station-related training procedures in a virtual environment, The data management component allows users to quickly and easily retrieve information related to objects on the station, enhancing their ability to generate accurate procedures. Users can associate new information with objects and have that information stored in a database.

Betts, Bradley J.↗

NASA NTRS2013

Miga Aero Actuator and 2D Machined Mechanical Binary Latch

Shape memory alloy (SMA) actuators provide the highest force-to-weight ratio of any known actuator. They can be designed for a wide variety of form factors from flat, thin packages, to form-matching packages for existing actuators. SMA actuators can be operated many thousands of times, so that ground testing is possible. Actuation speed can be accurately controlled from milliseconds to position and hold, and even electronic velocity-profile control is possible. SMA actuators provide a high degree of operational flexibility, and are truly smart actuators capable of being accurately controlled by onboard microprocessors across a wide range of voltages. The Miga Aero actuator is a SMA actuator designed specifically for spaceflight applications. Providing 13 mm of stroke with either 20- or 40-N output force in two different models, the Aero actuator is made from low-outgassing PEEK (polyether ether ketone) plastic, stainless steel, and nickel-titanium SMA wires. The modular actuator weighs less than 28 grams. The dorsal output attachment allows the Aero to be used in either PUSH or PULL modes by inverting the mounting orientation. The SPA1 actuator utilizes commercially available SMA actuator wire to provide 3/8-in. (approx. =.1 cm) of stroke at a force of over 28 lb (approx. = .125 N). The force is provided by a unique packaging of the single SMA wire that provides the output force of four SMA wires mechanically in parallel. The output load is shared by allowing the SMA wire to slip around the output attachment end to adjust or balance the load, preventing any individual wire segment from experiencing high loads during actuation. A built-in end limit switch prevents overheating of the SMA element following actuation when used in conjunction with the Miga Analog Driver [a simple MOSFET (metal oxide semiconductor field-effect transistor) switching circuit]. A simple 2D machined mechanical binary latch has been developed to complement the capabilities of SMA wire actuators. SMA actuators typically perform ideally as latch-release devices, wherein a spring-loaded device is released when the SMA actuator actuates in one direction. But many applications require cycling between two latched states open and closed.

Gummin, Mark A.↗

DOE OSTI2016

IEC 61850: Technology Standards and Cyber-Security Threats

Substations constitute a fundamental part in providing reliable electricity to consumers. For a substation to maintain electricity reliability and its own real-time operability, communication between its components is inevitable. Before the emergence of IEC 61850, inter-substation communication was established via expensive copper wires with limited capabilities. IEC 61850 is the standard set by the International Electrotechnical Commission (IEC) Technical Committee Number 57 Working Group 10 and IEEE for Ethernet (IEEE 802.3)-based communication in electrical substations. Like many power grid systems standards, IEC 61850 was set without extensive consideration for critical security measures. This paper discusses IEC 61850 technology standards and applications thoroughly and points out major security vulnerabilities it introduces in the context of current cyber-physical smart grid systems.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2020

Development of an Encoding Method on an Co-simulation Platform for Mitigating the Impact of Unreliable Communication

This report presents a hardware-in-the-loop (HIL) based modeling approach for simulating impacts of unreliable communication on the performance of centralized volt-var control and for developing an encoding method to mitigate the impacts. First, an asynchronous real-time HIL simulation platform is introduced to enable multi-rate co-simulation of a distribution system with many inverter-based distributed energy resources (DERs). The distribution system is modeled by milliseconds phasor-based models and the DERs are modeled by micro-seconds power electronic models. Communication connections between a centralized volt-var controller (modeled externally to the HIL testbed) and smart inverters are built by implementing Modbus links and the Long Term Evolution network. On this co-simulation platform, an enhanced, augmented Lagrangian multiplier based encoded data recovery (EALM-EDR) algorithm for mitigating the impact of unreliable communication is developed and validated. Simulation results demonstrate the efficacy of using the HIL-based co-simulation platform as a power grid digital twin for developing algorithms that coordinate a large number of heterogeneous control systems through wired and wireless communication links.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2026

Development of Wireless Power Technology for Use in Electrochromic Window Retrofit Applications

Electrochromic (EC) windows, often referred to as smart windows, have the ability to adjust their tint in response to electrical signals, thereby controlling the amount of sunlight and heat entering a building. This dynamic modulation can lead to significant energy savings by reducing the reliance on artificial lighting and minimizing the load on heating, ventilation, and air conditioning (HVAC) systems. However, the widespread adoption of electrochromic window technology, especially in existing buildings, faces challenges, particularly concerning the installation cost associated with the need for electrical wiring to power and control the EC glass (tinting). In this project, GuRu Wireless demonstrated that it’s mmWave-based wireless power energy transfer technology can provide the necessary power for operation of electrochromic windows, wirelessly, and address the wiring challenges of electrochromic windows in retrofit applications.

24 POWER TRANSMISSION AND DISTRIBUTION↗

NASA NTRS2015

3D Printing of Advanced Biocomposites on Earth and Beyond

Human exploration off planet is severely limited by the cost of launching materials into space and re-supply. Thus materials brought from earth must be light, stable and reliable at destination. Using traditional approaches a lunar or Mars base would require either transporting a hefty store of metals or heavy manufacturing equipment and construction materials for in situ extraction; both would severely limit any other mission objectives. Long-term human space presence requires periodic replenishment, adding a massive cost overhead. Even robotic missions often sacrifice science goals for heavy radiation and thermal protection. Biology has the potential to solve these problems because it can replicate and repair itself, and do a wide variety of chemical reactions including making food, fuel and materials. Synthetic biology can greatly enhance and expand life's evolved repertoire. Using natural and synthetically altered organisms as the feedstock for additive manufacturing could one day make possible the dream of producing bespoke tools, food, smart fabrics and even replacement organs on demand. To this end our lab has produced a proof-of-concept bioprinter with nearly one-cell resolution. Genetically engineering yeast cells to secrete bioproducts subsequent to printing allows the potential to make biomaterials with a fine microstructure. Imagine a production system that, at a few micron scale resolution, can add mollusk shell for compressive strength per unit mass, spider silk or collagen for tensile strength per unit mass, and potentially biologically-deposited wires. Now imagine what new products can be enabled by such a technology, on earth or beyond

Metals↗

NASA NTRS2014

3D Printing of Advanced Biocomposites on Earth and Beyond

Biology↗

DOE OSTI2021

A generic method for interfacing IEDs using low voltage interfaces to real-time simulators with hardware in the loop

This study presents an interface method (IM) to interconnect real-time simulators (RTSs) without amplifiers for different intelligent electronic devices (IEDs), such as protective relays, smart meters, and other devices. It is a significant topic for the power systems protection community because there are many protection devices with different requirements. These protection devices have pinouts that measure bus voltages/currents and breaker pole states and generate trip/close pulse signals. Most of the emulation test beds with RTSs and HIL need amplifiers to connect IEDs from different product manufacturers because the low-voltage interface levels are not available in some instruction manuals. Additionally, commercial amplifiers have cutoff frequency limitations and have an excessive cost when several IEDs are wired onto test beds. Then, the validation of protection and control systems with RTSs and IEDs in the loop from different vendors without amplifiers results in an unfeasible alternative. In this paper, the IM was based on using an interface box, power source, and RTS to identify IED inputs/outputs. Here, the sequence to recognize IED pinouts and calculate the current/voltage scaling factors is described. The IM was validated satisfactorily with RTS and a protection device (with unknown pinouts) in the loop.

42 ENGINEERING↗

NASA NTRSDate not supplied

Additively Manufactured Ink-based Cell Batteries for Flexible Conformational Applications

With the rise of additively manufactured electronics, the importance of thin, flexible printed batteries has increased for shape-conformal electronics. Traditionally, battery cells such as industry-standard lithium-ion batteries, have been rigid and therefore unable to conform to time-variant surfaces such as smart cards/RFID devices, disposable battery-powered skin patches, foldable electronic devices, and IoT nodes. Aligned with the effort to advance technologies on printed electronics for habitat systems and advanced manufacturing, this proof-of-concept will focus on printing a 50 mAh Zn-Ag battery implementing a DIW Technique. After prototype manufacturing, electrical and environmental testing on the flexible battery cell will be conducted to the evaluate energy and power density over 50 charge cycles under standard atmosphere conditions. The project aims to provide PCB designers, fabricators, and assemblers an integrated battery package to eliminate external batteries, external wiring and connectors, and conformational complexity. Potential end uses of the printed battery process will be within Martian and lunar habitat systems, Gateway, and surface vehicles, or aerial robots where space and geometry is a restriction.

Printed Electronics↗

DOE OSTI2020

Nanotechnology for catalysis and solar energy conversion

This roadmap on Nanotechnology for Catalysis and Solar Energy Conversion focuses on the application of nanotechnology in addressing the current challenges of energy conversion: 'high efficiency, stability, safety, and the potential for low-cost/scalable manufacturing' to quote from the contributed article by Nathan Lewis. This roadmap focuses on solar-to-fuel conversion, solar water splitting, solar photovoltaics and bio-catalysis. It includes dye-sensitized solar cells (DSSCs), perovskite solar cells, and organic photovoltaics. Smart engineering of colloidal quantum materials and nanostructured electrodes will improve solar-to-fuel conversion efficiency, as described in the articles by Waiskopf and Banin and Meyer. Semiconductor nanoparticles will also improve solar energy conversion efficiency, as discussed by Boschloo et al in their article on DSSCs. Perovskite solar cells have advanced rapidly in recent years, including new ideas on 2D and 3D hybrid halide perovskites, as described by Spanopoulos et al 'Next generation' solar cells using multiple exciton generation (MEG) from hot carriers, described in the article by Nozik and Beard, could lead to remarkable improvement in photovoltaic efficiency by using quantization effects in semiconductor nanostructures (quantum dots, wires or wells). These challenges will not be met without simultaneous improvement in nanoscale characterization methods. Terahertz spectroscopy, discussed in the article by Milot et al is one example of a method that is overcoming the difficulties associated with nanoscale materials characterization by avoiding electrical contacts to nanoparticles, allowing characterization during device operation, and enabling characterization of a single nanoparticle. Besides experimental advances, computational science is also meeting the challenges of nanomaterials synthesis. The article by Kohlstedt and Schatz discusses the computational frameworks being used to predict structure–property relationships in materials and devices, including machine learning methods, with an emphasis on organic photovoltaics. The contribution by Megarity and Armstrong presents the 'electrochemical leaf' for improvements in electrochemistry and beyond. In addition, biohybrid approaches can take advantage of efficient and specific enzyme catalysts. These articles present the nanoscience and technology at the forefront of renewable energy development that will have significant benefits to society.

14 SOLAR ENERGY↗

NASA NTRS2011

Intelligent Wireless Sensor Networks for System Health Monitoring

Wireless sensor networks (WSN) based on the IEEE 802.15.4 Personal Area Network (PAN) standard are finding increasing use in the home automation and emerging smart energy markets. The network and application layers, based on the ZigBee 2007 Standard, provide a convenient framework for component-based software that supports customer solutions from multiple vendors. WSNs provide the inherent fault tolerance required for aerospace applications. The Discovery and Systems Health Group at NASA Ames Research Center has been developing WSN technology for use aboard aircraft and spacecraft for System Health Monitoring of structures and life support systems using funding from the NASA Engineering and Safety Center and Exploration Technology Development and Demonstration Program. This technology provides key advantages for low-power, low-cost ancillary sensing systems particularly across pressure interfaces and in areas where it is difficult to run wires. Intelligence for sensor networks could be defined as the capability of forming dynamic sensor networks, allowing high-level application software to identify and address any sensor that joined the network without the use of any centralized database defining the sensors characteristics. The IEEE 1451 Standard defines methods for the management of intelligent sensor systems and the IEEE 1451.4 section defines Transducer Electronic Datasheets (TEDS), which contain key information regarding the sensor characteristics such as name, description, serial number, calibration information and user information such as location within a vehicle. By locating the TEDS information on the wireless sensor itself and enabling access to this information base from the application software, the application can identify the sensor unambiguously and interpret and present the sensor data stream without reference to any other information. The application software is able to read the status of each sensor module, responding in real-time to changes of PAN configuration, providing the appropriate response for maintaining overall sensor system function, even when sensor modules fail or the WSN is reconfigured. The session will present the architecture and technical feasibility of creating fault-tolerant WSNs for aerospace applications based on our application of the technology to a Structural Health Monitoring testbed. The interim results of WSN development and testing including our software architecture for intelligent sensor management will be discussed in the context of the specific tradeoffs required for effective use. Initial certification measurement techniques and test results gauging WSN susceptibility to Radio Frequency interference are introduced as key challenges for technology adoption. A candidate Developmental and Flight Instrumentation implementation using intelligent sensor networks for wind tunnel and flight tests is developed as a guide to understanding key aspects of the aerospace vehicle design, test and operations life cycle.

networks↗

DOE OSTI2024

Scalable Thin Light-Emitting Diode (LED) Light Sheet Platform

The goal of the Scalable Thin Light-Emitting Diode (LED) Light Sheet Platform project is to derisk the manufacturing scalability for a high chip count heterogeneous smart lighting platform, with the potential to enable significant energy savings through dynamic directional light control and custom. Specifically, the project derisks the scalability of a disruptive new computer controlled microassembly fabrication process SRI International is developing, to address fundamental cost barriers to mass production of high chip count systems. This is key for enabling mass adoption and thus maximum societal energy savings impact. The LED light sheet technology is a smart illumination platform that can be applied to lighting, signage, and display. It has features and a form factor similar to bendable or conformal OLED light sheets but uses more efficient LEDs with a remote phosphor layer that is very close to the LED to deliver a luminous efficacy that exceeds 125 lumen/Watt and enable > 50% Lighting Application Efficiency (LAE) energy savings. During Budget Period 1 (BP1), all of the BP1 milestones were successfully completed: (M2.0.1) Design demonstrator details that will meet the final project goals, (M6.1.1) Show lighting output model can predict illuminance, spatial, spectral distribution for specific light-sheet designs and use case, (M3.2.1) Automated loading supports 200 chip arrays, and (M3.3.1) Finish first interconnect process run for 200 chip array. The BP1 Go/No-Go Decision Point (G/NG 1) 200 chip demonstrator sample was in the process of final assembly and test at the end of BP1 on December 31, 2023. The objective was successfully achieved on January 16, 2024, when a wired 200-chip sample underwent confirmation testing that demonstrated a 93.75% first pass electrical yield that successfully exceeded the 75% first-pass electrical yield BP1 G/NG requirement. In addition, all 93.75% of the sample devices lit up, further demonstrating the ability to assemble and transfer small LED chips without damaging their functionality.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

NASA NTRS2011

Maturation of Structural Health Management Systems for Solid Rocket Motors

Concepts of an autonomous and automated space-compliant diagnostic system were developed for conditioned-based maintenance (CBM) of rocket motors for space exploration vehicles. The diagnostic system will provide real-time information on the integrity of critical structures on launch vehicles, improve their performance, and greatly increase crew safety while decreasing inspection costs. Using the SMART Layer technology as a basis, detailed procedures and calibration techniques for implementation of the diagnostic system were developed. The diagnostic system is a distributed system, which consists of a sensor network, local data loggers, and a host central processor. The system detects external impact to the structure. The major functions of the system include an estimate of impact location, estimate of impact force at impacted location, and estimate of the structure damage at impacted location. This system consists of a large-area sensor network, dedicated multiple local data loggers with signal processing and data analysis software to allow for real-time, in situ monitoring, and longterm tracking of structural integrity of solid rocket motors. Specifically, the system could provide easy installation of large sensor networks, onboard operation under harsh environments and loading, inspection of inaccessible areas without disassembly, detection of impact events and impact damage in real-time, and monitoring of a large area with local data processing to reduce wiring.

Quing, Xinlin↗

DOE OSTI2020

Scaling Up metal additive manufacturing process to fabricate molds for composite manufacturing

Direct Energy Deposition (DED) systems are currently used to repair and maintain existing parts in the aerospace and automotive industries. This paper discusses an effort to scale up the DED technique in order to Additively Manufacture (AM) molds and dies used in the composite manufacturing industry. The US molds and dies market has been in a rapid decline over the last decade due to outsourcing to non-US entities. Oak Ridge National Laboratory (ORNL), Wolf Robotics and Lincoln Electric have developed a Metal Big Area Additive Manufacturing (MBAAM) system that uses a high deposition rate and a low-cost wire feedstock material. In this work we used the MBAAM system with a mild steel wire, ER70S-6, to fabricate a compression molding mold for composite structures used in automotive and mass-transit applications. In addition, the mechanical properties of the AM structure were investigated, and it was found that the MBAAM process delivers parts with high planar isotropic behavior. The paper investigates the microstructure and grain of the printed articles to confirm the roots of the observed planar isotropic properties. Here, the manufactured AM mold was used to fabricate 50 composite parts with no observed mold deformations.

36 MATERIALS SCIENCE↗

NASA NTRS2013

Conductive Carbon Nanotube Inks for Use with Desktop Inkjet Printing Technology

Inkjet printing is a common commercial process. In addition to the familiar use in printing documents from computers, it is also used in some industrial applications. For example, wire manufacturers are required by law to print the wire type, gauge, and safety information on the exterior of each foot of manufactured wire, and this is typically done with inkjet or laser printers. The goal of this work was the creation of conductive inks that can be applied to a wire or flexible substrates via inkjet printing methods. The use of inkjet printing technology to print conductive inks has been in testing for several years. While researchers have been able to get the printing system to mechanically work, the application of conductive inks on substrates has not consistently produced adequate low resistances in the kilohm range. Conductive materials can be applied using a printer in single or multiple passes onto a substrate including textiles, polymer films, and paper. The conductive materials are composed of electrical conductors such as carbon nanotubes (including functionalized carbon nanotubes and metal-coated carbon nanotubes); graphene, a polycyclic aromatic hydrocarbon (e.g., pentacene and bisperipentacene); metal nanoparticles; inherently conductive polymers (ICP); and combinations thereof. Once the conductive materials are applied, the materials are dried and sintered to form adherent conductive materials on the substrate. For certain formulations, increased conductivity can be achieved by printing on substrates supported by low levels of magnetic field alignment. The adherent conductive materials can be used in applications such as damage detection, dust particle removal, smart coating systems, and flexible electronic circuitry. By applying alternating layers of different electrical conductors to form a layered composite material, a single homogeneous layer can be produced with improved electrical properties. It is believed that patterning alternate layers of different conductors may improve electrical pathways through alignment of the conductors and band gap optimization. One feature of this innovation is that flexible conductive traces could be accomplished with a conductive ink having a surface resistivity of less than 10 ohms/square. Another result was that a composite material comprising a mixture of carbon nanotubes and metallic nanoparticles could be applied by inkjet printing to flexible substrates, and the resulting applied material was one to two orders of magnitude more conductive than a material made by printing inks containing carbon nanotubes alone.

Roberson, Luke↗

NASA NTRS2003

Three-Dimensional Venturi Sensor for Measuring Extreme Winds

A three-dimensional (3D) Venturi sensor is being developed as a compact, rugged means of measuring wind vectors having magnitudes of as much as 300 mph (134 m/s). This sensor also incorporates auxiliary sensors for measuring temperature from -40 to +120 F (-40 to +49 C), relative humidity from 0 to 100 percent, and atmospheric pressure from 846 to 1,084 millibar (85 to 108 kPa). Conventional cup-and-vane anemometers are highly susceptible to damage by both high wind forces and debris, due to their moving parts and large profiles. In addition, they exhibit slow recovery times contributing to an inaccurately high average-speed reading. Ultrasonic and hot-wire anemometers overcome some of the disadvantages of the cup and-vane anemometers, but they have other disadvantageous features, including limited dynamic range and susceptibility to errors caused by external acoustic noise and rain. In contrast, the novel 3D Venturi sensor is less vulnerable to wind damage because of its smaller profile and ruggedness. Since the sensor has no moving parts, it provides increased reliability and lower maintenance costs. It has faster response and recovery times to changing wind conditions than traditional systems. In addition, it offers wide dynamic range and is expected to be relatively insensitive to rain and acoustic energy. The Venturi effect in this sensor is achieved by the mirrored double-inflection curve, which is then rotated 360 to create the desired detection surfaces. The curve is optimized to provide a good balance of pressure difference between sensor ports and overall maximum fluid velocity while in the shape. Four posts are used to separate the two shapes, and their size and location were chosen to minimize effects on the pressure measurements. The 3D Venturi sensor has smart software algorithms to map the wind pressure exerted on the surfaces of the design. Using Bernoulli's equation, the speed of the wind is calculated from the differences among the pressure readings at the various ports. The direction of the wind is calculated from the spatial distribution and magnitude of the pressure readings. All of the pressure port sizes and locations have been optimized to minimize measurement errors and to reside in areas demonstrating a stable pressure reading proportional to the velocity range.

Zysko, Jan A.↗