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NASA NTRS2009

Technology Transfer Challenges: A Case Study of User-Centered Design in NASA's Systems Engineering Culture

The Upper Stage (US) section of the National Aeronautics and Space Administration's (NASA) Ares I rocket will require internal access platforms for maintenance tasks performed by humans inside the vehicle. Tasks will occur during expensive critical path operations at Kennedy Space Center (KSC) including vehicle stacking and launch preparation activities. Platforms must be translated through a small human access hatch, installed in an enclosed worksite environment, support the weight of ground operators and be removed before flight - and their design must minimize additional vehicle mass at attachment points. This paper describes the application of a user-centered conceptual design process and the unique challenges encountered within NASA's systems engineering culture focused on requirements and "heritage hardware". The NASA design team at Marshall Space Flight Center (MSFC) initiated the user-centered design process by studying heritage internal access kits and proposing new design concepts during brainstorming sessions. Simultaneously, they partnered with the Technology Transfer/Innovative Partnerships Program to research inflatable structures and dynamic scaffolding solutions that could enable ground operator access. While this creative, technology-oriented exploration was encouraged by upper management, some design stakeholders consistently opposed ideas utilizing novel, untested equipment. Subsequent collaboration with an engineering consulting firm improved the technical credibility of several options, however, there was continued resistance from team members focused on meeting system requirements with pre-certified hardware. After a six-month idea-generating phase, an intensive six-week effort produced viable design concepts that justified additional vehicle mass while optimizing the human factors of platform installation and use. Although these selected final concepts closely resemble heritage internal access platforms, challenges from the application of the user-centered process provided valuable lessons for improving future collaborative conceptual design efforts.

Quick, Jason↗

NASA NTRSDate not supplied

Multidisciplinary Design Optimization of Low-Boom Supersonic Aircraft with Mission Constraints

Design of low-boom supersonic aircraft is heavily dictated by aircraft volume and lift distributions. These unique design characteristics make it a challenge to enforce mission requirements (such as static margins and trim requirements) during design optimization. This low-boom design challenge is resolved by using reversed equivalent area targets for low-fidelity low-boom design and a decomposition method for multidisciplinary design optimization(MDO).The corresponding low-boom MDO problem includes aircraft mission constraints for cruise ranges, cruise speeds, trim margin for low-boom cruise, static margins for takeoff/cruise/landing, tail rotation angles for trim at takeoff/landing, takeoff/landing field lengths, and approach velocity, as well as volume constraints for cabin and main landing gear packaging. The decomposition method is developed to optimally resolve the conflicts between the low-boom design objective and other design constraints. The decomposition method is successfully applied to design a low-boom supersonic configuration that carries 40 passengers, has low-boom cruise of Mach 1.6 with range ≥ 2,500 nm, and can also cruise at Mach 1.8 with range ≥ 3,600 nm. The generated configuration satisfies all specified mission constraints and has the potential to achieve a low-boom ground noise level below 75 PLdB.

Wu Li↗

NASA NTRS2013

NASA's Space Launch System: Moving Toward the Launch Pad

The National Aeronautics and Space Administration's (NASA's) Space Launch System (SLS) Program, managed at the Marshall Space Flight Center, is making progress toward delivering a new capability for human space flight and scientific missions beyond Earth orbit. Developed with the goals of safety, affordability, and sustainability in mind, the SLS rocket will launch the Orion Multi-Purpose Crew Vehicle (MPCV), equipment, supplies, and major science missions for exploration and discovery. Supporting Orion's first autonomous flight to lunar orbit and back in 2017 and its first crewed flight in 2021, the SLS will evolve into the most powerful launch vehicle ever flown, via an upgrade approach that will provide building blocks for future space exploration and development. NASA is working to develop this new capability in an austere economic climate, a fact which has inspired the SLS team to find innovative solutions to the challenges of designing, developing, fielding, and operating the largest rocket in history. This paper will summarize the planned capabilities of the vehicle, the progress the SLS program has made in the 2 years since the Agency formally announced its architecture in September 2011, and the path the program is following to reach the launch pad in 2017 and then to evolve the 70 metric ton (t) initial lift capability to 130-t lift capability. The paper will explain how, to meet the challenge of a flat funding curve, an architecture was chosen which combines the use and enhancement of legacy systems and technology with strategic new development projects that will evolve the capabilities of the launch vehicle. This approach reduces the time and cost of delivering the initial 70 t Block 1 vehicle, and reduces the number of parallel development investments required to deliver the evolved version of the vehicle. The paper will outline the milestones the program has already reached, from developmental milestones such as the manufacture of the first flight hardware and the record-breaking testing of the J-2X engine, to life-cycle milestones such as the vehicle's Preliminary Design Review. The paper will also discuss the remaining challenges in both delivering the 70 t vehicle and in evolving its capabilities to the 130 t vehicle, and how the program plans to accomplish these goals. As this paper will explain, SLS is making measurable progress toward becoming a global infrastructure asset for robotic and human scouts of all nations by harnessing business and technological innovations to deliver sustainable solutions for space exploration

Creech, Stephen D.↗

NASA NTRS1998

Field Guide for Designing Human Interaction with Intelligent Systems

The characteristics of this Field Guide approach address the problems of designing innovative software to support user tasks. The requirements for novel software are difficult to specify a priori, because there is not sufficient understanding of how the users' tasks should be supported, and there are not obvious pre-existing design solutions. When the design team is in unfamiliar territory, care must be taken to avoid rushing into detailed design, requirements specification, or implementation of the wrong product. The challenge is to get the right design and requirements in an efficient, cost-effective manner. This document's purpose is to describe the methods we are using to design human interactions with intelligent systems which support Space Shuttle flight controllers in the Mission Control Center at NASA/Johnson Space Center. Although these software systems usually have some intelligent features, the design challenges arise primarily from the innovation needed in the software design. While these methods are tailored to our specific context, they should be extensible, and helpful to designers of human interaction with other types of automated systems. We review the unique features of this context so that you can determine how to apply these methods to your project Throughout this Field Guide, goals of the design methods are discussed. This should help designers understand how a specific method might need to be adapted to the project at hand.

Malin, Jane T.↗

NASA NTRS2002

An Automated Method to Compute Orbital Re-entry Trajectories with Heating Constraints

Determining how to properly manipulate the controls of a re-entering re-usable launch vehicle (RLV) so that it is able to safely return to Earth and land involves the solution of a two-point boundary value problem (TPBVP). This problem, which can be quite difficult, is traditionally solved on the ground prior to flight. If necessary, a nearly unlimited amount of time is available to find the 'best' solution using a variety of trajectory design and optimization tools. The role of entry guidance during flight is to follow the pre- determined reference solution while correcting for any errors encountered along the way. This guidance method is both highly reliable and very efficient in terms of onboard computer resources. There is a growing interest in a style of entry guidance that places the responsibility of solving the TPBVP in the actual entry guidance flight software. Here there is very limited computer time. The powerful, but finicky, mathematical tools used by trajectory designers on the ground cannot in general be converted to do the job. Non-convergence or slow convergence can result in disaster. The challenges of designing such an algorithm are numerous and difficult. Yet the payoff (in the form of decreased operational costs and increased safety) can be substantiaL This paper presents an algorithm that incorporates features of both types of guidance strategies. It takes an initial RLV orbital re-entry state and finds a trajectory that will safely transport the vehicle to Earth. During actual flight, the computed trajectory is used as the reference to be flown by a more traditional guidance method.

Zimmerman, Curtis↗

NASA NTRS2020

Multidisciplinary Design Optimization of Low-Boom Supersonic Aircraft with Mission Constraints

Conceptual design of low-boom supersonic aircraft is heavily dictated by aircraft volume and lift distributions. These unique design characteristics make it a challenge to enforce mission requirements (such as static margins and trim requirements) during design optimization. This low-boom design challenge is resolved by using reversed equivalent area targets for low-fidelity low-boom inverse design and a block coordinate optimization (BCO) method for multidisciplinary design optimization (MDO). The corresponding low-boom MDO problem includes aircraft mission constraints on ranges, cruise speeds, trim for low-boom cruise, static margins for takeoff/cruise/landing, takeoff/landing field lengths, approach velocity, and tail rotation angles for trim at takeoff/landing, as well as fuselage volume constraints for passengers and main gear storage. The BCO method is developed to optimally resolve the conflicts between the low-boom inverse design objective and other design constraints. This method is successfully applied to design a low-boom supersonic configuration that carries 40 passengers, flies a low-boom mission with cruise Mach of 1.6 and range of 2,500 nm, and cruises overwater at Mach 1.8 with range of 3,600 nm. The generated configuration satisfies all specified mission constraints and has the potential to match a reversed equivalent area target with ground noise level below 70 PLdB.

Multidisciplinary design optimization↗

NASA NTRS1997

Development and Operation of a Material Identification and Discrimination Imaging Spectroradiometer

Many imaging applications require quantitative determination of a scene's spectral radiance. This paper describes a new system capable of real-time spectroradiometric imagery. Operating at a full-spectrum update rate of 30Hz, this imager is capable of collecting a 30 point spectrum from each of three imaging heads: the first operates from 400 nm to 950 nm, with a 2% bandwidth; the second operates from 1.5 micro-m to 5.5 micro-m with a 1.5% bandwidth; the third operates from 5 micro-m to 12 micro-m, also at a 1.5% bandwidth. Standard image format is 256 x 256, with 512 x 512 possible in the VIS/NIR head. Spectra of up to 256 points are available at proportionately lower frame rates. In order to make such a tremendous amount of data more manageable, internal processing electronics perform four important operations on the spectral imagery data in real-time. First, all data in the spatial/spectral cube of data is spectro-radiometrically calibrated as it is collected. Second, to allow the imager to simulate sensors with arbitrary spectral response, any set of three spectral response functions may be loaded into the imager including delta functions to allow single wavelength viewing; the instrument then evaluates the integral of the product of the scene spectral radiances and the response function. Third, more powerful exploitation of the gathered spectral radiances can be effected by application of various spectral-matched filtering algorithms to identify pixels whose relative spectral radiance distribution matches a sought-after spectral radiance distribution, allowing materials-based identification and discrimination. Fourth, the instrument allows determination of spectral reflectance, surface temperature, and spectral emissivity, also in real-time. The spectral imaging technique used in the instrument allows tailoring of the frame rate and/or the spectral bandwidth to suit the scene radiance levels, i.e., frame rate can be reduced, or bandwidth increased to improve SNR when viewing low radiance scenes. The unique challenges of design and calibration are described. Pixel readout rates of 160 MHz, for full frame readout rates of 1000 Hz (512 x 512 image) present the first challenge; processing rates of nearly 600 million integer operations per second for sensor emulation, or over 2 billion per second for matched filtering, present the second. Spatial and spectral calibration of 66,536 pixels (262,144 for the 512 x 512 version) and up to 1,000 spectral positions mandate novel decoupling methods to keep the required calibration memory to a reasonable size. Large radiometric dynamic range also requires care to maintain precision operation with minimum memory size.

Dombrowski, Mark↗

NASA NTRS2016

Optimization of NTP System Truss to Reduce Radiation Shield Mass

The benefits of nuclear thermal propulsion are numerous and relevant to the current NASA mission goals involving but not limited to the crewed missions to mars and the moon. They do however also present new and unique challenges to the design and logistics of launching/operating spacecraft. One of these challenges, relevant to this discussion, is the significant mass of the shielding which is required to ensure an acceptable radiation environment for the spacecraft and crew. Efforts to reduce shielding mass are difficult to accomplish from material and geometric design points of the shield itself, however by increasing the distance between the nuclear engines and the main body of the spacecraft the required mass of the shielding is lessened considerably. The mass can be reduced significantly per unit length, though any additional mass added by the structure to create this distance serves to offset those savings, thus the design of a lightweight structure is ideal. The challenges of designing the truss are bounded by several limiting factors including; the loading conditions, the capabilities of the launch vehicle, and achieving the ideal truss length when factoring for the overall mass reduced. Determining the overall set of mass values for a truss of varying length is difficult since to maintain an optimally designed truss the geometry of the truss or its members must change. Thus the relation between truss mass and length for these loading scenarios is not linear, and instead has relation determined by the truss design. In order to establish a mass versus length trend for various truss designs to compare with the mass saved from the shield versus length, optimization software was used to find optimal geometric properties that still met the design requirements at established lengths. By solving for optimal designs at various lengths, mass trends could be determined. The initial design findings show a clear benefit to extending the engines as far from the main structure of the spacecraft as the launch vehicle's payload volume would allow when comparing mass savings verse the additional structure.

Scharber, Luke L.↗

DOE OSTI2022

Challenge Problem 1: Preliminary Model Development and Assessment of Flexible Heat Transfer Modeling Approaches

This report presents the modeling progress of a university consortium studying flexible modeling for turbulent heat transfer. In the context of advanced nuclear reactor design, where challenges include non-unity Prandtl fluids, free and mixed convection, and transitional flow, computational fluid dynamics methods are underutilized due to low confidence in modeling approaches and high computational cost. This report evaluates the performance of engineering CFD models in diabatic, buoyant turbulent flow. It finds that all turbulence models including several variants of the k-ε and k-ω models struggle to predict accurate turbulent momentum and heat transfer in such flows. The Nusselt numbers have been compared between the models and the DNS data, where calculations have been performed for each case and trends have shown a good agreement between DNS estimated Nusselt numbers and available correlations as well as experimental data. A novel DNS correlation for high Pr cases as they are transitioning from mixed convection to natural convection has been proposed. While Nusselt number errors relative to DNS range from 20% to 50%, the models capture similar trends to DNS with respect to Nusselt suppression and amplification under varying levels of buoyancy effect. This report also highlights model form error as a significant contributor to CFD predictions and proposes a framework for quantifying model error and improving confidence in CFD calculations. To improve the predictive capability of engineering CFD models, data-driven approaches for turbulence models are investigated. Theoretical frameworks based on the invariant tensor / vector basis neural networks for prediction of Reynolds stresses and turbulent heat fluxes are employed. The models are developed using direct numerical simulations data for forced convection flows of different fluids in vertical planar channel domain. The framework is implemented in spectral element solvers Nek5000 / nekRS and has shown a potential for future development and consideration of mixed convection flows.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2026

Study the Protection Improvements for a Weak Grid Area With High IBRs

NLR is collaborating with Florida Power & Light (FPL) and GE to investigate power system stability and protection reliability challenges in a weak-grid region with high penetration of inverter-based resources (IBRs). This presentation will primarily focus on the protection aspects of the study. We will share key insights from this real-world project, including best practices for developing high-fidelity fault study models, establishing a controller-hardware-in-the-loop (CHIL) platform for testing physical relays, identifying system-level protection challenges, and designing enhanced protection schemes to address those issues. Through this discussion, the audience will gain practical understanding of protection studies in IBR-dominated systems, the emerging challenges associated with reduced fault current and altered transient behavior, and effective mitigation strategies. In particular, we will highlight the critical importance of IBR compliance with IEEE 2800-2022 to ensure dependable and secure protection relay operation in modern transmission systems.

24 POWER TRANSMISSION AND DISTRIBUTION↗

NASA NTRS2023

The Design of the Low-Earth Orbit Flight Test of an Inflatable Decelerator (LOFTID) Reentry Vehicle (RV)

This discussion will involve the design and architecture of the Low-Earth Orbit Flight Test of an Inflatable Decelerator (LOFTID) Reentry Vehicle (RV). It will describe the structure and modular design of the RV, expounding on its various subsystems, including power and commanding, data handling and recovery, instrumentation, the inflation system, and the aeroshell. The unique launch vehicle architecture for the LOFTID mission, as a massive rideshare payload, required the development of supporting flight systems, including the Payload Adapter Separation System (PASS) and the Reentry Vehicle Payload Adapter Interface Ring (RVPAIR). To do no harm to the primary mission, the LOFTID team also designed and delivered a flightworthy Mass Simulator as risk reduction in the event the RV was not ready in time for the primary mission launch date. Various challenges and design trades will be discussed, along with a brief description of the RV performance in flight.

R J Bodkin↗

NASA NTRSDate not supplied

The Design of the Low-Earth Orbit Flight Test of an Inflatable Decelerator (LOFTID) Reentry Vehicle (RV)

R J Bodkin↗

NASA NTRS1990

Lunar astronomical observatories - Design studies

The best location in the inner solar system for the grand observatories of the 21st century may be the moon. A multidisciplinary team including university students and faculty in engineering, astronomy, physics, and geology, and engineers from industry is investigating the moon as a site for astronomical observatories and is doing conceptual and preliminary designs for these future observatories. Studies encompass lunar facilities for radio astronomy and astronomy at optical, ultraviolet, and infrared wavelengths of the electromagnetic spectrum. Although there are significant engineering challenges in design and construction on the moon, the rewards for astronomy can be great, such as detection and study of earth-like planets orbiting nearby stars, and the task for engineers promises to stimulate advances in analysis and design, materials and structures, automation and robotics, foundations, and controls. Fabricating structures in the reduced-gravity environment of the moon will be easier than in the zero-gravity environment of earth orbit, as Apollo and space-shuttle missions have revealed. Construction of observatories on the moon can be adapted from techniques developed on the earth, with the advantage that the moon's weaker gravitational pull makes it possible to build larger devices than are practical on earth.

Johnson, Stewart W.↗

DOE OSTI2020

The CLAS12 superconducting magnets

As part of the Jefferson Lab 12 GeV upgrade, the Hall B CLAS12 system requires two superconducting iron-free magnets — a torus and a solenoid. The physics requirements to maximize space for the detectors guided engineers toward particular coil designs for each of the magnets which, in turn, led to the choice of using conduction cooling. The torus consists of 6 trapezoidal NbTi coils connected in series with an operating current of 3770 A. The solenoid is an actively shielded 5 T magnet consisting of 5 NbTi coils connected in series operating at 2416 A. Within the hall, the two magnets are located in close proximity to each other and are completely covered both inside and outside by particle detectors. Stringent size limitations were imposed for both magnets and introduced particular design and fabrication challenges. This paper describes the design, construction, installation, commissioning, and operation of the two magnets.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

NASA NTRS1982

AGT100 turbomachinery

High-performance turbomachinery components have been designed and tested for the AGT100 automotive engine. The required wide range of operation coupled with the small component size, compact packaging, and low cost of production provide significant aerodynamic challenges. Aerodynamic design and development testing of the centrifugal compressor and two radial turbines are described. The compressor achieved design flow, pressure ratio, and surge margin on the initial build. Variable inlet guide vanes have proven effective in modulating flow capacity and in improving part-speed efficiency. With optimum use of the variable inlet guide vanes, the initial efficiency goals have been demonstrated in the critical idle-to-70% gasifier speed range. The gasifier turbine exceeded initial performance goals and demonstrated good performance over a wide range. The radial power turbine achieved 'developed' efficiency goals on the first build.

Tipton, D. L.↗

NASA NTRS1999

Experiments on Evolving Software Models of Analog Circuits

Analog circuits are of great importance in electronic system design since the world is fundamentally analog in nature. While the amount of digital design activity far outpaces that of analog design, most digital systems require analog modules for interfacing with the external world. It was recently estimated that approximately 60% of digital application- specific integrated circuit designs incorporated analog circuits. With challenging analog circuit design problems and few analog design engineers, there are economic reasons for automating the analog design process, especially time-to-market considerations. Techniques for analog circuit design automation began appearing about two decades ago. These methods incorporated heuristics [6], knowledge bases [1], simulated annealing [5], and other algorithms. Efforts using techniques from evolutionary computation began appearing over the last few years. These include the use of genetic algorithms to select electronic component values (for example, the resistance value of a resistor), to select circuit topologies, and to design amplifiers using a limited set of canned topologies [4]. A genetic programming-based analog circuit design system has been demonstrated in which the circuit sizes, component values, and the circuit topologies are determined automatically [3]. The genetic-algorithm systems typically represent circuit structures as vectors of parameters encoded in binary strings, while the genetic programming system manipulates tree data structures.

Lohn, Jason D.↗

NASA NTRSDate not supplied

Development of Thermal Control Devices for Extreme Lunar Environments at Marshall Space Flight Center

NASA’s return to the moon brings many challenges, including issues with sustainable survival on the Lunar surface. One of the key challenges with sustainability is designing adequate thermal control systems that allow for surface systems to survive both during the day and the Lunar Night. The extreme thermal environments on the Lunar surface are a challenging design space for thermal engineers. At equatorial regions, the Lunar noon can be very hot, requiring systems with high heat rejection to the environment. At polar regions, such as those targeted by the return to the moon, the Lunar night temperatures plummet to -200 degrees Celsius or lower. Such temperatures are formidable and require specialized thermal control systems to allow surface assets to surface the long night.

Will Johnson↗

DOE OSTI2020

Utilizing Commercial Submersible Mixer Pumps for Sludge Removal in Savannah River Site's Tank 26 - 20289

The Savannah River Site (SRS) Liquid Waste System (LWS) safely manages, stores, treats, and dispositions liquid radioactive waste. The LWS consists of 51 underground waste storage tanks (eight of which are operationally closed and filled with grout), waste evaporators, treatment facilities, and solidification facilities, known as the Defense Waste Processing Facility (DWPF) and Saltstone Production Facility (SPF). One of the waste storage tanks, Tank 26, was placed into service in 1980 as an F Tank Farm (FTF) Evaporator Feed Tank. From 1980 to 2013, Tank 26 received F Canyon receipts and dilute supernate that was then transferred to the 242-16F FTF Evaporator for volume reduction. In 2013, the steam tube bundle failed in the FTF Evaporator, and the decision was made not to repair/resume evaporator operation. During operation of Tank 26, solids built up to a level of 2.03 m in the tank with a volume of 1062.9 kL. Due to the evaporator failure and subsequent shutdown, the solids in Tank 26 were selected to feed Sludge Batch 10, which is collected and prepped prior to being sent to DWPF for final disposition. To accomplish solids removal, Commercial Submersible Mixer Pumps (CSMPs) were selected to slurry the solids in preparation to be sent to Tank 51. Four CSMPs were installed in Tank 26 with each one installed in a separate quadrant of Tank 26. This work would mark the first deployment of CSMPs in an SRS waste tank. The CSMPs were developed in response to operational issues from previous mixing pumps and budgetary constraints. The CSMPs use the concept of modifying commercially available equipment for nuclear waste applications. The CSMPs consist of a 230-horsepower submersible mixing pump (manufactured by GPM, Inc.) joined to a mast fabricated at SRS. For this application, Savannah River Remediation (SRR) design services was challenged to provide a mast design that required no steel superstructure support system on top of Tank 26. Also, SRR design services provided a simplified Tank 26 riser interface that did not require extensive machine parts to adjust height of the suction screen of the CSMP within the tank. Other design improvements include no requirements for tank top radiation monitors and no requirements for flushing of the CSMPs during startup/shutdown operations. The CSMPs were operated at an initial height of 2.29 m above the Tank 26 bottom for 10 days. After sludge sounding, the CSMPs were lowered to a height of 1.52 m with no issues due to proper work planning and the simplified riser interface. With the CSMPs lowered to a level of 1.52 meters above the tank bottom, the CSMPs were operated for 12 days and another sounding was performed. The sounding level came back matching the disturbance depth results of the first pump run. Chemistry samples were analyzed while the tank was left to settle. The analysis revealed enough weight percent solids to provide good feed to Sludge Batch 10. Also, the results revealed the supernate within the mixture would provide good salt solution feed to Salt Waste Processing Facility (SWPF) Salt Batch 3. So, the plan was modified to let the disturbed solids settle and decant the salt solution for addition to SWPF Salt Batch 3. Then water will be added back to Tank 26, and the CSMPs run in order to wash the solids to decrease settling time prior to being sent to Tank 51 for Sludge Batch 10. Utilizing CSMPs for waste removal in an SRS Tank has provided a cost-effective means for further waste removal efforts. In addition, the CSMPs are easier to operate by utilizing a robust and simplified design. The CSMPs performed quite well with no process shutdown or delays during operation. As a result, CSMPs are integral to the future of removing radioactive waste from storage tanks at SRS. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗