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NASA NTRS2016

Design and Development of a Methane Cryogenic Propulsion Stage for Human Mars Exploration

NASA is currently working on the Evolvabe Mars Campaign (EMC) study to outline transportation and mission options for human exploration of Mars. One of the key aspects of the EMC is leveraging current and planned near-term technology investments to build an affordable and evolvable approach to Mars exploration. This leveraging of investments includes the use of high-power Solar Electric Propulsion (SEP) systems, evolved from those currently under development in support of the Asteroid Redirect Mission (ARM), to deliver payloads to Mars. The EMC is considering several transportation options that combine solar electric and chemical propulsion technologies to deliver crew and cargo to Mars. In one primary architecture option, the SEP propulsion system is used to pre-deploy mission elements to Mars while a high-thrust chemical propulsion system is used to send crew on faster ballistic transfers between Earth and Mars. This high-thrust chemical system uses liquid oxygen - liquid methane main propulsion and reaction control systems integrated into the Methane Cryogenic Propulsion Stage (MCPS). Over the past year, there have been several studies completed to provide critical design and development information related to the MCPS. This paper is intended to provide a summary of these efforts. A summary of the current point of departure design for the MCPS is provided as well as an overview of the mission architecture and concept of operations that the MCPS is intended to support. To leverage the capabilities of solar electric propulsion to the greatest extent possible, the EMC architecture pre-deploys to Mars orbit the stages required for returning crew from Mars. While this changes the risk posture of the architecture, it can provide some mass savings by using higher-efficiency systems for interplanetary transfer. However, this does introduce significantly longer flight times to Mars which, in turn, increases the overall lifetime of the stages to as long as 2500 days. This unique aspect to the concept of operations introduces several challenges, specifically related to propellant storage and engine reliability. These challenges and some potential solutions are discussed. Specific focus is provided on two key technology areas; propulsion and cryogenic fluid management. In the area of propulsion development, the development of an integrated methane propulsion system that combines both main propulsion and reaction control is discussed. This includes an overview of potential development paths, areas where development for Mars applications are complementary to development efforts underway in other parts of the aerospace industry, and commonality between the MCPS methane propulsion applications and other Mars elements, including the Mars lander systems. This commonality is a key affordability aspect of the Evolvable Mars Campaign. A similar discussion is provided for cryogenic fluid management technologies including a discussion of how using cryo propulsion in the Mars transportation application not only provides performance benefits but also leverages decades of technology development investments made by NASA and its aerospace contractor community.

Percy, Thomas K.↗

NASA NTRS2017

Solidification and Morphological Evolution of Al-Si Eutectics in Convector-Diffusive Conditions

The Al-Si material system is an important and has been studied for over half century with a focus on industrial applications in high strength and high conductivity alloys. A great deal of researches have been focused on controlling the morphology and hence performance through the addition of small impurities and by processing conditions. Most of the structure-property correlations are based on the post solidified micromorphology and growth conditions. This material system is unique and has been explored for heat spreader, controlling coefficient of expansion by adjusting composition of silicon and in designing composites. The Al-Si system is very interesting system for understanding the dendritic (Al-rich side) eutectic transition. Recently this system has been of great interest because of its applications in designing heat spreader, low temperature flux to grow SiC large substrates and in controlling the coefficient of expansion of Al-based alloys. We have performed extensive experiments to understand eutectic transition and to understand the morphological evolution in presence of impurities. We will discuss the results of dendritic transition into faceted long grains in convector-diffusive conditions. In this presentation we will present morphological transition in presence of carbon impurity and development of novel morphology.

Singh, N. B.↗

DOE OSTI2023

Demonstrate FARM supervisory capabilities for a thermal energy storage problem for the DETAIL facility: IES Simulation Ecosystem Control System Development

The goal of the power dispatch problem for an Integrated Energy System (IES) is to adjust the power output and the heat flow of each component to maximize the profitability of the whole unit. Facilities that can integrate real-time digital signals, mock nuclear power, thermal energy storage and industrial heat use via high-temperature electrolysis were constructed at INL to support the research activities. The Dynamic Energy Technology and Integration Laboratory (DETAIL) houses the Microreactor Agile Non-nuclear Experimental Test Bed (MAGNET) and the Thermal Energy Distribution System (TEDS). In this report, the hierarchical control system architecture proposed in June 2023 milestone for the flexible operation of DETAIL facility is finalized and demonstrated. A brief description of the components and the corresponding Dymola models from the HYRBID repository is first provided. Then, the current control strategy is presented. In particular, the approach for generating the set-point trajectories to be fed to the PI controllers is analyzed, and its limits were identified. To preserve safe operation over both long-time and real-time horizons, the integration of a Supervisory Control layer embedding a modified version of FARM (Feasible Actuator Range Modifier) module is proposed. FARM is a component of the RAVEN-based FORCE framework designed to support HERON module at optimizing the operation of IES units. The proposed control system for DETAIL foresees FARM to be applied twice, i.e., the original version (“FARM-Validator”) aiding the solution of the power dispatch problem, and a modified version (“FARM-Supervisory”) coordinating the PID controllers. Despite the kernel of the two modules is the same, their tasks are quite different. The former intervenes at the beginning of each hour to prevent constraint violations over long time periods, the latter addresses real-time control tasks and monitors the response of constrained variables at a much finer time resolution. A tentative procedure for training the embedded Digital Twins with the experimental data is also proposed. Finally, the capabilities of the designed architecture and the impact of the added Supervisory Control layer are demonstrated by simulating a representative power dispatch scenario.

25 ENERGY STORAGE↗

NASA NTRS2008

Generating Safety-Critical PLC Code From a High-Level Application Software Specification

The benefits of automatic-application code generation are widely accepted within the software engineering community. These benefits include raised abstraction level of application programming, shorter product development time, lower maintenance costs, and increased code quality and consistency. Surprisingly, code generation concepts have not yet found wide acceptance and use in the field of programmable logic controller (PLC) software development. Software engineers at Kennedy Space Center recognized the need for PLC code generation while developing the new ground checkout and launch processing system, called the Launch Control System (LCS). Engineers developed a process and a prototype software tool that automatically translates a high-level representation or specification of application software into ladder logic that executes on a PLC. All the computer hardware in the LCS is planned to be commercial off the shelf (COTS), including industrial controllers or PLCs that are connected to the sensors and end items out in the field. Most of the software in LCS is also planned to be COTS, with only small adapter software modules that must be developed in order to interface between the various COTS software products. A domain-specific language (DSL) is a programming language designed to perform tasks and to solve problems in a particular domain, such as ground processing of launch vehicles. The LCS engineers created a DSL for developing test sequences of ground checkout and launch operations of future launch vehicle and spacecraft elements, and they are developing a tabular specification format that uses the DSL keywords and functions familiar to the ground and flight system users. The tabular specification format, or tabular spec, allows most ground and flight system users to document how the application software is intended to function and requires little or no software programming knowledge or experience. A small sample from a prototype tabular spec application is shown.

Source record↗

NASA NTRS2013

Helicopter Flight Test of a Compact, Real-Time 3-D Flash Lidar for Imaging Hazardous Terrain During Planetary Landing

A second generation, compact, real-time, air-cooled 3-D imaging Flash Lidar sensor system, developed from a number of cutting-edge components from industry and NASA, is lab characterized and helicopter flight tested under the Autonomous Precision Landing and Hazard Detection and Avoidance Technology (ALHAT) project. The ALHAT project is seeking to develop a guidance, navigation, and control (GN&C) and sensing system based on lidar technology capable of enabling safe, precise crewed or robotic landings in challenging terrain on planetary bodies under any ambient lighting conditions. The Flash Lidar incorporates a 3-D imaging video camera based on Indium-Gallium-Arsenide Avalanche Photo Diode and novel micro-electronic technology for a 128 x 128 pixel array operating at a video rate of 20 Hz, a high pulse-energy 1.06 μm Neodymium-doped: Yttrium Aluminum Garnet (Nd:YAG) laser, a remote laser safety termination system, high performance transmitter and receiver optics with one and five degrees field-of-view (FOV), enhanced onboard thermal control, as well as a compact and self-contained suite of support electronics housed in a single box and built around a PC-104 architecture to enable autonomous operations. The Flash Lidar was developed and then characterized at two NASA-Langley Research Center (LaRC) outdoor laser test range facilities both statically and dynamically, integrated with other ALHAT GN&C subsystems from partner organizations, and installed onto a Bell UH-1H Iroquois "Huey" helicopter at LaRC. The integrated system was flight tested at the NASA-Kennedy Space Center (KSC) on simulated lunar approach to a custom hazard field consisting of rocks, craters, hazardous slopes, and safe-sites near the Shuttle Landing Facility runway starting at slant ranges of 750 m. In order to evaluate different methods of achieving hazard detection, the lidar, in conjunction with the ALHAT hazard detection and GN&C system, operates in both a narrow 1deg FOV raster-scanning mode in which successive, gimbaled images of the hazard field are mosaicked together as well as in a wider, 4.85deg FOV staring mode in which digital magnification, via a novel 3-D superresolution technique, is used to effectively achieve the same spatial precision attained with the more narrow FOV optics. The lidar generates calibrated and corrected 3-D range images of the hazard field in real-time and passes them to the ALHAT Hazard Detection System (HDS) which stitches the images together to generate on-the-fly Digital Elevation Maps (DEM's) and identifies hazards and safe-landing sites which the ALHAT GN&C system can then use to guide the host vehicle to a safe landing on the selected site. Results indicate that, for the KSC hazard field, the lidar operational range extends from 100m to 1.35 km for a 30 degree line-of-sight angle and a range precision as low as 8 cm which permits hazards as small as 25 cm to be identified. Based on the Flash Lidar images, the HDS correctly found and reported safe sites in near-real-time during several of the flights. A follow-on field test, planned for 2013, seeks to complete the closing of the GN&C loop for fully-autonomous operations on-board the Morpheus robotic, rocket-powered, free-flyer test bed in which the ALHAT system would scan the KSC hazard field (which was vetted during the present testing) and command the vehicle to landing on one of the selected safe sites.

Roback, VIncent E.↗

DOE OSTI2023

Grid Optimization Competition on Synthetic and Industrial Power Systems

This paper summarizes a grid optimization (GO) competition effort in the United States to find the best solution strategies for up to interconnect-scale power system networks with around 32,000 buses. The optimization problem is a mixedinteger, non-convex non-linear problem, (MINLP) and includes discrete variables such as unit commitment and line switching, control settings (transformer taps and phase shifters with impedance correction tables), and bus shunts. The case study includes six actual industry grids as well as 16 realistic synthetic grids created by three different dataset teams. The winners are selected and ranked based on scoring criteria, which consider the solution quality (such as objective functions) within time limits. Nine winner teams are selected from 26 competitor teams. The results achieved by different teams are described and the performance of different algorithms on synthetic grids and actual industry grids are compared and analyzed.

mixed-integer non-linear programming↗

NASA NTRS1987

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.↗

NASA NTRS2015

Control and Non-Payload Communications (CNPC) Prototype Radio - Generation 2 Security Flight Test Report

NASA Glenn Research Center (GRC), in cooperation with Rockwell Collins, is working to develop a prototype Control and Non-Payload Communications (CNPC) radio platform as part of NASA Integrated Systems Research Program's (ISRP) Unmanned Aircraft Systems (UAS) Integration in the National Airspace System (NAS) project. A primary focus of the project is to work with the Federal Aviation Administration (FAA) and industry standards bodies to build and demonstrate a safe, secure, and efficient CNPC architecture that can be used by industry to evaluate the feasibility of deploying a system using these technologies in an operational capacity. GRC has been working in conjunction with these groups to assess threats, identify security requirements, and to develop a system of standards-based security controls that can be applied to the GRC prototype CNPC architecture as a demonstration platform. The proposed security controls were integrated into the GRC flight test system aboard our S-3B Viking surrogate aircraft and several network tests were conducted during a flight on November 15th, 2014 to determine whether the controls were working properly within the flight environment. The flight test was also the first to integrate Robust Header Compression (ROHC) as a means of reducing the additional overhead introduced by the security controls and Mobile IPv6. The effort demonstrated the complete end-to-end secure CNPC link in a relevant flight environment.

Communication Networks↗

NASA NTRS1996

The Design, Planning and Control of Robotic Systems in Space

Dubowsky, Steven↗

NASA NTRS1996

The Design, Planning and Control of Robotic Systems in Space

In the future, robotic systems will be expected to perform important tasks in space, in orbit and in planetary exploration. In orbit, current technology requires that tasks such as the repair, construction and maintenance of space stations and satellites be performed by astronaut Extra Vehicular Activity (EVA). Eliminating, the need for astronaut EVA through the use of space manipulators would greatly reduce both mission costs and hazards to astronauts. In planetary exploration, cost and logistical considerations clearly make the use of autonomous and telerobotic systems also very attractive, even in cases where an astronaut explorer might be in the area. However, such applications introduce a number of technical problems not found in conventional earth-bound industrial robots. To design useful and practical systems to meet the needs of future space missions, substantial technical development is required, including in the areas of the design, control and planning. The objectives of this research program were to develop such design paradigms and control and planning algorithms to enable future space robotic systems to meet their proposed mission objectives. The underlying intellectual focus of the program is to construct a set of integrated design, planning and control techniques based on an understanding of the fundamental mechanics of space robotic systems. This work was to build upon the results obtained in our previous research in this area supported by NASA Langley Research Center in which we have made important contributions to the area of space robotics. This program was proposed and accepted as a three year research program, a period of time necessary to make the type of fundamental developments to make a significant contributions to space robotics. Unfortunately, less than a year into the program it became clear that the NASA Langley Research Center would be forced by budgetary constraints to essentially leave this area of research. As a result, the total funding we received under this grant represented approximately one year of the original, proposed and approved, funding. For some time, there was substantial uncertainty that even this very reduced level of funding would be provided. The spending of the reduced available funds was spread just over two years to provide the support to permit the MS students who had joined the program to receive their master's degree and terminate their studies in this area.

Dubowsky, Steven↗

NASA NTRS1989

On discrete control of nonlinear systems with applications to robotics

Much progress has been reported in the areas of modeling and control of nonlinear dynamic systems in a continuous-time framework. From implementation point of view, however, it is essential to study these nonlinear systems directly in a discrete setting that is amenable for interfacing with digital computers. But to develop discrete models and discrete controllers for a nonlinear system such as robot is a nontrivial task. Robot is also inherently a variable-inertia dynamic system involving additional complications. Not only the computer-oriented models of these systems must satisfy the usual requirements for such models, but these must also be compatible with the inherent capabilities of computers and must preserve the fundamental physical characteristics of continuous-time systems such as the conservation of energy and/or momentum. Preliminary issues regarding discrete systems in general and discrete models of a typical industrial robot that is developed with full consideration of the principle of conservation of energy are presented. Some research on the pertinent tactile information processing is reviewed. Finally, system control methods and how to integrate these issues in order to complete the task of discrete control of a robot manipulator are also reviewed.

Eslami, Mansour↗

DOE OSTI2020

PRIME: a real-time cyber-physical systems testbed: from wide-area monitoring, protection, and control prototyping to operator training and beyond

As the power grid continues to evolve with advanced wide-area monitoring, protection, and control (WAMPAC) algorithms, there is an increasing need for realistic testbed environments with industry-grade software and hardware-in-the-loop (HIL) to perform verification and validation studies. Such testbed environments serve as ideal platforms to perform WAMPAC prototyping, operator training, and also to study the impacts of different types of cyberattack scenarios on the operation of the grid. In this paper, we introduce PRIME (PNNL cybeR physIcal systeMs tEstbed): the testbed that integrates real-time transmission system simulator with commercial industry grade energy management system (EMS) software and remote hardware-in-the-loop (RHIL). PRIME is an end-to-end, modular testbed that allows high-fidelity RHIL experimentation of a power system. We present two detailed case studies (fault location and clearing in transmission system, and operator training) to showcase the capabilities of our PRIME testbed. Finally, we briefly discuss some of the potential limitations of our testbed in terms of scalability and flexibility to setup larger test systems and identify directions for future work to address those limitations.

42 ENGINEERING↗

DOE OSTI2025

Demonstration of and future perspective on scaling ultrafast-laser-ablation microstructuring of Li-ion battery electrodes to roll-to-roll production and large-format cells

This work demonstrates integration of an ultrafast laser onto a roll-to-roll machine, the laser structuring of a double-sided, 700 m long roll of graphite battery anode and its subsequent manufacture into 27 Ah prismatic cells. The electrode was ablated with a novel hybrid-microstructure composed of both hexagonally arranged pores for enhanced rate performance and channels for fast electrolyte wetting. Subsequently, this anode and a non-ablated baseline anode are paired with an NMC111 cathode for cell building and electrochemical characterization. Compared to the baseline, laser ablated cells demonstrated a reduction in soaking time of at least 60%, an improvement in fast charge capability with >30% more capacity accepted during 6C charging, and an extension of cycle life of >40% during 0.5C cycling. Further, a perspective is provided on scaling ultrafast laser ablation of battery electrodes to industrial throughputs. Additionally, lessons learned from this pilot-scale demonstration are provided in regards to optical architecture, debris removal, and system control. A techno-economic analysis is used to demonstrate that laser ablation can be integrated into existing electrode manufacturing facilities with only ≈$\$$1.3 per kWh increase (≈2%) in manufacturing cost. Preemptive electrode design for laser ablation is discussed as a further method for enhancing performance. Finally, an analysis of available laser systems and beam-scanning architectures is used to determine design requirements to scale process throughput to a state-of-the-art speed of 50 m min −1 . This analysis demonstrates that laser ablating Li-ion battery electrodes has multiple benefits to manufacturing and battery performance, that the technology already exists to achieve high laser-ablation throughputs, and that integrating ultrafast laser ablation to electrode manufacturing will not create a cost or processing bottleneck.

25 ENERGY STORAGE↗

DOE OSTI2024

Concept Study of Robotic Camera-Based Foreign Object Detection for EV Wireless Charging

Wireless charging of an electric vehicle (EV) is an emerging charging technology promising convenient, autonomous, and highly efficient EV charging without requiring heavy gauge cables. However, due to the strong electromagnetic field created by this process that surrounds the wireless charger, the presence of foreign objects can detrimentally interact with it, thus affecting wireless power transfer (WPT) performance or leading to harmful and unwanted safety risks. This paper presents the results for a concept study on a robotic camera-based foreign object detection (FOD) system, as a supplement to the industry-existing overlapped FOD coil array method, for EV wireless charging. A Raspberry PI 4 control board and compatible Raspberry PI Camera Module 2 are used to implement camera-based object detection. The FOD program was developed using a state-of-the-art deep learning object detection model with the OpenCV and Pytorch library and is compatible with camera module hardware. A dry-run test with Raspberry PI and a camera module was conducted and the preliminary FOD function was verified. The feasibility assessment is also validated by comparing the performance of five existing state-of-the-art deep learning object detection models for vehicles, animals, persons, and metals subsets, respectively. Satisfactory performance on the benchmark datasets is observed by the tests, but further improvements are needed in future work when detecting small-sized metallic objects. A programable robotic car is also under development as ongoing work for carrying the Raspberry PI and camera module while moving for the maintenance process.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2020

Recommended Functionalities for Improving Cybersecurity of Distributed Energy Resources

The current electric grid is transitioning through increasing penetration of distributed energy resources (DERs), which include intermittent renewable generation resources on the distribution side. Both the monitoring and control of DERs require extensive data-exchange and communication networks. These networks lead to cyber vulnerabilities and risks of new kinds of cyberattacks that may be extremely destructive for power system operations. Although current standards, such as IEEE Std. 1547-2018, do not discuss cybersecurity measures for DERs, cybersecurity controls should be developed for securing DER systems at the device level, communications level, and applications level. This paper discusses the current industry's best practices related to DER cybersecurity and proposes recommended functionalities for improving the cybersecurity posture of DERs, specifically at the device/distribution level. These practical recommendations have been discussed and verified with the industry through a DER cybersecurity working group.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2021

Optics-on-a-chip for ultrafast manipulation of 350-MHz hard x-ray pulses

Microelectromechanical systems (MEMS) are miniature devices integrated into a vast range of industrial and consumer applications. Optical MEMS are developed for dynamic spatiotemporal control in lightwave manipulation and communication as modulators, switches, multiplexers, spectrometer, etc. However, they have not been shown to function similarly in sub-nm wavelength regimes, namely, with hard x-rays, as high-brilliance pulsed x-rays have proven powerful for addressing challenges in time-domain science, from energy conversion to neurobiological control. While desirable temporal properties of x-ray pulses can be enhanced by optics, conventional x-ray optics are inherently massive in size, hence, never dynamic. We demonstrate highly ultrafast x-ray optics-on-a-chip based on MEMS capable of modulating hard x-ray pulses exceeding 350 MHz, 10 3 × higher than any other mechanical modulator, with a pulse purity >10 6 without compromising the spectral brilliance. Moreover, the timing characteristics of the devices can be tuned on-the-fly to deliver optimal pulse properties to create a host of dynamic x-ray instruments and applications, impossible with traditional optics of 10 9 × bulkier and more massive. The advent of the ultrafast optics-on-a-chip heralds a new paradigm of x-ray photonics, time-domain science, and accelerator diagnostics, especially at not only the future-generation light sources that offer coherent and high-frequency pulses but also lab-based facilities that normally do not offer timing structures.

42 ENGINEERING↗

DOE OSTI2022

Enhanced Component Performance Study: Air-Operated Valves 1998–2020

This report presents an enhanced performance evaluation of air-operated valves (AOVs) at U.S. commercial nuclear power plants. The data used in this study are based on the operating experience failure reports from calendar year 1998 through 2020 as reported in the Institute of Nuclear Power Operations (INPO) Industry Reporting and Information System (IRIS). The AOV failure modes considered are failure-to-open/close (FTOC), failure to operate or control (FTOP), and spurious operation (SO). The component reliability estimates and the reliability data are trended for the most recent 10-year period while yearly estimates for reliability are provided for the entire study period. The following trends were identified for the most recent 10-year period: o Extremely statistically significant increasing trend for the frequency of FTOC demands (demands per reactor year) for low-demand (= 20 demands per year) AOVs o Extremely statistically significant increasing trend for the frequency of FTOC demands for high-demand (> 20 demands per year) AOVs o Highly statistically significant decreasing trend for the failure rate of FTOP for low-demand AOVs o Highly statistically significant decreasing trend for the frequency of FTOP events (failures per reactor year) for low-demand AOVs o Statistically significant decreasing trend for the failure rate of SO for low-demand AOVs o Statistically significant decreasing trend for the frequency of SO events (failures per reactor year) for low-demand AOVs.

99 GENERAL AND MISCELLANEOUS↗

DOE OSTI2022

Enhanced Component Performance Study: Motor-Operated Valves 1998-2020

This report presents an enhanced performance evaluation of motor-operated valves (MOVs) at U.S. commercial nuclear power plants. The data used in this study are based on the operating experience failure reports from calendar year 1998 through 2020 as reported in the Institute of Nuclear Power Operations (INPO) Industry Reporting and Information System (IRIS). The MOV failure modes considered are fail to open or close (FTOC), fail to operate or control (FTOP), and spurious operation (SO). The component reliability estimates and the reliability data are trended for the most recent 10-year period while yearly estimates for reliability are provided for the entire study period. The following increasing trend was identified for MOVs for the most recent 10-year period: • Low-demand MOV frequency of FTOC demands (demands per reactor year). The following increasing trends were identified for MOVs for the most recent 10-year period: • Low-demand MOV FTOC failure probability • Low-demand MOV frequency of FTOC events (failures per reactor year).

99 GENERAL AND MISCELLANEOUS↗