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All sourcesNASA NTRSDOE OSTI
DOE OSTI2011

Assessment of Prototypic and Closed Loop Operation during Pulse Jet Mixer Tests with Non-Cohesive Solids to Develop Scale-up Relationships

Scaled tests were conducted to develop correlations describing pulse jet mixer (PJM) performance with non-cohesive solids in water. These correlations were developed in scaled test systems that incorporated certain simplified aspects including non-prototypic refill associated with closed-loop operation of the mixing jets. When this test data was compared with experiments that used prototypic PJM refill, a difference in the critical suspension velocity (UCS) was identified. The non-prototypic aspects of the initial testing were reviewed and assessed. The effects of non-prototypic refill associated with the closed loop operation of the jets, previously known to affect solids cloud height, can be described in terms of a modified settling velocity. When the modified settling velocity is incorporated into the physical model, the adjusted new physical model does a better job of predicting UCS results for prototypic PJM refill tests. The adjusted new physical model was bench-marked with data taken during three prototypic drive tests with a mono-disperse simulant, a 3-part medium distribution stimulant and a 5-part broad distribution simulant The applicability of the non-prototypic scale-up behavior to prototypic testing was analyzed. The effects of non-prototypic refill caused measured values of UCS to be somewhat reduced at larger scales. Hence the scale-up exponents for the non-prototypic drive tests are believed to be smaller than they would have been had there been prototypic refill. Estimated scale-up exponents for the prototypic testing were developed for 8 and 12 pulse tube configurations.

comparison between prototypic and simplified drive↗
DOE OSTI2016

Contingency Contractor Optimization Phase 3 Sustainment Platform Requirements - Contingency Contractor Optimization Tool - Prototype

Sandia National Laboratories (Sandia) is in Phase 3 Sustainment of development of a prototype tool, currently referred to as the Contingency Contractor Optimization Tool - Prototype (CCOTP), under the direction of OSD Program Support. CCOT-P is intended to help provide senior Department of Defense (DoD) leaders with comprehensive insight into the global availability, readiness and capabilities of the Total Force Mix. The CCOT-P will allow senior decision makers to quickly and accurately assess the impacts, risks and mitigating strategies for proposed changes to force/capabilities assignments, apportionments and allocations options, focusing specifically on contingency contractor planning. During Phase 2 of the program, conducted during fiscal year 2012, Sandia developed an electronic storyboard prototype of the Contingency Contractor Optimization Tool that can be used for communication with senior decision makers and other Operational Contract Support (OCS) stakeholders. Phase 3 used feedback from demonstrations of the electronic storyboard prototype to develop an engineering prototype for planners to evaluate. Sandia worked with the DoD and Joint Chiefs of Staff strategic planning community to get feedback and input to ensure that the engineering prototype was developed to closely align with future planning needs. The intended deployment environment was also a key consideration as this prototype was developed. Initial release of the engineering prototype was done on servers at Sandia in the middle of Phase 3. In 2013, the tool was installed on a production pilot server managed by the OUSD(AT&L) eBusiness Center. The purpose of this document is to specify the CCOT-P engineering prototype platform requirements as of May 2016. Sandia developed the CCOT-P engineering prototype using common technologies to minimize the likelihood of deployment issues. CCOT-P engineering prototype was architected and designed to be as independent as possible of the major deployment components such as the server hardware, the server operating system, the database, and the web server. This document describes the platform requirements, the architecture, and the implementation details of the CCOT-P engineering prototype.

42 ENGINEERING↗
NASA NTRS1993

Integration and evaluation of a simulator designed to be used within a dynamic prototyping environment

The human computer interface (HCI) prototyping environment is designed to allow developers to rapidly prototype systems so that the interface and functionality of a system can be evaluated and iteratively refined early in the development process. This keeps development costs down by modifying the interface during the requirements definition phase, thus minimizing changes that need to be made during and after flight code development. Problems occur within a system when the user interface is not adequately developed and when designers and developers have an incomplete understanding of the system requirements. A process has been developed for prototyping on-board payload displays for Space Station Freedom. This prototyping process consists of five phases: identification of known requirements, analysis of the requirements, development of a formal design representation and specification, development of the prototype, and evaluation of the prototype. The actual development of the prototype involves prototyping the displays, developing a low fidelity simulator, building of an interface (or communication) between the displays and the simulator, integration of these components, and testing to ensure that the interface does what the developer expects. This research integrates and evaluates a software tool which has been developed to serve as a simulator within the prototyping environment. The tool is being evaluated to determine whether or not it meets the basic requirements which are needed for a low fidelity simulator within this environment. In order to evaluate the architecture and its components, a human computer interface for and a simulator of an automobile have been developed as a prototype. The individual components (i.e., the interface and simulator) have been developed, and the current research was designed to integrate and test the complete working system within the prototyping environment. The following sections will describe the architecture and components of the rapid prototyping environment, the development of a system to assess the environment, and the integration and evaluation of PERCNET.

Moore, Loretta A.↗
NASA NTRS2010

Ares I-X Ground Diagnostic Prototype

Automating prelaunch diagnostics for launch vehicles offers three potential benefits. First, it potentially improves safety by detecting faults that might otherwise have been missed so that they can be corrected before launch. Second, it potentially reduces launch delays by more quickly diagnosing the cause of anomalies that occur during prelaunch processing. Reducing launch delays will be critical to the success of NASA's planned future missions that require in-orbit rendezvous. Third, it potentially reduces costs by reducing both launch delays and the number of people needed to monitor the prelaunch process. NASA is currently developing the Ares I launch vehicle to bring the Orion capsule and its crew of four astronauts to low-earth orbit on their way to the moon. Ares I-X will be the first unmanned test flight of Ares I. It is scheduled to launch on October 27, 2009. The Ares I-X Ground Diagnostic Prototype is a prototype ground diagnostic system that will provide anomaly detection, fault detection, fault isolation, and diagnostics for the Ares I-X first-stage thrust vector control (TVC) and for the associated ground hydraulics while it is in the Vehicle Assembly Building (VAB) at John F. Kennedy Space Center (KSC) and on the launch pad. It will serve as a prototype for a future operational ground diagnostic system for Ares I. The prototype combines three existing diagnostic tools. The first tool, TEAMS (Testability Engineering and Maintenance System), is a model-based tool that is commercially produced by Qualtech Systems, Inc. It uses a qualitative model of failure propagation to perform fault isolation and diagnostics. We adapted an existing TEAMS model of the TVC to use for diagnostics and developed a TEAMS model of the ground hydraulics. The second tool, Spacecraft Health Inference Engine (SHINE), is a rule-based expert system developed at the NASA Jet Propulsion Laboratory. We developed SHINE rules for fault detection and mode identification. The prototype uses the outputs of SHINE as inputs to TEAMS. The third tool, the Inductive Monitoring System (IMS), is an anomaly detection tool developed at NASA Ames Research Center and is currently used to monitor the International Space Station Control Moment Gyroscopes. IMS automatically "learns" a model of historical nominal data in the form of a set of clusters and signals an alarm when new data fails to match this model. IMS offers the potential to detect faults that have not been modeled. The three tools have been integrated and deployed to Hangar AE at KSC where they interface with live data from the Ares I-X vehicle and from the ground hydraulics. The outputs of the tools are displayed on a console in Hangar AE, one of the locations from which the Ares I-X launch will be monitored. The full paper will describe how the prototype performed before the launch. It will include an analysis of the prototype's accuracy, including false-positive rates, false-negative rates, and receiver operating characteristics (ROC) curves. It will also include a description of the prototype's computational requirements, including CPU usage, main memory usage, and disk usage. If the prototype detects any faults during the prelaunch period then the paper will include a description of those faults. Similarly, if the prototype has any false alarms then the paper will describe them and will attempt to explain their causes.

Schwabacher, Mark↗
DOE OSTI2015

Prototype Systems for Measuring Outdoor Air Intake Rates in Rooftop Air Handlers

The widespread absence of systems for real-time measurement and feedback control, of minimum outdoor air intake rates in HVAC systems contributes to the poor control of ventilation rates in commercial buildings. Ventilation rates affect building energy consumption and influence occupant health. The project designed fabricated and tested four prototypes of systems for measuring rates of outdoor air intake into roof top air handlers. All prototypes met the ±20% accuracy target at low wind speeds, with all prototypes accurate within approximately ±10% after application of calibration equations. One prototype met the accuracy target without a calibration. With two of four prototype measurement systems, there was no evidence that wind speed or direction affected accuracy; however, winds speeds were generally below usually 3.5 m s -1 (12.6 km h -1 ) and further testing is desirable. The airflow resistance of the prototypes was generally less than 35 Pa at maximum RTU air flow rates. A pressure drop of this magnitude will increase fan energy consumption by approximately 4%. The project did not have resources necessary to estimate costs of mass produced systems. The retail cost of components and materials used to construct prototypes ranged from approximately $1,200 to $1,700. The test data indicate that the basic designs developed in this project, particularly the designs of two of the prototypes, have considerable merit. Further design refinement, testing, and cost analysis would be necessary to fully assess commercial potential. The designs and test results will be communicated to the HVAC manufacturing community.

42 ENGINEERING↗
DOE OSTI2022

Prototype College Building Energy Model: Building Characteristics and Energy Simulation Results

The US Department of Energy supports the development of commercial building energy codes and standards. To support commercial building energy research activities and the development of commercial building energy codes and standards, continuous efforts have been made to convert 16 prototype building models, which cover 80% of US commercial building floor space, to OpenStudio prototype buildings. Additionally, the suite of prototype building models was expanded to include the addition of new building prototype models (e.g., courthouse, college building). Multiple sources, including databases, documented projects, and personal communications, were used to define the prototype college building, and a 4-story with 69,063 ft 2 building was considered as the prototype college building to represent an average-sized college building in the United States. To represent realistic occupancy schedules and increase the granularity of information, actual class reservation schedules were collected and used. This report documents the building and system characteristics of the prototype college building model combined with climate-specific and construction vintage–specific requirements for the building envelope and systems from ASHRAE Standard 90.1. The energy simulation results are presented for 4 construction vintages (2004, 2007, 2010, and 2013) and 15 ASHRAE climate zones. The site energy use intensity of the college building was compared with 2012 Commercial Building Energy Consumption Survey (CBECS) and ENERGY STAR data to verify the simulation results. The site energy use intensity of the college building ranged from 60 to 202.4 kBtu/ft 2 , and compared with the energy use intensities of Commercial Building Energy Consumption Survey (122.9 kBtu/ft 2 ) and ENERGY STAR (84.3 kBtu/ft 2 ) data, the prototype college building results are in a reasonable range.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
NASA NTRS1993

Characteristics of products generated by selective sintering and stereolithography rapid prototyping processes

The trend in the modern global economy towards free market policies has motivated companies to use rapid prototyping technologies to not only reduce product development cycle time but also to maintain their competitive edge. A rapid prototyping technology is one which combines computer aided design with computer controlled tracking of focussed high energy source (eg. lasers, heat) on modern ceramic powders, metallic powders, plastics or photosensitive liquid resins in order to produce prototypes or models. At present, except for the process of shape melting, most rapid prototyping processes generate products that are only dimensionally similar to those of the desired end product. There is an urgent need, therefore, to enhance the understanding of the characteristics of these processes in order to realize their potential for production. Currently, the commercial market is dominated by four rapid prototyping processes, namely selective laser sintering, stereolithography, fused deposition modelling and laminated object manufacturing. This phase of the research has focussed on the selective laser sintering and stereolithography rapid prototyping processes. A theoretical model for these processes is under development. Different rapid prototyping sites supplied test specimens (based on ASTM 638-84, Type I) that have been measured and tested to provide a data base on surface finish, dimensional variation and ultimate tensile strength. Further plans call for developing and verifying the theoretical models by carefully designed experiments. This will be a joint effort between NASA and other prototyping centers to generate a larger database, thus encouraging more widespread usage by product designers.

Cariapa, Vikram↗
DOE OSTI2015

Human Factors and Technical Considerations for a Computerized Operator Support System Prototype

A prototype computerized operator support system (COSS) has been developed in order to demonstrate the concept and provide a test bed for further research. The prototype is based on four underlying elements consisting of a digital alarm system, computer-based procedures, PI&D system representations, and a recommender module for mitigation actions. At this point, the prototype simulates an interface to a sensor validation module and a fault diagnosis module. These two modules will be fully integrated in the next version of the prototype. The initial version of the prototype is now operational at the Idaho National Laboratory using the U.S. Department of Energy’s Light Water Reactor Sustainability (LWRS) Human Systems Simulation Laboratory (HSSL). The HSSL is a full-scope, full-scale glass top simulator capable of simulating existing and future nuclear power plant main control rooms. The COSS is interfaced to the Generic Pressurized Water Reactor (gPWR) simulator with industry-typical control board layouts. The glass top panels display realistic images of the control boards that can be operated by touch gestures. A section of the simulated control board was dedicated to the COSS human-system interface (HSI), which resulted in a seamless integration of the COSS into the normal control room environment. A COSS demonstration scenario has been developed for the prototype involving the Chemical & Volume Control System (CVCS) of the PWR simulator. It involves a primary coolant leak outside of containment that would require tripping the reactor if not mitigated in a very short timeframe. The COSS prototype presents a series of operator screens that provide the needed information and soft controls to successfully mitigate the event.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2022

Defining the Prototype Convenience Store Building Characteristics

The US Department of Energy supports the development of commercial building energy codes and standards. To support commercial building energy research activities and the development of commercial building energy codes and standards, continuous efforts have been made to convert 30 prototype building models (20 different building types), which cover 80% of US commercial building floor space, to OpenStudio prototype buildings. Additionally, the suite of prototype building models was expanded to include the addition of new building prototype models (e.g., courthouse, college building). This report documents the building and system characteristics of the prototype convenience store building model. Multiple sources, including databases, documented projects, and personal communications, were used to define the prototype convenience store building characteristics, and a one-story, 3,000 ft 2 building was considered as the prototype convenience store to represent an average-sized convenience store in the United States. The Oak Ridge National Laboratory team defined the operational hours of the convenience store as 17 hours per day. The types of exterior walls, roof, and floor were defined as brick wall, metal surfacing roof, and slab-on-grade floor, respectively. Double glazing was selected, and the window-towall ratio was set as 15% on the front side. For the system part, packaged system and centralized water heater were selected for the space heating and cooling system and water heater system, respectively. In terms of the refrigerator system, the number of refrigerators and freezers were determined as eight closed cases and two walk-in units.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
NASA NTRS2008

Review, Selection and Installation of a Rapid Prototype Machine

The objective of this paper is to impress upon the reader the benefits and advantages of investing in rapid prototyping (additive manufacturing) technology thru the procurement of one or two new rapid prototyping machines and the creation of a new Prototype and Model Lab at the Kennedy Space Center (KSC). This new resource will be available to all of United Space Alliance, LLC (USA), enabling engineers from around the company to pursue a more effective means of communication and design with our co-workers, and our customer, the National Aeronautics and Space Administration (NASA). The Rapid Protoyping/3D printing industry mirrors the transition the CAD industry made several years ago, when companies were trying to justify the expenditure of converting to a 3D based system from a 2D based system. The advantages of using a 3D system seemed to be outweighed by the cost it would take to convert not only legacy 2D drawings into 3D models but the training of personnel to use the 3D CAD software. But the reality was that when a 3D CAD system is employed, it gives engineers a much greater ability to conceive new designs and the ability to engineer new tools and products much more effectively. Rapid Prototyping (RP) is the name given to a host of related technologies that are used to fabricate physical objects directly from Computer Aided Design (CAD) data sources. These methods are generally similar to each other in that they add and bond materials in a layer wise-fashion to form objects, instead of machining away material. The machines used in Rapid Prototyping are also sometimes referred to as Rapid Manufacturing machines due to the fact that some of the parts fabricated in a RP machine can be used as the finished product. The name "Rapid Prototyping" is really a misnomer. It is much more than prototypes and it is not always rapid.

McEndree, Caryl↗
NASA NTRS2015

T-38 Primary Flight Display Prototyping and HIVE Support Abstract & Summary

This fall I worked in EV3 within NASA's Johnson Space Center in The HIVE (Human Integrated Vehicles & Environments). The HIVE is responsible for human in the loop testing, getting new technologies in front of astronauts, operators, and users early in the development cycle to make the interfaces more human friendly. Some projects the HIVE is working on includes user interfaces for future spacecraft, wearables to alert astronauts about important information, and test beds to simulate mock missions. During my internship I created a prototype for T-38 aircraft displays using LabVIEW, learned how to use microcontrollers, and helped out with other small tasks in the HIVE. The purpose of developing a prototype for T-38 Displays in LabVIEW is to analyze functions of the display such as navigation in a cost and time effective manner. The LabVIEW prototypes allow Ellington Field AOD to easily make adjustments to the display before hardcoding the final product. LabVIEW was used to create a user interface for simulation almost identical to the real aircraft display. Goals to begin the T-38 PFD (Primary Flight Display) prototype included creating a T-38 PFD hardware display in a software environment, designing navigation for the menu's, incorporating vertical and horizontal navigation bars, and to add a heading bug for compass controls connected to the HSI (Horizontal Situation Indicator). To get started with the project, measurements of the entire display were taken. This enabled an accurate model of the hardware display to be created. Navigation of menu's required some exploration of different buttons on the display. The T-38 simulator and aircraft were used for examining the display. After one piece of the prototype was finished, another trip of to the simulator took place. This was done until all goals for the prototype were complete. Some possible integration ideas for displays in the near future are autopilot selection, touch screen displays, and crew member preferences. Complete navigation, control, and function customization will be achievable once a display is fully developed. Other than the T-38 prototyping, I spent time learning how to design small circuits and write code for them to function. This was done by adding electronic circuit components to breadboard and microcontroller then writing code to speak to those components through the microcontroller. I went through an Arduino starter kit to build circuits and code software that allowed the hardware to act. This work was planned to assist in a lighting project this fall but another solution was discovered for the lighting project. Other tasks that I assisted with, included hands on work such as mock-up construction/removal, logic analyzer repairs, and soldering with circuits. The unique opportunity to be involved work with NASA has significantly changed my educational and career goals. This opportunity has only opened the door to my career with engineering. I have learned over the span of this internship that I am fascinated by the type of work that NASA does. My desire to work in the aerospace industry has increased immensely. I hope to return to NASA to be more involved in the advancement of science, engineering, and spaceflight. My interests for my future education and career lie in NASA’s work - pioneering the future in space exploration, scientific discovery and aeronautics research.

Boniface, Andrew↗
NASA NTRS2026

Prototype Demonstration of Solar-Carbothermal System to Extract Oxygen From Regolith

The Carbothermal Reduction Demonstration (CaRD) project was an effort to develop a prototype system to demonstrate the extraction of oxygen from simulated lunar regolith using concentrated solar energy and a carbothermal reaction. The prototype consisted of a deployable solar concentrator capable of tracking the sun, carbothermal reactor, fluid system, gas analysis, and a solar concentrator control system consisting of avionics and software. These subsystems were developed by multiple NASA centers and a private industry partner, Sierra Space. The various teams worked together to define requirements and interfaces to successfully assemble the complex system and demonstrate an integrated solar carbothermal process. The solar concentrator developed at Glenn Research Center (GRC) was designed to be stowed for a launch environment then deployed on the lunar surface. It utilized a crossed dragone configuration of composite mirrors to direct horizontal sunlight onto a target 90° from the incoming sunlight. The key performance parameters for the solar concentrator were efficiency and power density. The carbothermal reactor was developed by Sierra Space through a separate project called the Carbothermal Oxygen Production Reactor (COPR) where it successfully demonstrated a fully automated process in a thermal vacuum environment [1]. The fluid system needed for the carbothermal reaction was also developed by Sierra Space and successfully demonstrated in the same thermal vacuum test. The gas analysis system was developed at Kennedy Space Center (KSC) and was required to determine the amount of oxygen extracted during each test. The gas analysis system was based on the Mass Spectrometer Observing Lunar Operations (MSOLO) instrument. Avionics and software for the CaRD prototype were also developed at KSC and based on experience with MSOLO avionics and software. The control system was designed to stow, deploy, track the sun, and perform beam alignment of the concentrated light. The prototype subsystems were integrated and tested at Johnson Space Center’s (JSC) Energy Systems Test Area. A heliostat was used to direct sunlight toward the prototype in a way that is representative of the sunlight conditions at the south pole of the Moon. When concentrated sunlight was focused on simulated lunar regolith within the reactor, the gas analysis team confirmed the presence of carbon monoxide gas, which confirmed that a solar carbothermal reaction took place. The key performance parameter for the integrated prototype was grams of oxygen extracted per kilowatt hour of energy arriving at the concentrator primary mirror. The prototype design successfully demonstrated end-to-end capability and further steps to achieve a flight capable system have been defined. With lunar data, engineers would be able to design a scaled-up system capable of extracting oxygen from regolith at useful quantities for crew life support and rocket propellant. On the long term, this method of In-Situ Resource Utilization could be used to drastically reduce the cost and risk of a sustained human presence on the Moon by reducing the amount of oxygen that would have to be delivered.

Koorosh R Araghi↗
NASA NTRS2026

Prototype Demonstration of Solar Carbothermal System to Extract Oxygen from Regolith

The Carbothermal Reduction Demonstration (CaRD) project was an effort to develop a prototype system to demonstrate the extraction of oxygen from simulated lunar regolith using concentrated solar energy and a carbothermal reaction. The prototype consisted of a deployable solar concentrator capable of tracking the sun, carbothermal reactor, fluid system, gas analysis, and a solar concentrator control system consisting of avionics and software. These subsystems were developed by multiple NASA centers and a private industry partner, Sierra Space. The various teams worked together to define requirements and interfaces to successfully assemble the complex system and demonstrate an integrated solar carbothermal process. The solar concentrator developed at Glenn Research Center (GRC) was designed to be stowed for a launch environment then deployed on the lunar surface. It utilized a crossed dragone configuration of composite mirrors to direct horizontal sunlight onto a target 90° from the incoming sunlight. The key performance parameters for the solar concentrator were efficiency and power density. The carbothermal reactor was developed by Sierra Space through a separate project called the Carbothermal Oxygen Production Reactor (COPR) where it successfully demonstrated a fully automated process in a thermal vacuum environment. The fluid system needed for the carbothermal reaction was also developed by Sierra Space and successfully demonstrated in the same thermal vacuum test. The gas analysis system was developed at Kennedy Space Center (KSC) and was required to determine the amount of oxygen extracted during each test. The gas analysis system was based on the Mass Spectrometer Observing Lunar Operations (MSOLO) instrument. Avionics and software for the CaRD prototype were also developed at KSC and based on experience with MSOLO avionics and software. The control system was designed to stow, deploy, track the sun, and perform beam alignment of the concentrated light. The prototype subsystems were integrated and tested at Johnson Space Center’s (JSC) Energy Systems Test Area. A heliostat was used to direct sunlight toward the prototype in a way that is representative of the sunlight conditions at the south pole of the Moon. When concentrated sunlight was focused on simulated lunar regolith within the reactor, the gas analysis team confirmed the presence of carbon monoxide gas, which confirmed that a solar carbothermal reaction took place. The key performance parameter for the integrated prototype was grams of oxygen extracted per kilowatt hour of energy arriving at the concentrator primary mirror. The prototype design successfully demonstrated end-to-end capability and further steps to achieve a flight capable system have been defined. With lunar data, engineers would be able to design a scaled-up system capable of extracting oxygen from regolith at useful quantities for crew life support and rocket propellant. On the long term, this method of In-Situ Resource Utilization could be used to drastically reduce the cost and risk of a sustained human presence on the Moon by reducing the amount of oxygen that would have to be delivered.

Aaron Paz↗
NASA NTRS2026

Prototype Demonstration of an Integrated Solar Concentrator System and Carbothermal Reactor Using Solar Energy to Extract Oxygen from Regolith

The Carbothermal Reduction Demonstration (CaRD) project was an effort to develop a prototype system to demonstrate the extraction of oxygen from simulated lunar regolith using concentrated solar energy and a carbothermal reaction. The prototype consisted of a deployable solar concentrator capable of tracking the sun, carbothermal reactor, fluid system, gas analysis, and a solar concentrator control system consisting of avionics and software. These subsystems were developed by multiple NASA centers and a private industry partner, Sierra Space. The various teams worked together to define requirements and interfaces to successfully assemble the complex system and demonstrate an integrated solar carbothermal process. The solar concentrator developed at Glenn Research Center (GRC) was designed to be stowed for a launch environment then deployed on the lunar surface. It utilized a crossed dragone configuration of composite mirrors to direct horizontal sunlight onto a target 90° from the incoming sunlight. The key performance parameters for the solar concentrator were efficiency and power density. The carbothermal reactor was developed by Sierra Space through a separate project called the Carbothermal Oxygen Production Reactor (COPR) where it successfully demonstrated a fully automated process in a thermal vacuum environment. The fluid system needed for the carbothermal reaction was also developed by Sierra Space and successfully demonstrated in the same thermal vacuum test. The gas analysis system was developed at Kennedy Space Center (KSC) and was required to determine the amount of oxygen extracted during each test. The gas analysis system was based on the Mass Spectrometer Observing Lunar Operations (MSOLO) instrument. Avionics and software for the CaRD prototype were also developed at KSC and based on experience with MSOLO avionics and software. The control system was designed to stow, deploy, track the sun, and perform beam alignment of the concentrated light. The prototype subsystems were integrated and tested at Johnson Space Center’s (JSC) Energy Systems Test Area. A heliostat was used to direct sunlight toward the prototype in a way that is representative of the sunlight conditions at the south pole of the Moon. When concentrated sunlight was focused on simulated lunar regolith within the reactor, the gas analysis team confirmed the presence of carbon monoxide gas, which confirmed that a solar carbothermal reaction took place. The key performance parameter for the integrated prototype was grams of oxygen extracted per kilowatt hour of energy arriving at the concentrator primary mirror. The prototype design successfully demonstrated end-to-end capability and further steps to achieve a flight capable system have been defined. With lunar data, engineers would be able to design a scaled-up system capable of extracting oxygen from regolith at useful quantities for crew life support and rocket propellant. On the long term, this method of In-Situ Resource Utilization could be used to drastically reduce the cost and risk of a sustained human presence on the Moon by reducing the amount of oxygen that would have to be delivered.

Oxygen from Regolith↗
DOE OSTI2023

Design, construction and commissioning of a technological prototype of a highly granular SiPM-on-tile scintillator-steel hadronic calorimeter

The CALICE collaboration is developing highly granular electromagnetic and hadronic calorimeters for detectors at future energy frontier electron-positron colliders. After successful tests of a physics prototype, a technological prototype of the Analog Hadron Calorimeter has been built, based on a design and construction techniques scalable to a collider detector. The prototype consists of a steel absorber structure and active layers of small scintillator tiles that are individually read out by directly coupled SiPMs. Each layer has an active area of 72 × 72 cm^2 and a tile size of 3 × 3 cm^2. With 38 active layers, the prototype has nearly 22,000 readout channels, and its total thickness amounts to 4.4 nuclear interaction lengths. The dedicated readout electronics provide time stamping of each hit with an expected resolution of about 1 ns. The prototype was constructed in 2017 and commissioned in beam tests at DESY. It recorded muons, hadron showers and electron showers at different energies in test beams at CERN in 2018. In this paper, the design of the prototype, its construction and commissioning are described. The methods used to calibrate the detector are detailed, and the performance achieved in terms of uniformity and stability is presented.

47 OTHER INSTRUMENTATION↗
DOE OSTI2011

Testing and modeling of diffusion bonded prototype optical windows under ITER conditions

Glass-metal joints are a part of ITER optical diagnostics windows. These joints must be leak tight for the safety (presence of tritium in ITER) and to preserve the vacuum. They must also withstand the ITER environment: temperatures up to 220 deg.C and fast neutron fluxes of {approx}3.10{sup 9} n/cm{sup 2}.s. At the moment, little information is available about glass-metal joints suitable for ITER. Therefore, we performed mechanical and thermal tests on some prototypes of an aluminium diffusion bonded optical window. Finite element modeling with Abaqus code was used to understand the experimental results. The prototypes were helium leaking probably due to very tiny cracks in the interaction layer between the steel and the aluminium. However, they were all able to withstand a thermal cycling test up to 200 deg. C; no damage could be seen after the tests by visual inspection. The prototypes successfully passed push-out test with a 500 N load. During the destructive push-out tests the prototypes broke at a 6-12 kN load between the aluminium layer and the steel or the glass, depending on the surface quality of the glass. The microanalysis of the joints has also been performed. The finite element modeling of the push-out tests is in a reasonable agreement with the experiments. According to the model, the highest thermal stress is created in the aluminium layer. Thus, the aluminium joint seems to be the weakest part of the prototypes. If this layer is improved, it will probably make the prototype helium leak tight and as such, a good ITER window candidate. (authors)

42 ENGINEERING↗
DOE OSTI2013

MPACT Fast Neutron Multiplicity System Prototype Development

This document serves as both an FY2103 End-of-Year and End-of-Project report on efforts that resulted in the design of a prototype fast neutron multiplicity counter leveraged upon the findings of previous project efforts. The prototype design includes 32 liquid scintillator detectors with cubic volumes 7.62 cm in dimension configured into 4 stacked rings of 8 detectors. Detector signal collection for the system is handled with a pair of Struck Innovative Systeme 16-channel digitizers controlled by in-house developed software with built-in multiplicity analysis algorithms. Initial testing and familiarization of the currently obtained prototype components is underway, however full prototype construction is required for further optimization. Monte Carlo models of the prototype system were performed to estimate die-away and efficiency values. Analysis of these models resulted in the development of a software package capable of determining the effects of nearest-neighbor rejection methods for elimination of detector cross talk. A parameter study was performed using previously developed analytical methods for the estimation of assay mass variance for use as a figure-of-merit for system performance. A software package was developed to automate these calculations and ensure accuracy. The results of the parameter study show that the prototype fast neutron multiplicity counter design is very nearly optimized under the restraints of the parameter space.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2012

Alstom's Chemical Looping Combustion Prototype for CO 2 Capture from Existing Pulverized Coal-Fired Power Plants

Alstom’s Limestone Chemical Looping (LCL™) process has the potential to capture CO 2 from new and existing coal-fired power plants while maintaining high plant power generation efficiency. This new power plant concept is based on a hybrid combustion- gasification process utilizing high temperature chemical and thermal looping technology. This process could also be potentially configured as a hybrid combustion-gasification process producing a syngas or hydrogen for various applications while also producing a separate stream of CO 2 for use or sequestration. The targets set for this technology is to capture over 90% of the total carbon in the coal at cost of electricity which is less than 20% greater than Conventional PC or CFB units. Previous work with bench scale test and a 65 kWt Process Development Unit Development (PDU) has validated the chemistry required for the chemical looping process and provided for the investigation of the solids transport mechanisms and design requirements. The objective of this project is to continue development of the combustion option of chemical looping (LCL-C™) by designing, building and testing a 3 MWt prototype facility. The prototype includes all of the equipment that is required to operate the chemical looping plant in a fully integrated manner with all major systems in service. Data from the design, construction, and testing will be used to characterize environmental performance, identify and address technical risks, reassess commercial plant economics, and develop design information for a demonstration plant planned to follow the proposed Prototype. A cold flow model of the prototype will be used to predict operating conditions for the prototype and help in operator training. Operation of the prototype will provide operator experience with this new technology and performance data of the LCL-C™ process, which will be applied to the commercial design and economics and plan for a future demonstration plant.

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