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At least 721 records · Page 40

All sources NASA NTRS DOE OSTI

DOE OSTI2022

A machine learning approach for clinker quality prediction and nonlinear model predictive control design for a rotary cement kiln

Abstract Cement manufacturing is energy‐intensive (5Gj/t) and comprises a significant portion of the energy footprint of concrete systems. Incorporating modern monitoring, simulation and control systems will allow lower energy use, lower environmental impact, and lower costs of this widely used construction material. One of the goals of the CESMII roadmap project on the Smart Manufacturing of Cement included developing an analytical process model for clinker quality that includes the chemistry of the kiln feed and accounts for critical process variables. This predictive model will be used in nonlinear model predictive control system designed to significantly reduce process energy use while maintaining or improving product quality. In the cement manufacturing plant used in this study, the kiln feed (meal) is tested every 12 h and used to estimate the mineral composition of the cement kiln output (clinker) using the stoichiometry‐based Bogue's model and the expertise of the plant operators. During kiln operation, kiln output (clinker) is sampled and tested every 2 h to measure its chemical and mineral composition. The predicted and measured values of the clinker composition are used by the plant operators to adjust the kiln input stream and the production process characteristics to maintain stable operation and uniform product quality. However, the time delay between prediction and testing, along with inaccuracies inherent in the Bogue's model have made any process changes designed to minimize energy use problematic, especially in‐light of potential clinker quality issues that process changes often pose. A new analytical model that integrates quality information and process operation information has been developed from data collected from 2 years of production from an operating cement facility. To make the model fuel‐type‐independent, consumed heat energy was computed in the model instead of fuel type and amount. A Feedforward Network was trained and tailored from collected data. Many data‐based simulations were conducted to quantitatively evaluate the proposed model and the 5‐fold cross‐validation procedure was used to test the models. The resulting predictive model was shown to have a low root mean square error (MSE) with respect to the estimated clinker mineral composition compared to that using the industry standard “Bogue’ model”. The end goal of this work was to develop a single machine learning tool that allows the use of quality control data and process control variables to improve energy efficiency of the process in a continuous fashion. The proposed nonlinear model predictive control system (NMPC) can generate predicted kiln production characteristics based on manipulated variables in manner that accurately follows the target product quality values. Simulation results also show that the proposed model produced accurate predictions of kiln outputs that fell within the required constraints, while manipulating control variables within typical operational ranges.

Ali, Asem M.↗

NASA NTRS2016

Wire Rope Failure on the Guppy Winch

On January 6, 2016 at El Paso, the Guppy winch motor was changed. After completion of the operational checks, the load bar was being reinstalled on the cargo pallet when the motor control FORWARD relay failed in the energized position. The pallet was pinned at all locations (each pin has a load capacity of 16,000 lbs.) while the winch was running. The wire rope snapped before aircraft power could be removed. After disassembly, the fractured wire rope was shipped to ES4 lab for further characterization of the wire rope portion of the failure. The system was being operated without a clear understanding of the system capability and function. The proximate cause was the failure of the K48 -Forward Winch Control Relay in the energized position, which allowed the motor to continuously run without command from the hand controller, and operation of the winch system with both controllers connected to the system. This prevented the emergency stop feature on the hand controller from functioning as designed. An electrical checkout engineering work instruction was completed and identified the failed relay and confirmed the emergency stop only paused the system when the STOP button on both connected hand controllers were depressed simultaneously. The winch system incorporates a torque limiting clutch. It is suspected that the clutch did not slip and the motor did not stall or overload the current limiter. Aircraft Engineering is looking at how to change the procedures to provide a checkout of the clutch and set to a slip torque limit appropriate to support operations.

Figert, John↗

NASA NTRS2015

Aerodynamic Load Analysis of a Variable Camber Continuous Trailing Edge Flap System on a Flexible Wing Aircraft

This paper presents an investigative aerodynamic analysis conducted on the novel control surface known as a Variable Camber Continuous Trailing Edge Flap (VCCTEF). The VCCTEF is modeled as a control effector on the NASA Generic Transport Model (GTM) where wing flexibility is considered. Aerodynamic modeling of the aircraft is conducted using vortex-lattice method (VLM), and an aeroelastic model of the aircraft that utilizes a coupled finite-element analysis (FEA) vortex-lattice solution is employed. VLM solutions are used to determine quasi-steady aerodynamic loading over the aeroelastic wing structures with VCCTEF. The load data is used to calculate aerodynamic sensitivities to control surface deployment and is also integrated to determine overall hinge moments. This analysis is conducted for different flight conditions, where control sensitivities compare the VCCTEF effectiveness against conventional control surfaces. Hinge moment results provide insight into aeroelastic wing loads, and worst case hinge moments for the VCCTEF can be estimated. Results show that the VCCTEF offers greater control authority than conventional ailerons at cruise, and nominal flap settings are determined for a low-speed take-off condition where the VCCTEF maintains comparable control effectiveness. Worst case hinge moment values are presented, where for a possible VCCTEF configuration, the stiff wing model demonstrates up to a 5.90 percent increase in flap hinge moment relative to a rigid model, and a reduced stiffness model demonstrates up to an 11.42 percent increase.

Aeroelasticity↗

DOE OSTI2024

Exploiting Saturation Regimes and Surface Effects to Tune Composite Design: Single Platelet Nanocomposites of Peptoid Nanosheets and CaCO 3

Mineral-polymer composites found in nature exhibit exceptional structural properties essential to their function, and transferring these attributes to the synthetic design of functional materials holds promise across various sectors. Biomimetic fabrication of nanocomposites introduces new pathways for advanced material design and explores biomineralization strategies. This study presents a novel approach for producing single platelet nanocomposites composed of CaCO 3 and biomimetic peptoid (N-substituted glycines) polymers, akin to the bricks found in the brick-and-mortar structure of nacre, the inner layer of certain mollusc shells. The significant aspect of the proposed strategy is the use of organic peptoid nanosheets as the scaffolds for brick formation, along with their controlled mineralization in solution. Here, we employ the B28 peptoid nanosheet as a scaffold, which readily forms free-floating zwitterionic bilayers in aqueous solution. The peptoid nanosheets were mineralized under consistent initial conditions (σ calcite = 1.2, pH 9.00), with variations in mixing conditions and supersaturation profiles over time aimed at controlling the final product. Nanosheets were mineralized in both feedback control experiments, where supersaturation was continuously replenished by titrant addition and in batch experiments without a feedback loop. Complete coverage of the nanosheet surface by amorphous calcium carbonate was achieved under specific conditions with feedback control mineralization, whereas vaterite was the primary CaCO 3 phase observed after batch experiments. Thermodynamic calculations suggest that time-dependent supersaturation profiles as well as the spatial distribution of supersaturation are effective controls for tuning the mineralization extent and product. We anticipate that the control strategies outlined in this work can serve as a foundation for the advanced and scalable fabrication of nanocomposites as building blocks for nacre-mimetic and functional materials.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2017

Effects of a chirped bias voltage on ion energy distributions in inductively coupled plasma reactors

The metrics for controlling reactive fluxes to wafers for microelectronics processing are becoming more stringent as feature sizes continue to shrink. Recent strategies for controlling ion energy distributions to the wafer involve using several different frequencies and/or pulsed powers. Although effective, these strategies are often costly or present challenges in impedance matching. With the advent of matching schemes for wide band amplifiers, other strategies to customize ion energy distributions become available. In this study, we discuss results from a computational investigation of biasing substrates using chirped frequencies in high density, electronegative inductively coupled plasmas. Depending on the frequency range and chirp duration, the resulting ion energy distributions exhibit components sampled from the entire frequency range. However, the chirping process also produces transient shifts in the self-generated dc bias due to the reapportionment of displacement and conduction with frequency to balance the current in the system. Finally, the dynamics of the dc bias can also be leveraged towards customizing ion energy distributions.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

NASA NTRS1980

Electronic system for high power load control

Parallel current paths are divided into two groups, with control devices in the current paths of one group each having a current limiting resistor, and the control devices in the other group each having no limiting resistor, so that when the control devices of the second group are turned fully on, a short circuit is achieved by the arrangement of parallel current paths. Separate but coordinated control signals are provided to turn on the control devices of the first group and increase their conduction toward saturation as a function of control input, and when fully on, or shortly before, to turn on the control devices of the second group and increase their conduction toward saturation as a function of the control input as that input continues to increase. Electronic means may be used to generate signals. The system may be used for 1-V characteristic measurements of solar arrays as well as for other load control purposes.

Miller, E. L.↗

NASA NTRS2000

Remote Control and Data Acquisition: A Case Study

This paper details software tools developed to remotely command experimental apparatus, and to acquire and visualize the associated data in soft real time. The work was undertaken because commercial products failed to meet the needs. This work has identified six key factors intrinsic to development of quality research laboratory software. Capabilities include access to all new instrument functions without any programming or dependence on others to write drivers or virtual instruments, simple full screen text-based experiment configuration and control user interface, months of continuous experiment run-times, order of 1% CPU load for condensed matter physics experiment described here, very little imposition of software tool choices on remote users, and total remote control from anywhere in the world over the Internet or from home on a 56 Kb modem as if the user is sitting in the laboratory. This work yielded a set of simple robust tools that are highly reliable, resource conserving, extensible, and versatile, with a uniform simple interface.

DeGennaro, Alfred J.↗

NASA NTRS2008

Control Architecture for Robotic Agent Command and Sensing

Control Architecture for Robotic Agent Command and Sensing (CARACaS) is a recent product of a continuing effort to develop architectures for controlling either a single autonomous robotic vehicle or multiple cooperating but otherwise autonomous robotic vehicles. CARACaS is potentially applicable to diverse robotic systems that could include aircraft, spacecraft, ground vehicles, surface water vessels, and/or underwater vessels. CARACaS incudes an integral combination of three coupled agents: a dynamic planning engine, a behavior engine, and a perception engine. The perception and dynamic planning en - gines are also coupled with a memory in the form of a world model. CARACaS is intended to satisfy the need for two major capabilities essential for proper functioning of an autonomous robotic system: a capability for deterministic reaction to unanticipated occurrences and a capability for re-planning in the face of changing goals, conditions, or resources. The behavior engine incorporates the multi-agent control architecture, called CAMPOUT, described in An Architecture for Controlling Multiple Robots (NPO-30345), NASA Tech Briefs, Vol. 28, No. 11 (November 2004), page 65. CAMPOUT is used to develop behavior-composition and -coordination mechanisms. Real-time process algebra operators are used to compose a behavior network for any given mission scenario. These operators afford a capability for producing a formally correct kernel of behaviors that guarantee predictable performance. By use of a method based on multi-objective decision theory (MODT), recommendations from multiple behaviors are combined to form a set of control actions that represents their consensus. In this approach, all behaviors contribute simultaneously to the control of the robotic system in a cooperative rather than a competitive manner. This approach guarantees a solution that is good enough with respect to resolution of complex, possibly conflicting goals within the constraints of the mission to be accomplished by the vehicle(s).

Huntsberger, Terrance↗

DOE OSTI2023

The Variable Continuous Bimaterial Interface in the San Jacinto Fault Zone Revealed by Dense Seismic Array Analysis of Fault Zone Head Waves

Key factors controlling earthquake ruptures include fault geometry, continuity, and seismic velocity structure around the fault. We present a novel tool that better informs deep bimaterial fault geometry embedded in distributed damage and seismicity, associated velocity contrasts across the fault, and their correlations with surface complexities. The method employs fault zone head and direct body waves and is applied to recordings from five spatiotemporally different seismic arrays along the complex San Jacinto fault zone (SJFZ) in southern California. We detect and distinguish these signals based on instantaneous phase coherence and relative energy in a cascading manner from one scale array to another. The analysis reveals a >70-km long continuous bimaterial interface within the SJFZ with several deep northeast dipping fault segments. The northern SJFZ, for instance, locates ~7 km northeast of its surface expression at 18-km depth. P-wave velocity contrasts range from near 0% to >15%, consistent with other bimaterial faults, and differ by a few % depending on fault-array azimuth, implying directional-dependent velocity contrasts. S-wave head waves and velocity contrasts are also imaged for the first time at the southern SJFZ, averaging to 2.9% in agreement with tomography results. The imaged geometry and continuity suggest the SJFZ initiated along remnant tectonic structures and translates to a rupture potential of M > 7.2, i.e., the sizes of its largest paleo-earthquakes. The P and S contrasts, and their ratios, have important implications for earthquake rupture speed, mode, directivity, and frictional heating along the SJFZ and other major faults globally.

58 GEOSCIENCES↗

DOE OSTI2022

Research on Deformation Law of Deep Foundation Pit of Station in Core Region of Saturated Soft Loess Based on Monitoring

Saturated soft loess has a large pore structure, high compressibility, low strength, fluid plastic state, and poor engineering properties. It is still one of the key problems that engineering needs to solve. In order to study the influence of deep foundation pit excavation in the saturated soft loess area on the deformation of foundation pits, the deformation laws of ground settlement, enclosure structure, and supporting axial force were clarified based on the field tests on the deformation characteristics of deep foundation pits in areas with the high-water level in saturated soft loess, combined with geological conditions and on-site construction procedures. The results indicate the following: water supply and construction process were found to be the main factor in changing the surface settlement curve of deep foundation pits in saturated soft loess; increasing the construction speed of the pit bottom floor, inverted braces, floor frame beams, and sidewall frame beams to close the structure, which is conducive to restraining the deformation of the continuous underground wall and foundation pits in similar areas. In the initial stage of support layout, the axial force of steel support tends to increase too fast or even exceed the standard control value. Therefore, a reasonable preadding axial force is an effective means to control the deformation of the continuous underground wall and the axial force of the steel support. The current research results may provide a reference for constructing deep foundation pits in similar areas.

Wang, Xueyan↗

NASA NTRS2020

Progress on Gust Load Alleviation Wind Tunnel Experiment and Aeroservoelastic Model Validation for a Flexible Wing with Variable Camber Continuous Trailing Edge Flap System

This paper discusses a wind tunnel experiment of active gust load alleviation of a flexible wing which took place at University of Washington (UW) in 2019. The experiment performed under a NASA SBIR contract with Scientific Systems Company, Inc (SSCI). The objective of the experiment is to demonstrate active controls of the Variable Camber Continuous Trailing Edge Flap (VCCTEF) system for gust load alleviation and real-time drag optimization. The wind tunnel model is a 8.2% sub-scale Common Research Model (CRM) wing. The wing structure is designed to provide a substantial degree of flexibility to represent that of a modern high-aspect ratio wing. Eight active control surfaces are employed in the VCCTEF. A new gust generator system was designed and installed by UW under a sub-contract with SSCI. The first test entry started in July 2019 and ended in September 2019. During this test entry, many significant issues were found with the hardware and software. The significant issues with the servos prevented the test objective from being completed. A follow-up second test entry in 2020 is being planned. The wing system is being repaired by SSCI. This paper reports on the progress of this experimental effort and the aeroservoelastic (ASE) model validation which was conducted during the test entry.

Nguyen, Nhan↗

NASA NTRS1994

SAVA 3: A testbed for integration and control of visual processes

The development of an experimental test-bed to investigate the integration and control of perception in a continuously operating vision system is described. The test-bed integrates a 12 axis robotic stereo camera head mounted on a mobile robot, dedicated computer boards for real-time image acquisition and processing, and a distributed system for image description. The architecture was designed to: (1) be continuously operating, (2) integrate software contributions from geographically dispersed laboratories, (3) integrate description of the environment with 2D measurements, 3D models, and recognition of objects, (4) capable of supporting diverse experiments in gaze control, visual servoing, navigation, and object surveillance, and (5) dynamically reconfiguarable.

Crowley, James L.↗

DOE OSTI2022

Hierarchical Control of Utility-Scale Solar PV Plants for Mitigation of Generation Variability and Ancillary Service Provision

This paper presents a hierarchical control system to mitigate the variability of solar photovoltaic (PV) power plant and provide ancillary services to the electric grid without the need for additional non-solar resources. With coordinated management of each inverter in the system, the control system commands the power plant to proactively curtail a small fraction of its instantaneous maximum power potential, which gives the plant enough headroom to ramp up production from the overall power plant, for a service such as regulation reserve. This control system is practical for continuously changing cloud cover conditions in partially cloudy days. A case study from a site in Hawaii with one-second resolution solar irradiance data is used to verify the efficacy of the proposed control system. The proposed control algorithm is subsequently compared with the alternative control technology from the literature, the grouping control algorithm; the results show that the proposed hierarchical control system is over 10 times more effective in reducing generator mileage to support power fluctuations from solar PV power plants.

14 SOLAR ENERGY↗

NASA NTRS1994

Early alterations in soleus GLUT-4, glucose transport, and glycogen in voluntary running rats

Voluntary wheel running (WR) by juvenile female rats was used as a noninterventional model of soleus muscle functional overload to study the regulation of insulin-stimulated glucose transport activity by the glucose transporter (GLUT-4 isoform) protein level and glycogen concentration. Soleus total protein content was significantly greater (+18%;P greater than 0.05) than in age-matched controls after 1 wk of WR, and this hypertrophic response continued in weeks 2-4 (+24-32%). GLUT-4 protein was 39% greater than in controls in 1-wk WR soleus, and this adaptation was accompanied by a similar increase in in vitro insulin-stimulated glucose transport activity(+29%). After 2 and 4 wk of WR, however, insulin-stimulated glucose transport activity had returned to control levels, despite a continued elevation (+25-28%) of GLUT-4 protein. At these two time points, glycogen concentration was significantly enhanced in WR soleus (+21-42%), which coincided with significant reductions in glycogen synthase activity ratios (-23 to-41%). These results indicate that, in this model of soleus muscle functional overload, the GLUT-4 protein level may initially regulate insulin-stimulated glucose transport activity in the absence of changes in other modifying factors. However,this regulation of glucose transport activity by GLUT-4 protein may be subsequently overridden by elevated glycogen concentration.

Henriksen, Erik J.↗

NASA NTRS1973

Inertial reference unit

The inertial reference unit is a high performance gyro attitude reference system for use on the OAO spacecraft. The IRU is a three axis system, which provides both rate and attitude information for spacecraft control. The purpose of the IRU is to reduce the dependency on gimballed startrackers and, in turn, simplify the OAO ground operations by eliminating the need for the continual programming of gimballed startracker assignments in accordance with computed occultation schedules. During normal operations, it is used to control the pitch and yaw axes during experiment occultations and during spacecraft reorientations. The roll axis is continuously under control of the IRU except during brief periods for attitude update. To provide for these capabilities the IRU must be able to perform two basic functions. One is to maintain an inertially fixed reference for spacecraft control and the second is to accurately reorient the reference upon command.

Kull, F. J.↗

DOE OSTI2024

Innovating the next generation of commercial smart building software

Nearly 30% of commercial building energy use is wasted due to equipment faults and HVAC controls problems. The result is increased emissions, compromised comfort and productivity, and less reliable coordination of building power needs with a clean grid. The energy impact alone represents $17 billion in potential savings. Today’s smart building software provides a robust solution to address these operational deficiencies. Energy management and information systems (EMIS) are saving up to 9% on average, with two-year paybacks. They are being incorporated into energy management processes, commissioning services, and utility programs. As effective as they are, two barriers prevent even deeper benefits; limited personnel to fix problems once they are identified, and the expense and time to manually implement changes in control systems. In partnership with the research community, the EMIS industry is developing new capabilities to overcome these barriers. Moving beyond siloed products for either fault detection and diagnostics, or optimal control, these new capabilities empower users to not only automatically identify faults, but also to push corrective action, and control improvements to their buildings. In this paper, several areas for enhancements are documented: ‘one-time’ correction of faults such as setpoints, schedules, and economizer lockouts; short-term active testing for automated proportional integral derivative (PID) loop tuning and functional testing; and continuous supervisory control for demand flexibility and year-round efficiency. Results are presented from a pair of partner implementations out of a dozen providers integrating these enhancements into their products, including field tests from across the country, and insights into operator acceptance and integration into operations and maintenance practices.

Casillas, Armando↗

DOE OSTI2018

Reversible Surface Patterning by Dynamic Crosslink Gradients: Controlling Buckling in 2D

Abstract Harnessing the self‐organization of soft materials to make complex, well‐ordered surface patterns in a noninvasive manner is challenging. The wrinkling of thin films provides a compelling strategy to achieve this. Despite much attention, however, a simple, single‐step, reversible method that gives rise to controlled, two‐dimensional (2D) ordered, continuous, and discontinuous patterns has proven to be elusive. Here a novel, robust method is described to achieve this using an ultraviolet‐light‐sensitive anthracene‐containing polymer thin film. The origin of the patterns is the local buckling of the thin film, where the control over the topology is given by laterally patterning out‐of‐plane gradients in the crosslink density of the film. The underlying buckling mechanics and formation of the surface features are well‐described by finite element analysis. By illuminating the film with a photomask, local and long‐range patterns that can be both continuous and discontinuous are able to be written. Furthermore, the patterning is fully reversible over multiple cycles. The results demonstrate a simple strategy for erasable storage of information in a surface topography that has applications in memory, anticounterfeiting, and plasmonics.

Hou, Honghao↗

DOE OSTI2019

Fleetwide data-enabled reliability improvement of wind turbines

Wind farms are an indispensable driver toward renewable and nonpolluting energy resources. However, as ideal sites are limited, placement in remote and challenging locations results in higher logistics costs and lower average wind speeds. Therefore, it is critical to increase the reliability of the turbines to reduce maintenance costs. Robust implementation requires a thorough understanding of the loads subject to the turbine's control. Yet, such dynamically changing multidimensional loads are uncommon with other machinery, and generally underresearched. Therefore, a multitiered approach is proposed to investigate the load spectrum occurring in wind farms. Our approach relies on both fundamental research using controllable test rigs, as well as analyses of real-world loading conditions in high-frequency supervisory control and data acquisition data. A method is introduced to detect operational zones in wind farm data and link them with load distributions. Additionally, while focused research further investigates the load spectrum, a method is proposed that continuously optimizes the farm's control protocols without the need to fully understand the loads that occur. A case of gearbox failure is investigated based on a vast body of past experiments and suspect loads are identified. Starting from this evidence on the cause and effects of dynamic loads, the potential of our methods is shown by analyzing real-world farm loading conditions on a steady-state case of wake and developing a preventive row-based control protocol for a case of cascading emergency brakes induced by a storm.

17 WIND ENERGY↗