Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “CAD”

Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 1,009 records · Page 56

Development of an Extended Reality (XR) Tool for Earth Science Visualization

In this presentation, we will discuss our work in adapting the NASA open source XR software, the Mixed Reality Exploration Toolkit (MRET), to an earth science domain. MRET is a NASA open source XR software for rapidly building extended reality (XR) environments for NASA domain problems, e.g., pulling in CAD models of thermal vac chamber and Roman Space Telescope to do fit checks. Primarily used for hardware integration & test, we have been adapting and extending MRET for science problems. Traditionally, scientists view and analyze the result of calculated or measured observables with static 1-D, 2-D or 3-D plots. It can be difficult to identify, track and understand the evolution of key features due to poor viewing angles and the nature of flat computer screens. Additionally, numerical models, such as the NASA GEOS climate model, are almost exclusively formulated and analyzed on Eulerian grids with points fixed in space and time. However, atmospheric phenomena such as convective clouds, hurricanes and wildfire smoke plumes move with the 3-D flow field, and it is often difficult and unnatural to understand these phenomena in an Eulerian reference frame as opposed to the Lagrangian reference frame in which nature operates. As part of an Earth Science Technology Office (ESTO) proposal, we have been adapting MRET to be a scientific exploration and analysis XR tool with integrated Lagrangian Dynamics (LD) for the Goddard Earth Observing System (GEOS) numerical weather prediction model. We believe this will help scientists identify, track, and understand the evolution of Earth Science phenomena. This presentation will discuss current results in our work in developing this XR tool for Earth Science.

Thomas Grubb↗

Volumetric Assessment of UPRITE Exercises From Marker-Based Motion Capture

BACKGROUND Lack of volumetric data on full-body movement of exercises presents a challenge to ensuring the fit of crew member’s full range of motion on the International Space Station (ISS). The Upright Proprioception Retention via In-flight Training and Evaluation (UPRITE) is a sensorimotor countermeasure device designed for maintaining crew members’ proprioception in a microgravity environment. A footplate—attached to a static base—rotates in two degrees of freedom (pitch and roll) up to a 20 deg angle. An initial volumetric assessment assuming an upright standing posture produced a cone-like shape with a narrow bottom and wide top. Such general volumetric assessments risk creating an overly conservative volume estimate, taking up more space than is necessary on the already limited interior space of the ISS, and neglecting necessary volume due to oversimplifying assumptions. Rather, higher-fidelity volumetric assessments offer more comprehensive insights in an environment where every area counts. The main objective of this work is to provide the spatial parameters of exercises on the UPRITE such that it is placed on the ISS according to its volumetric demands or that usage is adjusted to fit the available space. METHODS In 2023, a data collection was performed originally to inform loads and dynamics of system use and was recently leveraged for volumetric assessment. Three human subjects representing different body types (~63-76 inches in stature) performed a variety of board manipulations using UPRITE with body weight offload. The test collected the 3D positional data of a modified full-body Plug-in Gait marker set [1] via a 16-camera OptiTrack MoCap system. After processing – filling marker gaps and trimming data – in OptiTrack Motive, the recorded marker location data, which included device markers, was exported to a readable trajectory file. To accurately represent the full volume defining landmarks, additional markers were digitally added to an unscaled Modified Full Body Model [2]. The model was then scaled according to its subject parameters upon which an inverse kinematics analysis was performed. A custom plugin yielded model marker location data files. Volumetric analyses were performed on the recorded trajectory and model trajectory files using a custom Python-built tool that extracted the marker location data and plotted it in a 3D space. Concerned with only the maximum volume of the motion, a 3D convex hull analysis was applied to the plot, extracting the vertices or external points of the eventual 3D CAD output, dubbed aptly as a “volume shell”. This overall approach was based on guidance in a NASA-STD-3001 Technical Brief [3]. RESULTS AND DISCUSSION Batch volumetric assessment on the exercises for each subject was performed, producing high-fidelity volume shells in minimal time. Preliminary results highlighted the value in higher-fidelity volumes based on collected data when possible. For example, revolving a single posture in the cone assessment would not have sufficiently captured a single leg stance; rather, it would need to involve swinging the leg both forward and back. Additional observations and the maximal dimensions of the volumes, including those based on scaled data for ISS anthropometric requirements, will be presented at the Human Research Program Investigator’s Workshop. CONCLUSIONS While this work’s primary objective was for the UPRITE-to-ISS integration, the tool built to conduct this analysis has wide applications for future exercise systems as an informational tool for optimal device placement. The tool and its findings also have implications for exercise device design and spacecraft interior considerations on Gateway, the Lunar Pressurized Rover, and beyond. REFERENCES [1] Bell, C. A., et al. (2023) Recent Improvements and Verification of a Full Body Model in OpenSim. NASA Human Research Program Investigator’s Workshop. https://ntrs.nasa.gov/citations/20230001080 [2] Lostroscio, K., et al (2023) The Digital Astronaut Simulation. AHFE International Conference on Human Factors in Design, Engineering, and Computing for All. [3] Exercise Overview. (2023) NASA-STD-3001 Technical Brief. https://www.nasa.gov/wp-content/uploads/2023/12/ochmo-tb-031-exercise-overview.pdf?emrc=9d454c?emrc=9d454c

L D Quinto↗

Toward Adaptive Mixed-Element Unstructured Grids for Simulations of Viscous Flows

Accurate prediction of surface skin friction and heat transfer for viscous flow applications using computational fluid dynamics tools necessitates thin wall-normal elements in the boundary layer. A tetrahedral adaptation process is extended to incorporate the advancing front local reconnection procedure. Thin boundary-layer grids are adapted from the solution, which governs the boundary-layer grid parameters such as first cell height off the wall. The process enables grid-converged steady-state results from a CAD file. Results are presented across the speed range from low subsonic flow over an airfoil to high-speed flows over blunt bodies and a rocket.

CFD↗

Toward Adaptive Mixed-Element Unstructured Grids for Simulations of Viscous Flows

Accurate prediction of surface skin friction and heat transfer for viscous flow applications using computational fluid dynamics tools necessitates thin wall-normal elements in the boundary layer. A tetrahedral adaptation process is extended to incorporate the advancing front local reconnection procedure. Thin boundary-layer grids are adapted from the solution, which governs the boundary-layer grid parameters such as first cell height off the wall. The process enables grid-converged steady-state results from a CAD file. Results are presented across the speed range from low subsonic flow over an airfoil to high-speed flows over blunt bodies and a rocket.

chemically reacting flow↗

Distributed Sensing Node Configuration

A vision and radar sensor integration strategy for surveillance of Advance Air Mobility Mission concept of airspace is contained in the CAD drawing in this publication developed as part of NASA's Transformational Tools and Technology project. High-density airspace operations with multiple aircraft type and potentially noncooperative aircraft require distributed sensor detection and tracking systems to monitor airspace for safe, autonomous flight operations for advanced air mobility, urban air mobility, and high density small uncrewed air systems (SUAS) flight concepts. Contained herein are drawings that are available in the stp and creo file formats of the distributed sensing nodes. Additional dovetail integration is included to enable rapid changing of embedded system. A day in the life node deployment is included in the 2023_last_flight_day.mp4. Please cite this publication if you use these drawings. This sensor configuration methodology is presented in detail in the publication reference below. Chester Dolph, Thomas Lombaerts, Corey A. Ippolito, Vahram Stepanyan, Evan Kawamura, Keerthana Kannan, George Szatkowski, Todd Ferante, Christopher Morris, Federica Vitiello, Flavia Causa, Roberto Opromolla and Giancarmine Fasano. "Distributed Sensor Fusion of Ground and Air Nodes using Vision and Radar Modalities for Tracking Multirotor Small Uncrewed Air Systems and Birds," AIAA 2024-1781. AIAA SCITECH 2024 Forum. January 2024.

Chester V Dolph↗

Development of the METMAN Thermal Desktop Human Model for System Integration

Human thermal analysis and model development inform NASA’s space suit development, vehicle/habitat design, and survivability studies. Historically, human thermal models such as the 41-node metabolic man (METMAN) and the Wissler model have been standalone software tools developed with FORTRAN, a programming language known for its high performance in computationally intensive applications. Though efficient, these standalone programs pose challenges to coupled human-system analysis with detailed life support and thermal control subsystem models in other commercial software. This paper describes the conversion of the METMAN human thermal model from a standalone FORTRAN program to a model in Thermal Desktop (Ansys), a commonly used CAD-based simulation software for engineering that specializes in heat transfer, thermal radiation, and fluid flow analysis. This format was chosen to best facilitate model sharing and compatibility, enabling the direct integration of METMAN human thermal analysis with subsystem models across NASA programs and commercial partners.

Elizabeth Thurston↗

Emerging Technologies in the Built Environment: Geographic Information Science (GIS), 3D Printing, and Additive Manufacturing

Abstract 1: Geographic information systems emerged as a computer application in the late 1960s, led in part by projects at ORNL. The concept of a GIS has shifted through time in response to new applications and new technologies, and is now part of a much larger world of geospatial technology. This presentation discusses the relationship of GIS and estimating hourly and seasonal energy consumption profiles in the building sector at spatial scales down to the individual parcel. The method combines annual building energy simulations for city-specific prototypical buildings and commonly available geospatial data in a GIS framework. Abstract 2: This presentation focuses on 3D printing technologies and how they have rapidly evolved over the past couple of years. At a basic level, 3D printing produces physical models quickly and easily from 3D CAD, BIM (Building Information Models), and other digital data. Many AEC firms have adopted 3D printing as part of commercial building design development and project delivery. This presentation includes an overview of 3D printing, discusses its current use in building design, and talks about its future in relation to the HVAC industry. Abstract 3: This presentation discusses additive manufacturing and how it is revolutionizing the design of commercial and residential facilities. Additive manufacturing utilizes a broad range of direct manufacturing technologies, including electron beam melting, ultrasonic, extrusion, and laser metal deposition for rapid prototyping. While there is some overlap with the 3D printing talk, this presentation focuses on the materials aspect of additive manufacturing and also some of the more advanced technologies involved with rapid prototyping. These technologies include design of carbon fiber composites, lightweight metals processing, transient field processing, and more.

New, Joshua Ryan↗

Fabrication and Testing of Deflecting Cavities for APS

Jefferson Lab (Newport News, Virginia) in collaboration with Argonne National Laboratory (Argonne, IL) has fabricated and tested four first article, 2.8 GHz, deflecting SRF cavities, for Argonne's Short-Pulse X-ray (SPX) project. These cavities are unique in many ways including the fabrication techniques in which the cavity cell and waveguides were fabricated. These cavity subcomponents were milled from bulk large grain niobium ingot material directly from 3D CAD files. No forming of sub components was used with the exception of the beam-pipes. The challenging cavity and helium vessel design and fabrication results from the stringent RF performance requirements required by the project and operation in the APS ring. Production challenges and fabrication techniques as well as testing results will be discussed in this paper.

Mammosser, John↗

Breaking Barriers in Polymer Additive Manufacturing

Additive Manufacturing (AM) enables the creation of complex structures directly from a computer-aided design (CAD). There are limitations that prevent the technology from realizing its full potential. AM has been criticized for being slow and expensive with limited build size. Oak Ridge National Laboratory (ORNL) has developed a large scale AM system that improves upon each of these areas by more than an order of magnitude. The Big Area Additive Manufacturing (BAAM) system directly converts low cost pellets into a large, three-dimensional part at a rate exceeding 25 kg/h. By breaking these traditional barriers, it is possible for polymer AM to penetrate new manufacturing markets.

additive manufacturing↗

DIATOM (Data Initialization and Modification) Library Version 7.0

DIATOM is a library that provides numerical simulation software with a computational geometry front end that can be used to build up complex problem geometries from collections of simpler shapes. The library provides a parser which allows for application-independent geometry descriptions to be embedded in simulation software input decks. Descriptions take the form of collections of primitive shapes and/or CAD input files and material properties that can be used to describe complex spatial and temporal distributions of numerical quantities (often called “database variables” or “fields”) to help define starting conditions for numerical simulations. The capability is designed to be general purpose, robust and computationally efficient. By using a combination of computational geometry and recursive divide-and-conquer approximation techniques, a wide range of primitive shapes are supported to arbitrary degrees of fidelity, controllable through user input and limited only by machine resources. Through the use of call-back functions, numerical simulation software can request the value of a field at any time or location in the problem domain. Typically, this is used only for defining initial conditions, but the capability is not limited to just that use. The most recent version of DIATOM provides the ability to import the solution field from one numerical solution as input for another.

Crawford, David A.↗

Effects of Fuel Composition on EGR Dilution Tolerance in Spark Ignited Engines

Fuel-specific differences in exhaust gas recirculation (EGR) dilution tolerance are studied in a modern, direct-injection single-cylinder research engine. A total of 6 model fuel blends are examined at a constant research octane number (RON) of 95 using n-heptane, iso-octane, toluene, and ethanol. Laminar flame speeds for these mixtures, which were calculated two different methods (an energy fraction mixing rule and a detailed kinetic simulation), spanned a range of about 6 cm/s. A constant fueling nominal load of 350 kPa IMEPg at 2000 rpm was operated with varying CA50 from 8-20 CAD aTDCf, and with EGR increasing until a COV of IMEP of 5% is reached. The results illustrate that flame speed affects EGR dilution tolerance; fuels with increased flame speeds increase EGR tolerance. Specifically, flame speed correlates most closely to the initial flame kernel growth, measured as the time of ignition to 5% mass fraction burned. The effect of the latent heat of vaporization on the flame speed is taken into account for the ethanol-containing fuels. At a 30 vol% blend level, the increased enthalpy of vaporization of ethanol compared to conventional hydrocarbons can decrease the temperature at the time of ignition by a maximum of 15 C, which can account for up to a 3.5 cm/s decrease in flame speed. The ethanol-containing fuels, however, still exhibit a flame speed advantage, and a dilution tolerance advantage over the slower flame-speed fuels. The fuel-specific differences in dilution tolerance are significant at the condition examined, allowing for a 50% relative increase in EGR (4% absolute difference in EGR) at a constant COV of IMEP of 3%.

dilution tolerance↗

Design Methodology: ASICs with complex in-pixel processing for Pixel Detectors

The development of Application Specific Integrated Circuits (ASIC) for pixel detectors with complex in-pixel processing using Computer Aided Design (CAD) tools that are, themselves, mainly developed for the design of conventional digital circuits requires a specialized approach. Mixed signal pixels often require parasitically aware detailed analog front-ends and extremely compact digital back-ends with more than 1000 transistors in small areas below 100μm x 100μm. These pixels are tiled to create large arrays, which have the same clock distribution and data readout speed constraints as in, for example, micro-processors. The methodology uses a modified mixed-mode on-top digital implementation flow to not only harness the tool efficiency for timing and floor-planning but also to maintain designer control over compact parasitically aware layout.

43 PARTICLE ACCELERATORS↗

Topology Optimization of Cellular Structure.

This paper presents an end-to-end design process for compliance minimization based topological optimization of cellular structures through to the realization of a final printed product. Homogenization is used to derive properties representative of these structures through direct numerical simulation of unit cell models of the underlying periodic structure. The resulting homogenized properties are then used assuming uniform distribution of the cellular structure to compute the final macro-scale structure. A new method is then presented for generating an STL representation of the final optimized part that is suitable for printing on typical industrial machines. Quite fine cellular structures are shown to be possible using this method as compared to other approaches that use nurb based CAD representations of the geometry. Finally, results are presented that illustrate the fine-scale stresses developed in the final macro-scale optimized part and suggestions are made as to incorporate these features into the overall optimization process.

42 ENGINEERING↗

Additive Manufacturing: The Rise of a Technology and the Need for Quality Control and Inspection Techniques

Additive manufacturing (AM) technology, also known as three-dimensional (3D) printing, rapid prototyping (RP), or solid free forms (SFF), was developed back in the early 1980s. The technology was quickly commercialized in the late 1980s, and since then, the technology has been widely used in different applications at several industrial sectors. AM offers distinct advantages from traditional, subtractive manufacturing techniques. Traditional subtractive manufacturing techniques, including milling, drilling, and turning, are techniques that start with a large block of stock material, which is then subtracted from until the final desired product is reached, leaving much of the initial block as wasted scrap. In the AM process, the part is constructed by depositing material layer by layer in the Z-direction until the final product is produced, leaving little to no waste. The process starts with a computer-aided design (CAD) model that gets sliced into individual layers using software that generates instructions, known as G-code, which are sent to the AM machine. Here, this process allows complex geometry construction that traditional methods would have diffi-culty accomplishing or fail completely. In some cases, a secondary finishing process is needed such as polishing, sintering, curing, sanding, powder removal, or painting.

36 MATERIALS SCIENCE↗

CREATING TOOLPATHS WITHOUT STARTS AND STOPS FOR EXTRUSION-BASED SYSTEMS

Toolpath generation for extrusion-based additive manufacturing systems, called slicing, involves operations on polygonal contours that are derived from an STL file. Slicing generates multiple paths per layer (both closed-loop and open-loop) that are designed to optimally fill the space outlined by the polygon(s). In the course of printing a layer, the extruder must start and stop, the tip must be wiped, and the extruder must travel between paths without printing. Any amount of time the printer spends moving without printing is considered wasted time because the part isn’t being constructed. In addition, the start/stop point, known as the seam, is often a blemish on the surface of the part that contributes to weaker material properties. Therefore, a single path for creating multi-bead walled structures is desirable because it would save machine time and create parts with better surface finish. This paper will cover one method of modifying the CAD file and slicing engine to allow for parts to be printed without starting and stopping the extruder.

Roschli, Alex↗

Validation and Parametric Investigations Using a Lumped Thermal Parameter Model of an Internal Permanent Magnet Motor: Preprint

One of the key challenges for the electric vehicle industry is to develop high-power-density electric motors. Achieving higher power density requires efficient heat removal from inside the motor. In order to improve thermal management, a multi-physics modeling framework that is able to accurately predict the behavior of the motor, while being computationally efficient, is essential. This paper first presents a detailed validation of a Lumped Parameter Thermal Network (LPTN) model of an Internal Permanent Magnet (IPM) synchronous motor within the commercially available Motor-CAD® modeling environment. The IPM motor’s stator is studied at steady state, and winding losses are generated by a constant DC current. The validation is based on temperature comparison with experimental data and with more detailed Finite Element Analysis (FEA). All critical input parameters of the LPTN are considered in detail for each layer of the stator, especially the contact resistances between the impregnation, liner, laminations and housing. Finally, a sensitivity analysis for each of the critical input parameters is provided. A maximum difference of 4% - for the highest temperature in the slot windings and the end windings - was found between the LPTN and the experimental data. Comparing the results from the LPTN and the FEA model, the maximum difference was 2% for the highest temperature in the slot windings and end windings. As for the LTPN sensitivity analysis, the thermal parameter with the highest sensitivity was found to be the liner-to-lamination contact resistance. The latter is often ignored in the literature, whereas its impact on temperature rise was found to be more significant than any other contact resistance within the stator.

ADVANCED PROPULSION SYSTEMS↗

Long Reach Robotic Arm

The Accelerator Division at Fermilab began a robotics program, known as the AD Robotics Initiative. A multi-axis robotic arm was proposed to be included in the program. This summer internship, our team began the planning and design for this project, called the Long Reach Robotic Arm. The problem is that critical systems around the magnets require analysis when water leaks cause them to fail. However, the tightly compacted parts and the quadrupole magnet, weighing approximately 1,000 pounds, cause access viewing problems. The process of having to dismantle and remove the magnet is time-consuming; it is not an efficient solution. The goal for the Long Reach Robotic Arm was to extend and reach behind the component of the Main Injector while "snaking" around and avoiding obstructions. At the start of the project, my teammate, Amanda Hoeksema, and I coded a program in the C language that will determine the number of links and their respective lengths for the robot arm. After, we began the 3D CAD model of the robot arm, base, and counterweight system. The design of the Long Reach Robotic Arm provided a learning experience in learning how to code in the C programming language, using SDL libraries and understanding mechanical engineering.

43 PARTICLE ACCELERATORS↗

Optimal Efficiency and Operational Cost Savings: A Framework for Automated Rooftop PV Placement

Residential energy consumers are charged based on a utility rate structure, such as net metering or feed-in tariff. To lower consumers' electricity bills, expensive batteries are deployed to reduce the electricity fed from the grid during peak hours. However, strategic photovoltaic (PV) panel placement enables the reduction of operational energy cost while considering the spatial feasibility and efficiency for hosting rooftop PV. In this paper, we present a framework to automatically identify the optimal location of rooftop PV panels on residential buildings. Our framework integrates multiple workflows, including energy and environmental simulation, parametric modeling, and optimization to identify the ideal location of PV panels to balance the demand and supply at a building and community scale. These workflows are linked using the Grasshopper plug-in for Rhinoceros CAD software. The framework includes two different workflows, each satisfying a target for optimal PV placement: (a) maximizing PV panel efficiency, where users aim to maximize energy generation, and (b) minimizing operational energy cost, where "best'' panels are selected considering utility rates for operational energy cost. Our framework is demonstrated in a residential community in Fort Collins, Colorado, to generate the optimal PV placement for each of the two aforementioned targets. Results from the two workflows are compared to illustrate the effect of PV location and orientation on solar energy production efficiency and operational energy cost. The developed workflows are introduced as tools within the Grasshopper plug-in to investigate the solar potential of rooftop PV panels while taking into account factors such as contextual shading, utility rate structures, and buildings' energy demand profiles.

30 DIRECT ENERGY CONVERSION↗