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At least 1,153 records · Page 64

Real-time process monitoring for direct ink write additive manufacturing

Direct ink write (DIW) printing of reactive resins presents a unique challenge due to the time-dependent nature of the rheological and chemical properties of the ink. As a result, careful print optimization or process control is important to obtain consistent, high quality prints. The present invention uses a flow-through characterization cell for in situ chemical monitoring of a resin ink during DIW printing. Additionally, in-line extrusion force monitoring can be combined with off-line post inspection using machine vision. By combining in-line spectroscopy and force monitoring, it is possible to follow reaction kinetics (for example, curing of a reactive resin) and viscosity changes during printing, which can be used for a closed-loop process control. Additionally, the capability of machine vision to automatically identify and quantify print artifacts can be incorporated on the printing line to enable real-time, AI-assisted quality control of the printed products. Together, these techniques can form the building blocks of an optimized process control strategy when complex reactive ink must be used to produce printed hardware.

Cook, Adam W.↗

A real-time simulator of a turbofan engine

A real-time digital simulator of a Pratt and Whitney F100 engine has been developed for real-time code verification and for actuator diagnosis during full-scale engine testing. This self-contained unit can operate in an open-loop stand-alone mode or as part of closed-loop control system. It can also be used for control system design and development. Tests conducted in conjunction with the NASA Advanced Detection, Isolation, and Accommodation program show that the simulator is a valuable tool for real-time code verification and as a real-time actuator simulator for actuator fault diagnosis. Although currently a small perturbation model, advances in microprocessor hardware should allow the simulator to evolve into a real-time, full-envelope, full engine simulation.

Litt, Jonathan S.↗

Free-piston Stirling engine conceptual design and technologies for space power, phase 1

As part of the SP-100 program, a phase 1 effort to design a free-piston Stirling engine (FPSE) for a space dynamic power conversion system was completed. SP-100 is a combined DOD/DOE/NASA program to develop nuclear power for space. This work was completed in the initial phases of the SP-100 program prior to the power conversion concept selection for the Ground Engineering System (GES). Stirling engine technology development as a growth option for SP-100 is continuing after this phase 1 effort. Following a review of various engine concepts, a single-cylinder engine with a linear alternator was selected for the remainder of the study. The relationships of specific mass and efficiency versus temperature ratio were determined for a power output of 25 kWe. This parametric study was done for a temperature ratio range of 1.5 to 2.0 and for hot-end temperatures of 875 K and 1075 K. A conceptual design of a 1080 K FPSE with a linear alternator producing 25 kWe output was completed. This was a single-cylinder engine designed for a 62,000 hour life and a temperature ratio of 2.0. The heat transport systems were pumped liquid-metal loops on both the hot and cold ends. These specifications were selected to match the SP-100 power system designs that were being evaluated at that time. The hot end of the engine used both refractory and superalloy materials; the hot-end pressure vessel featured an insulated design that allowed use of the superalloy material. The design was supported by the hardware demonstration of two of the component concepts - the hydrodynamic gas bearing for the displacer and the dynamic balance system. The hydrodynamic gas bearing was demonstrated on a test rig. The dynamic balance system was tested on the 1 kW RE-1000 engine at NASA Lewis.

Penswick, L. Barry↗

Software-Defined Virtual Synchronous Condenser

Synchronous condensers (SCs) play important roles in integrating wind energy into relatively weak power grids. However, the design of SCs usually depends on specific application requirements and may not be adaptive enough to the frequently-changing grid conditions caused by the transition from conventional to renewable power generation. This paper devises a software-defined virtual synchronous condenser (SDViSC) method to address the challenges. Our contributions are fourfold: 1) design of a virtual synchronous condenser (ViSC) to enable full converter wind turbines to provide built-in SC functionalities; 2) engineering SDViSCs to transfer hardware-based ViSC controllers into software services, where a Tustin transformation-based software-defined control algorithm guarantees accurate tracking of fast dynamics under limited communication bandwidth; 3) a software-defined networking-enhanced SDViSC communication scheme to allow enhanced communication reliability and reduced communication bandwidth occupation; and 4) Prototype of SDViSC on our real-time, cyber-in-the-loop digital twin of large-wind-farm in an RTDS environment. Furthermore, extensive test results validate the excellent performance of SDViSC to support reliable and resilient operations of wind farms under various physical and cyber conditions.

17 WIND ENERGY↗

The use of interleaving for reducing radio loss in convolutionally coded systems

The use of interleaving after convolutional coding and deinterleaving before Viterbi decoding is proposed. This effectively reduces radio loss at low-loop Signal to Noise Ratios (SNRs) by several decibels and at high-loop SNRs by a few tenths of a decibel. Performance of the coded system can further be enhanced if the modulation index is optimized for this system. This will correspond to a reduction of bit SNR at a certain bit error rate for the overall system. The introduction of interleaving/deinterleaving into communication systems designed for future deep space missions does not substantially complicate their hardware design or increase their system cost.

Divsalar, D.↗

Conceptual design of a closed loop nutrient solution delivery system for CELSS implementation in a micro-gravity environment

Described here are the results of a study to develop a conceptual design for an experimental closed loop fluid handling system capable of monitoring, controlling, and supplying nutrient solution to higher plants. The Plant Feeder Experiment (PFE) is designed to be flight tested in a microgravity environment. When flown, the PFX will provide information on both the generic problems of microgravity fluid handling and the specific problems associated with the delivery of the nutrient solution in a microgravity environment. The experimental hardware is designed to fit into two middeck lockers on the Space Shuttle, and incorporates several components that have previously been flight tested.

Schwartzkopf, Steven H.↗

Design of a battery charger for the NASA EOS space platform

A battery charger design for the NASA Earth Observing System (EOS) space platform has been developed and tested. The authors discuss the design of the battery charger power state and its current and voltage control loops. In addition to restoring energy to the batteries, this charger regulates the spacecraft bus voltage during the posteclipse transition period. The battery charger design and analysis were facilitated by use of the pulse-width-modulated (PWM) switch model and the new continuous-time model for current-mode control. Analyses of the battery charger small-signal behavior are compared to hardware measurements to verify modeling accuracy.

Sizemore, Tom↗

Development of a Compact Efficient Cooling Pump for Space Suit Life Support Systems

With the increasing demands placed on extravehicular activity (EVA) for the International Space Station (ISS) assembly and maintenance, along with planned lunar and Martian missions, the need for increased human productivity and capability becomes ever more critical. This is most readily achieved by reduction in space suit weight and volume, and increased hardware reliability, durability, and operating lifetime. Considerable progress has been made with each successive generation of space suit design; from the Apollo A7L suit, to the current Shuttle Extravehicular Mobile Unit (EMU) suit, and the next generation Constellation Space Suit Element (CSSE). However, one area of space suit design which has continued to lag is the fluid pump used to drive the water cooling loop of the Primary Life Support System (PLSS). The two main types of fluid pumps typically used in space applications are rotodynamic pumps (pumping is achieved through a rotary vaned impeller) and displacement pumps (which includes rotary and diaphragm pumps). The rotating and moving parts found in the pumps and electric motor add significantly to the susceptibility to wear and friction, thermal mismatch, and complexity of the pumps. Electric motor-driven pumps capable of achieving high operational reliability are necessarily large, heavy, and energy inefficient. This report describes a development effort conducted for NASA by Lynntech, Inc., who recently demonstrated the feasibility of an electrochemically-driven fluid cooling pump. With no electric motor and minimal lightweight components, an electrochemically-driven pump is expected to be significantly smaller, lighter and achieve a longer life time than conventional rotodynamic and displacement pumps. By employing sulfonated polystyrene-based proton exchange membranes, rather than conventional Nafion membranes, a significant reduction in the actuator power consumption was demonstrated. It was also demonstrated that these membranes possess the necessary mechanical strength, durability, and temperature range for long life space operation. The preliminary design for a Phase II prototype pump compares very favorably to the fluid cooling pumps currently used in space suit portable life support systems (PLSS). Characteristics of the electrochemically-driven pump are described and the benefits of the technology as a replacement for electric motor pumps in mechanically pumped single-phase fluid loops (MPFLs) is discussed.

vanBoeyen, Roger W.↗

In-Flight Evaluation of the Traffic Aware Planner on the NASA HU-25A Guardian Aircraft

NASA’s Traffic Aware Planner (TAP) software is a research-prototype decision support tool that provides pilots with time- and fuel-saving route recommendations that optimize their current trajectory. The software runs on a first-of-a-kind system architecture onboard three aircraft in revenue service conducting operational evaluations with a major domestic airline. Therefore, significant NASA-internal testing is required prior to releasing the software to the partner airline. This paper describes a flight test plan that exercises the functionality of the TAP software in a representative operational environment, describes the system architecture developed and implemented for the NASA Langley HU-25A Guardian aircraft to support the test objectives, presents outcomes of the flight test campaign, and discusses use cases that demonstrate the value of flight testing for this activity.Research into flight path optimization of transport aircraft conducted by the National Aeronautics and SpaceAdministration (NASA) has produced an operational concept known as Traffic Aware Strategic Aircrew Requests(TASAR) [1, 2]. This near-term concept [3] provides the aircrew with a flight deck decision support tool known asthe Traffic Aware Planner (TAP). The TAP software leverages a growing number of information sources on the flightdeck to make time- and fuel-saving route optimization recommendations to the aircrew while en route. The aircrewcan then use the suggestions provided by the tool to make route change requests with a greater likelihood of acceptanceby air traffic control (ATC). Since TASAR is a concept intended for the current operational environment, it isintentionally designed to have no safety-critical impact or require any changes to current Federal AviationAdministration (FAA) rules and procedures [4, 5].The research prototype TAP system [6–8], explained further in Section III.C, continually incorporates up-to-dateaircraft state data from onboard avionics, as well as the latest position of surrounding traffic, the most recent windforecast, and the most recent convective weather forecast, in order to calculate candidate trajectory modifications thatimprove upon the current active route. These trajectories account for user-selectable objective functions [3] of reducedfuel burn, reduced flight time, or an airline-derived combination of factors known as trip cost. Previous analyses andsimulations have estimated substantial savings for airlines employing this technique within the U.S. National AirspaceSystem (NAS) [9–11]. Operational evaluations with Alaska Airlines seek to validate these projected benefits usingmeasured data while simultaneously providing benefits to the airline [12, 13].The TAP software has undergone a number of human-in-the-loop simulations [14] and flight test activities[15–17] in order to validate the operational concept, evaluate human factors considerations (e.g., workload, usability,distraction, etc.), and to assess the ability of the software to function in a representative operational environment (e.g.,connected to live avionics data, using in-flight internet connectivity, etc.). However, these simulations and flight testcampaigns did not account for the hardware architecture implemented on the three aircraft for Alaska Airlines’operational evaluations of the TAP software. Therefore, a need was identified to thoroughly test the functionality ofthe software in a similar hardware architecture to that of the partner airline’s aircraft. Information regarding testapparatus and environments used to evaluate TAP prior to testing on the HU-25A can be found in reference [18].A campaign of flight trials on a NASA aircraft, the HU-25A Guardian, was conducted to ensure that the researchprototype TAP system functions well in a configuration similar to the Alaska Airlines aircraft prior to deployment.This airborne, networked environment enables an assessment of the operational factors unique to the flight environment. Additionally, this activity evaluated the effectiveness and benefit of new TAP functionality andoperation in a relevant flight environment while allowing the rapid prototyping of new concepts and features.This paper is organized as follows: Section II discusses the details of the flight test plan, flight profiles, and theduties of personnel involved with conducting flight operations. Section III describes the test platform, avionicsequipage, and system architecture. Section IV presents a discussion of results, and Section V contains concludingremarks.

Underwood, Matthew C.↗

Europa Clipper Thermal Control Design

This paper details the design developments of the Europa Clipper spacecraft thermal control system and its primary element the Heat Redistribution System (HRS). The Europa Clipper spacecraft will launch in the early 2020s and will have multiple flybys of Jupiter’s icy moon, Europa. The HRS, which utilizes a Mechanically Pumped Fluid Loop (MPFL) to reclaim waste heat from an avionics vault module and redistribute it to the propulsion module and radiator, has become an integral part of the spacecraft architecture both in terms of mechanical configuration and spacecraft operations capability. A walkthrough on the planned implementation of the HRS on the primary spacecraft modules is provided along with a description on thermal control of spacecraft hardware not located on the HRS vault, where thermal isolation and tolerance to extreme thermal environment drives the hardware designs.

Bhandari, Pradeep↗

Prototype part task trainer: A remote manipulator system simulator

The Part Task Trainer program (PTT) is a kinematic simulation of the Remote Manipulator System (RMS) for the orbiter. The purpose of the PTT is to supply a low cost man-in-the-loop simulator, allowing the student to learn operational procedures which then can be used in the more expensive full scale simulators. PTT will allow the crew members to work on their arm operation skills without the need for other people running the simulation. The controlling algorithms for the arm were coded out of the Functional Subsystem Requirements Document to ensure realistic operation of the simulation. Relying on the hardware of the workstation to provide fast refresh rates for full shaded images allows the simulation to be run on small low cost stand alone work stations, removing the need to be tied into a multi-million dollar computer for the simulation. PTT will allow the student to make errors which in full scale mock up simulators might cause failures or damage hardware. On the screen the user is shown a graphical representation of the RMS control panel in the aft cockpit of the orbiter, along with a main view window and up to six trunion and guide windows. The dials drawn on the panel may be turned to select the desired mode of operation. The inputs controlling the arm are read from a chair with a Translational Hand Controller (THC) and a Rotational Hand Controller (RHC) attached to it.

Shores, David↗

In-Space technology experiments program. A high efficiency thermal interface (using condensation heat transfer) between a 2-phase fluid loop and heatpipe radiator: Experiment definition phase

Space Station elements and advanced military spacecraft will require rejection of tens of kilowatts of waste heat. Large space radiators and two-phase heat transport loops will be required. To minimize radiator size and weight, it is critical to minimize the temperature drop between the heat source and sink. Under an Air Force contract, a unique, high-performance heat exchanger is developed for coupling the radiator to the transport loop. Since fluid flow through the heat exchanger is driven by capillary forces which are easily dominated by gravity forces in ground testing, it is necessary to perform microgravity thermal testing to verify the design. This contract consists of an experiment definition phase leading to a preliminary design and cost estimate for a shuttle-based flight experiment of this heat exchanger design. This program will utilize modified hardware from a ground test program for the heat exchanger.

Pohner, John A.↗

Functional Volume Assessment of an Early Version of the Mars Transit Habitat

During the summer of 2020, the NASA Mars Architecture Team (MAT) conducted a functional volume assessment of the Transit Habitat (TH). The TH has evolved substantially since that time and the current TH does not share the same internal configuration, but the insights gained from the assessment remain relevant. In virtually all architectures involving chemical, electric, or nuclear propulsion, the majority of the crew mission is spent aboard the TH. The Earth to Mars transit durations may vary from architecture to architecture, but all are on the order of hundreds of days, regardless of whether an opposition or conjunction class trajectory is selected, and regardless of whether the propulsion system is chemical, electric, or nuclear. Thus, the TH must provide capabilities appropriate to a very long duration. So, despite significant changes in the current Mars architecture over the past few years, this evaluation still provides useful recommendations in the form of habitability guidance that can be applied to current and future TH concepts. This assessment had six primary objectives: provide a sanity check to the BOC-derived TH layout; understand if we can fit the hardware and functional tasks in the volume; provide a high-level assessment of how aggressive the layout is; generate a list of challenges or assumptions necessary to make it work; generate a list of future work to refine understanding; and identify proposed requirements. All of this information is critical to drive habitat sizing studies and key architecture decisions. It was clear that a human-in-the-loop (HITL) evaluation of some kind would be necessary, but several challenges were immediately identified. The most information could be gleaned from a Desert Research and Technology Studies (DRATS) type of mission operations test (MOT), but the TH concept was too low fidelity to construct the type of prototype necessary to conduct a MOT, nor were their financial resources to do so. The next best option – and really the one most appropriate for the BOC’s stage of maturity – is a Virtual Reality (VR) walk-through evaluation. However, NASA was in a shutdown state due to the COVID-19 pandemic and the VR labs were inaccessible. As a result, a tabletop evaluation was created, using .jpg imagery from the ECM CAD model along with Excel-based datasheets. High-level crew living and working functions within the habitat were identified for evaluation. Questionnaires using Likert scales assessed acceptability of habitat functions and sim quality – the degree to which the function was represented in CAD. This enabled the evaluation to be conducted by personnel working remotely. Each function was evaluated individually along with several overarching habitability parameters and vehicle subsystems. The results of this evaluation are discussed, including methodological challenges and rating challenges. Acceptability results are discussed for functions that the participants were able to rate and participant comments for functions that could not be related are also described. Final conclusions are described, including challenges or assumptions needed to make the TH design acceptable, future work needed to refine understanding of the TH, and proposed habitat requirements based on test data.

Transit Habitat↗

Vibration isolation technology development to demonstration

The main thrust of these studies has resulted in an active inertial feedforward/feedback isolation system. This prototype magnetic suspension system has been demonstrated in a laboratory setting in six degrees-of-freedom and has been preliminarily characterized in its isolation performance with favorable results. This isolation system consists of a closed loop digital control system referencing a platform around six relative and six inertial sensors. These sensors control the isolated mass through nine attractive electromagnetic actuators with a system capability of +/- three-tenths of an inch travel in three dimensions. The development of a prototype system from design to fabrication leads directly into the demonstration phase of the project which will attempt a low gravity environmental demonstration of engineering hardware for the isolation of a scientific payload. The demonstration phase of the project will use an aircraft low gravity maneuver to establish a research testbed for the study of isolation hardware and control strategies in an off-loaded environment. In developing this demonstration capability the Lewis Learjet aircraft has been characterized through its parabolic flight maneuvers and a trunnioned experimental volume has been designed for the test of both active and passive isolation packages. This vibration isolation testbed is operational and has two data acquisition systems available for both autonomous and interactive operation, with a combined input capability of 32 channels.

Grodsinsky, Carlos↗

From orbital debris capture systems through internal combustion engines on Mars

The investigation and conceptualization of an orbital debris collector was the primary area of design. In addition, an alternate structural design for Space Station Freedom and systems supporting resource utilization at Mars and the moon were studied. Hardware for production of oxygen from simulate Mars atmosphere was modified to permit more reliable operation at low pressures (down to 10 mb). An internal combustion engine was altered to study how Mars atmosphere could be used as a diluent to control combustion temperatures and avoid excess Mars propellant production requirements that would result from either methane-rich or oxygen-rich, methane-oxygen combustion. An elastic loop traction system that could be used for lunar construction vehicles was refined to permit testing. A parabolic heat rejection radiator system was designed and built to determine whether it was capable of increasing heat rejection rates during lunar daytime operation. In addition, an alternate space station truss design, utilizing a pre-integrated concept, was studied and found to reduce estimate extravehicular activity (EVA) time and increase the structural integrity when compared to the original Warren truss concept. An orbital-debris-capturing spacecraft design which could be mated with the Orbital Maneuvering Vehicle was studied. The design identified Soviet C-1B boosters as the best targets of opportunity in Earth orbits between an altitude of 900 km and 1100 km and at an inclination of 82.9 deg. A dual robot pallet, which could be spun to match the tumbling rate of the C-1B booster, was developed as the conceptual design.

Source record↗

A structurally adaptive space crane concept for assembling space systems on orbit

A space crane concept is presented which is based on erectable truss hardware to achieve high stiffness and low mass booms and articulating-truss joints which can be assembled on orbit. The hardware is characterized by linear load-deflection response and is structurally predictable. The crane can be reconfigured into different geometries to meet future assembly requirements. Articulating-truss joint concepts with significantly different geometries are analyzed and found to have similar static and dynamic performance, which indicates that criteria other than structural and kinematic performance can be used to select a joint. Passive damping and an open-loop preshaped command input technique greatly enhance the structural damping in the space crane and may preclude the need for an active vibrations suppression system.

Dorsey, John T.↗

Design Considerations for High-Speed Control Systems

Existing hardware integrated into versatile, high-speed control system. Report discusses five global design considerations to integrate array-processor, multimicroprocessor, and host-computer system architectures into versatile, high-speed controllers. Such controllers are capable of control throughputs as high as 36 MHz for 8-bit bytes and maintain constant interaction with non-real-time or user environment. Application example, architecture of high-speed, closed-loop controller used to control helicopter vibration actively discussed.

Jacklin, S. A.↗

Parametric Analysis of Life Support Systems for Future Space Exploration Missions

Having adopted a flexible path approach to space exploration, the National Aeronautics and Space Administration is in a process of evaluating future targets for space exploration. In order to maintain the welfare of a crew during future missions, a suite of life support technology is responsible for oxygen and water generation, carbon dioxide control, the removal of trace concentrations of organic contaminants, processing and recovery of water, and the storage and reclamation of solid waste. For each particular life support subsystem, a variety competing technologies either exist or are under aggressive development efforts. Each individual technology has strengths and weaknesses with regard to launch mass, power and cooling requirements, volume of hardware and consumables, and crew time requirements for operation. However, from a system level perspective, the favorability of each life support architecture is better assessed when the sub-system technologies are analyzed in aggregate. In order to evaluate each specific life support system architecture, the measure of equivalent system mass (ESM) was employed to benchmark system favorability. Moreover, the results discussed herein will be from the context of loop-closure with respect to the air, water, and waste sub-systems. Specifically, closure relates to the amount of consumables mass that crosses the boundary of the vehicle over the lifetime of a mission. As will be demonstrated in this manuscript, the optimal level of loop closure is heavily dependent upon mission requirements such as duration and the level of extra- vehicular activity (EVA) performed. Sub-system level trades were also considered as a function of mission duration to assess when increased loop closure is practical. Although many additional factors will likely merit consideration in designing life support systems for future missions, the ESM results described herein provide a context for future architecture design decisions toward a flexible path program.

Swickrath, Michael J.↗