SEARCH · Engineering Papers

Results for “lessons learned process”

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.

SourceResearch connectionFrom yearThrough year

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

At least 1,225 records · Page 68

All sources NASA NTRS DOE OSTI

DOE OSTI2024

Beam test results for the Endcap Timing ReadOut Chip (ETROC2) for the CMS ETL upgrade

The Endcap Timing ReadOut Chip (ETROC) for the Compact Muon Solenoid (CMS) Minimum ionizing particle Timing Detector (MTD) is designed to process Low Gain Avalanche Diode (LGAD) signals with a time resolution of 40-50ps per hit, with 30-35 ps per charged particle using two layer detector. The ETROC2, is the first full size (16x16 pixels) and full functionally design that has been tested in hadron and electron beams at CERN and DESY (Sep 2023 - June 2024). Precision timing studies at these test beams are done using a self-referential beam telescope composed of up to 4 layers/chips. This talk describes the ETROC2 beam telescope and summarizes the performance of the ETROC2 chips bump-bonded to (16x16) Fondazione Bruno Kessler (FBK) and Hamamatsu Photonics K.K. (HPK) LGAD sensors using results from recent test beams. The experiences and lessons learned during the course of these test beams are also detailed in this talk.

Safdari, Murtaza↗

NASA NTRS1989

Computerized structural mechanics for 1990's: Advanced aircraft needs

The needs for computerized structural mechanics (CSM) as seen from the standpoint of the aircraft industry are discussed. These needs are projected into the 1990's with special focus on the new advanced materials. Preliminary design/analysis, research, and detail design/analysis are identified as major areas. The role of local/global analyses in these different areas is discussed. The lessons learned in the past are used as a basis for the design of a CSM framework that could modify and consolidate existing technology and include future developments in a rational and useful way. A philosophy is stated, and a set of analyses needs driven by the emerging advanced composites is enumerated. The roles of NASA, the universities, and the industry are identified. Finally, a set of rational research targets is recommended based on both the new types of computers and the increased complexity the industry faces. Computerized structural mechanics should be more than new methods in structural mechanics and numerical analyses. It should be a set of engineering applications software products that combines innovations in structural mechanics, numerical analysis, data processing, search and display features, and recent hardware advances and is organized in a framework that directly supports the design process.

Viswanathan, A. V.↗

NASA NTRS2016

Large Payload Ground Transportation and Test Considerations

Many spacecraft concepts under consideration by the National Aeronautics and Space Administration’s (NASA’s) Evolvable Mars Campaign take advantage of a Space Launch System payload shroud that may be 8 to 10 meters in diameter. Large payloads can theoretically save cost by reducing the number of launches needed--but only if it is possible to build, test, and transport a large payload to the launch site in the first place. Analysis performed previously for the Altair project identified several transportation and test issues with an 8.973 meters diameter payload. Although the entire Constellation Program—including Altair—has since been canceled, these issues serve as important lessons learned for spacecraft designers and program managers considering large payloads for future programs. A transportation feasibility study found that, even broken up into an Ascent and Descent Module, the Altair spacecraft would not fit inside available aircraft. Ground transportation of such large payloads over extended distances is not generally permitted, so overland transportation alone would not be an option. Limited ground transportation to the nearest waterway may be possible, but water transportation could take as long as 67 days per production unit, depending on point of origin and acceptance test facility; transportation from the western United States would require transit through the Panama Canal to access the Kennedy Space Center launch site. Large payloads also pose acceptance test and ground processing challenges. Although propulsion, mechanical vibration, and reverberant acoustic test facilities at NASA’s Plum Brook Station have been designed to accommodate large spacecraft, special handling and test work-arounds may be necessary, which could increase cost, schedule, and technical risk. Once at the launch site, there are no facilities currently capable of accommodating the combination of large payload size and hazardous processing such as hypergolic fuels, pyrotechnic devices, and high pressure gasses. Ironically, the limiting factor to a national heavy lift strategy may not be the rocket technology needed to throw a heavy payload, but rather the terrestrial infrastructure—roads, bridges, airframes, and buildings—necessary to transport, acceptance test, and process large spacecraft. Failure to carefully consider where and how large spacecraft are manufactured, tested, and launched could result in unforeseen cost to modify existing (or develop new) infrastructure, or incur additional risk due to increased handling operations or eliminating key verifications. Although this paper focuses on the canceled Altair spacecraft as a case study, the issues identified here have wide applicability to other large payloads, including concepts under consideration for NASA’s Evolvable Mars Campaign.

Rucker, Michelle A.↗

DOE OSTI2020

Plowing Through the Cost Barrier: Zero Energy K-12 Schools for Less: Preprint

There is a perception that zero energy K–12 schools cost more than conventional schools. Zero energy schools provide a number of unique benefits to school districts, students and staff, and communities. Among other things, a zero energy school requires far less energy to operate than a conventional school and uses on-site renewable energy systems to offset that reduced energy load. The money saved on energy can often be used to enhance educational programs. But does the extra value come at a premium? Research findings indicate that not only can zero energy schools be designed and built on conventional school budgets, they can cost less. In an integrated design and construction process, the cost of zero energy measures can be offset by, for example, downsizing heating, ventilating, and air-conditioning systems, reducing both life cycle and first costs. These findings are based on an examination of 88 zero energy or zero energy ready schools across the United States built during the last 15 years. The data collected on these schools include capital costs and the experiences of owners and design teams. The goal was to understand the perceived cost barrier, given that each building was built with a predetermined budget. The results will help future school stakeholders, program administrators, and design teams counter the perceived cost barriers. Successful strategies for achieving zero energy at no initial cost are presented. The lessons learned from existing zero energy schools can help transform the market such that all new schools can be zero energy.

30 DIRECT ENERGY CONVERSION↗

NASA NTRS2003

The X-38 Spacecraft Fault-Tolerant Avionics System

In 1995 NASA began an experimental program to develop a reusable crew return vehicle (CRV) for the International Space Station. The purpose of the CRV was threefold: (i) to bring home an injured or ill crewmember; (ii) to bring home the entire crew if the Shuttle fleet was grounded; and (iii) to evacuate the crew in the case of an imminent Station threat (i.e., fire, decompression, etc). Built at the Johnson Space Center, were two approach and landing prototypes and one spacecraft demonstrator (called V201). A series of increasingly complex ground subsystem tests were completed, and eight successful high-altitude drop tests were achieved to prove the design concept. In this program, an unprecedented amount of commercial-off-the-shelf technology was utilized in this first crewed spacecraft NASA has built since the Shuttle program. Unfortunately, in 2002 the program was canceled due to changing Agency priorities. The vehicle was 80% complete and the program was shut down in such a manner as to preserve design, development, test and engineering data. This paper describes the X-38 V201 fault-tolerant avionics system. Based on Draper Laboratory's Byzantine-resilient fault-tolerant parallel processing system and their "network element" hardware, each flight computer exchanges information on a strict timescale to process input data, compare results, and issue voted vehicle output commands. Major accomplishments achieved in this development include: (i) a space qualified two-fault tolerant design using mostly COTS (hardware and operating system); (ii) a single event upset tolerant network element board, (iii) on-the-fly recovery of a failed processor; (iv) use of synched cache; (v) realignment of memory to bring back a failed channel; (vi) flight code automatically generated from the master measurement list; and (vii) built in-house by a team of civil servants and support contractors. This paper will present an overview of the avionics system and the hardware implementation, as well as the system software and vehicle command & telemetry functions. Potential improvements and lessons learned on this program are also discussed.

Kouba,Coy↗

NASA NTRS2016

Optical Testing and Verification Methods for the James Webb Space Telescope Integrated Science Instrument Module Element

NASA's James Webb Space Telescope (JWST) is a 6.6m diameter, segmented, deployable telescope for cryogenic IR space astronomy (~40K). The JWST Observatory includes the Optical Telescope Element (OTE) and the Integrated Science Instrument Module (ISIM) that contains four science instruments (SI) and the fine guider. The SIs are mounted to a composite metering structure. The SI and guider units were integrated to the ISIM structure and optically tested at the NASA Goddard Space Flight Center as a suite using the Optical Telescope Element SIMulator (OSIM). OSIM is a full field, cryogenic JWST telescope simulator. SI performance, including alignment and wave front error, were evaluated using OSIM. We describe test and analysis methods for optical performance verification of the ISIM Element, with an emphasis on the processes used to plan and execute the test. The complexity of ISIM and OSIM drove us to develop a software tool for test planning that allows for configuration control of observations, associated scripts, and management of hardware and software limits and constraints, as well as tools for rapid data evaluation, and flexible re-planning in response to the unexpected. As examples of our test and analysis approach, we discuss how factors such as the ground test thermal environment are compensated in alignment. We describe how these innovative methods for test planning and execution and post-test analysis were instrumental in the verification program for the ISIM element, with enough information to allow the reader to consider these innovations and lessons learned in this successful effort in their future testing for other programs.

spaceborne telescopes↗

DOE OSTI2022

Challenges and Lessons Learned in Applying Sensitivity Analysis to Building Stock Energy Models

Uncertainty Analysis (UA) and Sensitivity Analysis (SA) offer essential tools to determine the limits of inference of a model and explore the factors which have the most effect on the model outputs. However, despite a well established body of work applying UA and SA to models of individual buildings, a review of the literature relating to energy models for larger groups of buildings undertaken by Fennell et al. (2019) highlighted very limited application at larger scales. This contribution describes the efforts undertaken by a group of research teams in the context of IEA-EBC Annex 70 working with a diverse set of Building Stock Models (BSMs) to apply global sensitivity analysis methods and compare their results. Since BSMs are a class of model defined by their output and coverage rather than their structure and inputs, they represent a diverse set of modelling approaches. Key challenges for the application of SA are identified and explored, including the influence of model form, input data types and model outputs. This study combines results from 7 different modelling teams, each using different models across a range of urban areas to explore these challenges and begin the process of developing standardised workflows for SA of BSMs.

ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATION↗

NASA NTRSDate not supplied

A Model-Based Systems Engineering Journey to Developing a Concept of Operations

Starting in 2017, NASA’s Human Research Program (HRP) Exploration Medical Capability (ExMC) element began a systems engineering transition from traditional, document-centric development to model-centric development when defining its foundation medical systems. These foundation medical systems define a Concept of Operations (ConOps) and identify the generic requirements for a medical system based on assumptions about a generic crew and mission environments and guidance from NASA standards (e.g., Medical “Levels of Care”). By making the transition, ExMC intends to improve communication among stakeholders about foundation medical system requirements and content. In addition, this transition will enable ExMC to lower both development and crew treatment risks for future, mission-specific medical systems. ExMC followed a Model Based Systems Engineering (MBSE) paradigm when developing the foundation medical systems. A model-based approach provides several advantages over a traditional, document-centric approach. First, when Systems Engineers (SE) develop diagrams in a model using a standard modeling language, they produce information dense pictures that facilitate understanding much more efficiently with less room for misinterpretation than text. Second, due to the evolving nature of projects, documentation becomes out of date the minute it is published. This can result in people making decisions based on information that is no longer current, especially if they are referencing a locally-stored copy of a document. A model, on the other hand, is always up to date with the latest approved changes and information. It serves as a single point of truth. Third, a model-centric approach centralizes all important information in one place. Rather than having to flip through separate ConOps documents, design specifications, requirements specifications, and the like to coordinate information, a model captures the content in one, integrated spot. This integration makes tracing information from end-to-end easier with greater reliability. The ExMC Systems Engineering Lifecycle follows a well-defined process. ExMC Systems Engineers perform all major steps of the process, regardless of the development methodology. One of the first steps in the process is developing the ConOps that describes the operation of the system from the point of view of the users. It includes a list of the users and their needs, the goals of the medical system, key assumptions about the system, and definitions of the medical system’s operational environments. For this development effort, ExMC chose to replace the traditional text-based ConOps document with a model. While the decision to change the development workflow was not difficult, implementing the structural and organizational workflows were. It required showing ExMC’s users, most of whom are not Systems Engineers, how the information they require would be presented in the model and to gain their acceptance of this approach. This paper documents key lessons learned during the ConOps transformation by focusing on how the model represents information, the agile workflow used by SEs when developing the model and how it integrates into a project plan, how leadership influenced key users to accept the transformation, and how the users interact with the model information.

Jeffrey Robert Cohen↗

DOE OSTI2022

Community Energy Planning: Best Practices and Lessons Learned in NREL's Work with Communities

The clean energy transition is accelerating due to local, state, and national actions combined with external market forces. Regardless of where goals are set and decisions are made, clean energy deployment occurs on the ground in communities. As a result, communities increasingly need technical expertise and assistance with planning for and managing the energy transition. Building on decades of work with state, local, and tribal jurisdictions, the National Renewable Energy Laboratory (NREL) increasingly provides community-driven modeling, analysis, and technical assistance to enable more data-driven and equitable community energy planning. To inform and enhance NREL's capabilities in community energy planning and provide a resource for others working in this space, the Joint Institute for Strategic Energy Analysis (JISEA) Sustainable Communities Catalyzer supported this best-practices presentation based on interviews with seasoned NREL practitioners and a literature review on equitable community energy planning. Findings include five best practices for community energy planning that NREL practitioners and others can apply to strengthen their impact: 1) do your homework in preparation for community interactions; 2) be humble, authentic, and honest in your interactions with community members; 3) respect community agency in every step of the process; 4) meet the community where they are; 5) democratize participation.

best practices↗

DOE OSTI2021

Incentivizing Adoption of Software Quality Practices

Although many software teams across the laboratories comply with yearly software quality engineering (SQE) assessments, the practice of introducing quality into each phase of the software lifecycle, or the team processes, may vary substantially. Even with the support of a quality engineer, many teams struggle to adapt and right-size software engineering best practices in quality to fit their context, and these activities aren’t framed in a way that motivates teams to take action. In short, software quality is often a “check the box for compliance” activity instead of a cultural practice that both values software quality and knows how to achieve it. In this report, we present the results of our 6600 VISTA Innovation Tournament project, "Incentivizing and Motivating High Confidence and Research Software Teams to Adopt the Practice of Quality." We present our findings and roadmap for future work based on 1) a rapid review of relevant literature, 2) lessons learned from an internal design thinking workshop, and 3) an external Collegeville 2021 workshop. These activities provided an opportunity for team ideation and community engagement/feedback. Based on our findings, we believe a coordinated effort (e.g. strategic communication campaign) aimed at diffusing the innovation of the practice of quality across Sandia National Laboratories could over time effect meaningful organizational change. As such, our roadmap addresses strategies for motivating and incentivizing individuals ranging from early career to seasoned software developers/scientists.

96 KNOWLEDGE MANAGEMENT AND PRESERVATION↗

NASA NTRS1994

Linear Proof Mass Actuator

This paper describes the mechanical design, analysis, fabrication, testing, and lessons learned by developing a uniquely designed spaceflight-like actuator. The linear proof mass actuator (LPMA) was designed to attach to both a large space structure and a ground test model without modification. Previous designs lacked the power to perform in a terrestrial environment while other designs failed to produce the desired accelerations or frequency range for spaceflight applications. Thus, the design for a unique actuator was conceived and developed at NASA Langley Research Center. The basic design consists of four large mechanical parts (mass, upper housing, lower housing, and center support) and numerous smaller supporting components including an accelerometer, encoder, and four drive motors. Fabrication personnel were included early in the design phase of the LPMA as part of an integrated manufacturing process to alleviate potential difficulties in machining an already challenging design. Operating testing of the LPMA demonstrated that the actuator is capable of various types of load functions.

Holloway, Sidney E., III↗

NASA NTRS1995

Linear Proof Mass Actuator

This paper describes the mechanical design, analysis, fabrication, testing, and lessons learned by developing a uniquely designed spaceflight-like actuator. The Linear Proof Mass Actuator (LPMA) was designed to attach to both a large space structure and a ground test model without modification. Previous designs lacked the power to perform in a terrestrial environment while other designs failed to produce the desired accelerations or frequency range for spaceflight applications. Thus, the design for a unique actuator was conceived and developed at NASA Langley Research Center. The basic design consists of four large mechanical parts (Mass, Upper Housing, Lower Housing, and Center Support) and numerous smaller supporting components including an accelerometer, encoder, and four drive motors. Fabrication personnel were included early in the design phase of the LPMA as part of an integrated manufacturing process to alleviate potential difficulties in machining an already challenging design. Operational testing of the LPMA demonstrated that the actuator is capable of various types of load functions.

Holloway, S. E., III↗

NASA NTRS2003

Reference Material Kydex(registered trademark)-100 Test Data Message for Flammability Testing

The Marshall Space Flight Center (MSFC) Materials and Processes Technical Information System (MAPTIS) database contains, as an engineering resource, a large amount of material test data carefully obtained and recorded over a number of years. Flammability test data obtained using Test 1 of NASA-STD-6001 is a significant component of this database. NASA-STD-6001 recommends that Kydex 100 be used as a reference material for testing certification and for comparison between test facilities in the round-robin certification testing that occurs every 2 years. As a result of these regular activities, a large volume of test data is recorded within the MAPTIS database. The activity described in this technical report was undertaken to mine the database, recover flammability (Test 1) Kydex 100 data, and review the lessons learned from analysis of these data.

Engel, Carl D.↗

NASA NTRS2004

Results from an Investigation into Extra-Vehicular Activity (EVA) Training Related Shoulder Injuries

The number and complexity of extravehicular activities (EVAs) required for the completion and maintenance of the International Space Station (ISS) is unprecedented. The training required to successfully complete this magnitude of space walks presents a real risk of overuse musculoskeletal injuries to the EVA crew population. There was mounting evidence raised by crewmembers, trainers, and physicians at the Johnson Space Center (JSC) between 1999 and 2002 that suggested a link between training in the Neutral - Buoyancy Lab (NBL) and the several reported cases of shoulder injuries. The short- and long-term health consequences of shoulder injury to astronauts in training as well as the potential mission impact associated with surgical intervention to assigned EVA crew point to this as a critical problem that must be mitigated. Thus, a multi-directorate tiger team was formed in December of 2002 led by the EVA Office and Astronaut Office at the JSC. The primary objectives of this Tiger Team were to evaluate the prevalence of these injuries and substantiate the relationship to training in the NBL with the crew person operating in the EVA Mobility Unit (EMU). Between December 2002 and June of 2003 the team collected data, surveyed crewmembers, consulted with a variety of physicians, and performed tests. The results of this effort were combined with the vast knowledge and experience of the Tiger Team members to formulate several findings and over fifty recommendations. This paper summarizes those findings and recommendations as well as the process by which these were determined. The Tiger Team concluded that training in the NBL was directly linked to several major and minor shoulder injuries that had occurred. With the assistance of JSC flight surgeons, outside consultants, and the lead crewmember/physician on the team, the mechanisms of injury were determined. These mechanisms were then linked to specific aspects of the hardware design, operational techniques, and the training environment. During the 1999 to 2003 time frame many variables converged to make it impossible to determine with any accuracy which one or two root causes were primarily involved. Therefore a broad range of recommendations was established to prevent future injury to crewmembers training in the NBL in the near term. Many of these recommendations are lessons learned that are essentially timeless and therefore should be passed on to future EVA endeavors to ensure that hardware designs and operational techniques utilized in the future consider the demands of training on the human body here on earth.

Johnson, Brian J.↗

NASA NTRS2019

Evolving Management Strategies to Improve NASA Flagship's Cost and Schedule Performance: LUVOIR as a Case Study

The LUVOIR study process has brought to fruition an extremely exciting scientific mission concept. The 3.5 year LUVOIR study duration enabled an unprecedented level of scientific, engineering, and technology thoroughness prior to the Astro2020 Decadal. This detail also shed light on many technical and programmatic challenges for efficiently developing a mission of this scale. While NASA's flagships perform exquisitely once on-orbit, there is understandable growing frustration in their development cost and schedule overruns. We felt it incumbent upon ourselves to ask how we could improve on delivering LUVOIR (or any of NASA's future flagships) on schedule and on budget, not just for the next mission, but for all NASA large strategic missions to come. We researched past and current NASA flagship's lessons learned publications and other large government projects that pointed to some systemic challenges that will only grow with larger and more complex strategic missions. Our findings pointed us to some ways that could potentially evolve NASA's current flagship management practices to help improve on their development cost and schedule performance despite their growing complexity.. This paper briefly comments on the science motivation for NASA's flagships and on the science motivation for a LUVOIR-like mission. We argue the motivation for improving NASA's flagships development cost and schedule performance. We review the specific challenges of NASA's flagships to acknowledge their specific issues. We then examine the most repeated systemic challenges we found from previous NASA flagship and other large government project lessons learned/observed. Lastly, we offer recommendations to tackle these repeated systemic challenges facing NASA's flagships. The recommendations culminate into a proactive integrated development and funding framework to enable improving the execution of NASA's future flagship's cost and schedule performance.

Crooke, Julie A.↗

NASA NTRS2006

Leadership Challenges in ISS Operations: Lessons Learned from Junior and Senior Mission Control Personnel

The International Space Station (ISS) is operated by a multi-national, multi-organizational team that is dispersed across multiple locations, time zones, and work schedules. At NASA, both junior and senior mission control personnel have had to find ways to address the leadership challenges inherent in such work, but neither have had systematic training in how to do so. The goals of this study were to examine the major leadership challenges faced by ISS mission control personnel and to highlight the approaches that they have found most effective to surmount them. We pay particular attention to the approaches successfully employed by the senior personnel and to the training needs identified by the junior personnel. We also evaluate the extent to which responses are consistent across the junior and senior samples. Further, we compare the issues identified by our interview survey to those identified by a standardized questionnaire survey of mission control personnel and a contrasting group of space station crewmembers. We studied a sample of 14 senior ISS flight controllers and a contrasting sample of 12 more junior ISS controllers. Data were collected using a semi-structured qualitative interview and content analyzed using an iterative process with multiple coders and consensus meetings to resolve discrepancies. To further explore the meaning of the interview findings, we also conducted new analyses of data from a previous questionnaire study of 13 American astronauts, 17 Russian cosmonauts, and 150 U.S. and 36 Russian mission control personnel supporting the ISS or Mir space stations. The interview data showed that the survey respondents had substantial consensus on several leadership challenges and on key strategies for dealing with them, and they offered a wide range of specific tactics for implementing these strategies. Interview data from the junior respondents will be presented for the first time at the meeting. The questionnaire data showed that the US mission control sample reported a level of support from their management that compared favorably to national norms. American mission control personnel and Russian crewmembers reported higher supervisor support than American crewmembers and Russian mission control personnel. We will present the specific issues underlying these findings and compare and contrast the results from the two datasets. Although specific to space station personnel, our results are consistent with recent management, cultural, and aerospace research. We aim to use our results to improve training for current and future mission control personnel.

Clement, James L.↗

NASA NTRS2011

Development of Tools and Techniques for Processing STORRM Flight Data

While at JSC for the summer of 2011, I was assigned to work on the sensor test for Orion relative-navigation risk mitigation (STORRM) development test objective (DTO). The STORRM DTO was flown on-board Endeavor during STS-134. The objective of the STORRM DTO is to test the visual navigation system (VNS), which will be used as the primary relative navigation sensor for the Orion spacecraft. The VNS is a flash lidar system intended to provide both line of sight and range information during rendezvous and proximity operations. The STORRM DTO also serves as a testbed for the high-resolution docking camera. This docking camera will be used to provide piloting cues for the crew during proximity operations. These instruments were mounted next to the trajectory control sensor (TCS) in Endeavour s payload bay. My principle objective for the summer was to generate a best estimated trajectory (BET) for Endeavor using the flight data collected by the VNS during rendezvous and the unprecedented re-rendezvous with the ISS. I processed the raw images from the VNS to produce range and bearing measurements. I then aggregated these measurements and extracted the measurements corresponding to individual reflectors. I combined the information contained in these measurements with data from the Endeavour's inertial sensors using Kalman smoothing techniques to ultimately produce a BET. This work culminated with a final presentation of the result to division management. Development of this tool required that traditional linear smoothing techniques be modified in a novel fashion to permit for the inclusion of non-linear measurements. This internship has greatly helped me further my career by providing exposure to real engineering projects. I also have benefited immensely from the mentorship of the engineers working on these projects. Many of the lessons I learned and experiences I had are of particular value because then can only be found in a place like JSC.

Robinson, Shane↗

DOE OSTI2023

Observations and Lessons Learned From Installing Residential Roofing-Integrated Photovoltaics

Building-sited solar photovoltaics (PV) could play a key role in decarbonizing the building sector either through racked and mounted PV or through Building-integrated PV (BIPV). BIPV is installed into the building envelope itself, with solar cells and/or modules forming the outer layer of a building structure, thus transforming a single-purpose structure into one that serves the dual purposes of the building envelope and electricity. BIPV can be applied to building roofs, facades, awnings, pergolas, windows, skylights, balustrades, and other external surfaces. Given BIPV products vary widely, the focus of this research is residential roofing integrated PV (RIPV), where solar is incorporated into or otherwise replaces the roofing material. Previous research suggests that residential RIPV could reduce customer acquisition, labor, supply chain, and equipment costs. These products have yet to realize these cost savings and deployment remains significantly less than conventional rooftop PV as a relative share of the addressable market in the US. One potential barrier to broader residential roofing integrated PV deployment may be higher costs relative to conventional rooftop PV, primarily because the design and installation of these products is still evolving. Here, we explore residential RIPV cost-reduction opportunities by analyzing installation processes. Our study documents residential RIPV installations at 2 reroofing sites and the equivalent of 9 new construction sites in California through a methodology known as time and motion study. We also conducted interviews with subject-matter experts to identify barriers and solutions to maximize these products' market penetration. Our time and motion study breaks the RIPV installation process into four steps: 1) staging, unloading, and roof preparation; 2) fire resistant underlayment(s) (synthetic material laid between roof shingles and roof deck); 3) flashings and PV installation; and 4) wiring and monitoring. We measure the time required for each step in terms of worker-hours, representing an hour of labor from a single worker. We further normalize process time by dividing worker-hours by kilowatt (kW) of system capacity. The most time-intensive step was flashings and PV installation, taking around 2.4 worker-hours per kW on average and accounting for around 60% of the process time for an average installation. The total installation process took on average about 6.4 and 3.5 worker-hours per kW at the reroofing sites and new construction sites, respectively. For comparison, a previous time and motion study documented a time of 6.9 worker-hours per kW for conventional rooftop PV. The shorter RIPV installation times are consistent with previous studies suggesting that RIPV could be installed faster than conventional rooftop PV. The time and motion results and feedback from interviewees provide insights into potential residential RIPV cost reduction opportunities. Several interviewees suggested that these products would be more efficient if PV installation was more fully integrated into the roofing/construction industries, which currently use separate supply chains and skillsets. Further integration could reduce supply chain delays and labor force redundancies. Future research could explore specific ways to integrate these industries to help realize the cost savings potential of RIPV.

14 SOLAR ENERGY↗