SEARCH · Engineering Papers

Results for “controls prototyping”

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 1,369 records · Page 76

All sources NASA NTRS DOE OSTI

NASA NTRS2019

Electric Sail Tether Deployment System for CubeSats

An Electric Sail (E-Sail) propulsion system consists of long, thin tethers - positively-charged wires extending radially and symmetrically outward from a spacecraft. Tethers must be biased using a high-voltage power supply to ensure that the solar wind produces thrust. While the E-Sail concept shows great promise for flying heliopause missions with higher characteristic acceleration than solar sails, there are significant technical challenges related to deploying and controlling multiple tethers. A typical full-scale design involves a hub and spoke arrangement of 10 to 100 tethers, each 20 km long. In the last 20 years, there have been multiple space mission failures due to tether deployment and control issues, and most configurations involved a single tether. This paper describes an effort to develop and test a simple yet robust single-tether deployment system for a two-6U CubeSat configuration. The project included the following: a) Tether dynamic modeling/simulation b) E-Sail single-tether prototype development and testing c) Space environmental effects testing to identify best materials for further development. These three areas of investigation were needed to provide technical rationale for an E-Sail flight demonstration mission that is expected to be proposed for the 2022 time frame. The project team used an “agile” engineering approach in which E-Sail single-tether prototype designs were iteratively developed and tested to solve problems and identify design improvements. The agile approach was ideal for this low Technology Readiness Level (TRL) project because tether deployer development involved many unknowns in prototype development that could only be discovered through iterative cycles of construction and testing. Extensive modeling and simulation were accomplished for three types of tether deployment: a) Stage 1: propulsive separation with one 6U fixed b) Stage 2: propulsive spin-up with one 6U fixed c) Stage 3: propulsive spin-up with both 6Us free Simulation results were valuable for understanding the propulsive and braking forces needed for controlled tether deployment. This paper describes the evolution, insights, and test/ performance data related to the resultant single-tether two-6U E-Sail test article which has been demonstrated in a test laboratory. The development effort suggests near-term work needed to achieve a useful flight demonstration, and provides ideas for how multiple-tether deployment systems might evolve going forward. A planned next-generation E-Sail prototype will include autonomous propulsive tether deployment while monitoring tether tension, location on the floor, distance between tether ends, acceleration, velocity, and propellant used.

Tinker, Michael↗

DOE OSTI2022

Grid-Connected Modular Soft-Switching Solid State Transformers (M-S4T)

The objective of this project is to develop and verify the concept of a flexible and modular soft-switching solid-state transformer (M-S4T) for direct grid-connected applications. The ability to directly connect power electronics converters to the medium voltage grid (4 kV – 13 kV), and to potentially replace the passive and bulky, but ubiquitous 60 hertz service transformer in the 25 kVA to 100 kVA range, with a more flexible and controllable device, has been regarded as the ‘holy grail’ in grid control. However, this has proven to be extremely difficult. This project has developed the solutions to several key challenges of the direct grid-connected power electronics and realized a 7.2 kV M-S4T prototype. First, a protection method to protect the M-S4T from the high voltages (110 kV for the 13 kV system) that occur on the grid due to transients and lightning strikes have been developed and experimentally verified. Second, the realization and the operation of the M-S4T based on high-voltage SiC devices (>3.3 kV) and a medium-frequency medium-voltage low-leakage transformer in a single-stage solid-state transformer with zero-voltage switching, low dv/dt, and low electromagnetic interference has been successfully demonstrated up to 7.5 kV peak. Third, an oil-cooling system and stable communication and distributed control system for converter module voltage sharing have been developed and experimentally verified. The developed M-S4T has realized a modular universal high-performance power conversion system. This conversion system is scalable to different voltage and power levels and adaptable to four-quadrant bidirectional operation. Moreover, the use of passive cooling techniques meets the equipment life requirements, and the lightning protection scheme fulfills the basic insulation level specifications for direct grid connection. Such power conversion system opens up near-term opportunities, including energy storage, solar PV, or electric vehicle charging with significant cost and footprint savings. In the longer term, the possibility of replacing the utility distribution transformer with an M-S4T will be transformative for future distribution grids with a compact footprint and full controllability to enable high renewable energy and storage penetration. In addition to the main project, this report expands on the Plus-Up projected including as part of the main award. This project developed and demonstrated the technology for autonomous collaborative inverters that can be connected in an ad hoc manner to the grid. The aim of the project was to: (1) evaluate the existing techniques for grid-connected inverters and find their limitations; (2) develop detailed requirements for grid-connected inverters in the modern grid with millions of active nodes; (3) design a unified control strategy that brings more autonomy and intelligence to grid-connected inverters, and addresses parts of the issues with the existing techniques. The proposed technique, called UniCon, enables inverters to 1) connect/disconnect to/from the grid in an ad hoc manner; (2) work based on local sensing. Slow communication could be used for a more optimized behavior; (3) work automatically in both grid-forming/grid-following mode; (4) handle large disturbances, e.g., big load step and fault, in an oscillation-free manner; (5) work collaboratively with other inverters in steady-state and during transients. UniCon can be implemented in the middle-level control; hence it is agnostic to the vendor and to the implementation of the inner voltage/current and protection loops. Furthermore, a new synchronization scheme, based on deep learning, was developed that can extract the grid voltage phase and amplitude in a stable manner. The method is cheap to implement can improve the dynamic performance of the grid-connected inverters during fast transients, e.g., fault. The proposed control scheme was validated by (1) MATLAB/Simulink; (2) hardware-in-the-loop results, and; (3) experimental results using three inverters that form a microgrid in a down-scaled feeder. Lastly, both the M-S4T and UniCon have achieved promising tangible paths to markets. In the case of the M-S4T, the underlying technology — the Soft Switching Solid State Transformer (S4T) developed at the Georgia Tech Center for Distributed Energy (GT-CDE) has been licensed by GridBlock from the Georgia Tech Research Corporation, and GridBlock has been working with manufacturing partner Jabil (one of the largest US-based contract manufacturers) and system integrator Power Secure (largest deployer of microgrids in the US with 4.7 GW under management), to meet the strong initial demand. Similarly, GridBlock has an exclusive license to the UniCon technology, developed under this award by GT-CDE. The UniCon provides an intermediate control layer that enables the implementation of the higher-level ‘transactive’ control commands for the system. The architecture of the system - slow communications with the cloud for system optimization and setpoints, and the use of locally measured quantities for real-time control, provide a very robust and secure way of implementing a real-time must-run grid that is also secure and stable. This is a brand-new functionality that is critical for the future grid and key to GridBlock’s business model.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2019

Experimental and Numerical Study of Coating Thickness Using Multi-slot Air Knives

Gas-jet wiping is a widely employed production technology for controlling the final zinc coating thickness on a moving substrate during continuous hot-dip galvanizing. This paper presents an experimental investigation and numerical analysis of a prototype multi-slot air knife, which offers an increase in wiping efficiency relative to the traditional single-slot jet geometry in the continuous galvanizing process. The applicability of the analytical coating weight model of Elsaadawy et al. (Metall Mater Trans B, 38:413-424, 2007) to predict the final coating weight was determined for the multi-slot geometry, where particular focus was devoted to the effect of geometric parameters. Experimental measurements under a variety of knife geometry and process conditions agreed with the coating weight predictions of the analytical model. It was also shown that the air-knife geometric parameters had a significant effect on the pressure profile and shear stress distribution applied by the air knives to the moving substrate. It was determined that the final coating thickness was significantly affected by the auxiliary jet width, D{sub a}, where lighter coating weights at higher strip velocities (up to 5.4 pct at V{sub s} = 1.5 m/s) could be achieved by using the multi-slot air-knives prototype vs. the conventional single-slot configuration.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Computational discovery of stable and metastable ternary oxynitrides

Materials design from first principles enables exploration of uncharted chemical spaces. Extensive computational searches have been performed for mixed-cation ternary compounds, but mixed-anion systems are gaining increased interest as well. Central to computational discovery is the crystal structure prediction, where the trade-off between reliance on prototype structures and size limitations of unconstrained sampling has to be navigated. We approach this challenge by letting two complementary structure sampling approaches compete. We use the kinetically limited minimization approach for high-throughput unconstrained crystal structure prediction in smaller cells up to 21 atoms. On the other hand, ternary—and, more generally, multinary—systems often assume structures formed by atomic ordering on a lattice derived from a binary parent structure. Thus, we additionally sample atomic configurations on prototype lattices with cells up to 56 atoms. Using this approach, we searched 65 different charge-balanced oxide–nitride stoichiometries, including six known systems as the control sample. The convex hull analysis is performed both for the thermodynamic limit and for the case of synthesis with activated nitrogen sources. We identified 34 phases that are either on the convex hull or within a viable energy window for potentially metastable phases. We further performed structure sampling for “missing” binary nitrides whose energies are needed for the convex hull analysis. Among these, we discovered metastable Ce3N4 as a nitride analog of the tetravalent cerium oxide, which becomes stable under slightly activated nitrogen condition µN > +0.07 eV. Given the outsize role of CeO2 in research and application, Ce3N4 is a potentially important discovery.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2020

Advances in High-Power Wireless Charging Systems: Overview and Design Considerations

Wireless charging systems are foreseen as an effective solution to improve the convenience and safety of conventional conductive chargers. As this technology has matured, recent broad applications of wireless chargers to electrified transportation have indicated a trend toward higher power, power density, modularity, and scalability of designs. In this article, commercial systems and laboratory prototypes are reviewed, focusing mostly on the advances in high-power wireless charging systems. The recent endeavors in magnetic pad designs, compensation networks, power electronics converters, control strategies, and communication protocols are illustrated. Both stationary and dynamic (in-motion) wireless charging systems are discussed, and critical differences in their designs and applications are emphasized. On that basis, the comparisons among different solutions and design considerations are summarized to present the essential elements and technology roadmap that will be necessary to support large-scale deployment of high-power wireless charging systems. The review is concluded with the discussion of several fundamental challenges and prospects of high-power wireless power transfer (WPT) systems. Foreseen challenges include utilization of advanced materials, electric and electromagnetic field measurement and mitigation, customization, communications, power metering, and cybersecurity.

25 ENERGY STORAGE↗

NASA NTRS1975

An overview of NASA's digital fly-by-wire technology development program

The feasibility of using digital fly-by-wire systems to control aircraft was demonstrated by developing and flight testing a single channel system, which used Apollo hardware, in an F-8C test airplane. This is the first airplane to fly with a digital fly-by-wire system as its primary means of control and with no mechanical reversion capability. The development and flight test of a triplex digital fly-by-wire system, which will serve as an experimental prototype for future operational digital fly-by-wire systems, is underway.

Jarvis, C. R.↗

NASA NTRS1982

Geometric error characterization and error budgets

Procedures used in characterizing geometric error sources for a spaceborne imaging system are described using the LANDSAT D thematic mapper ground segment processing as the prototype. Software was tested through simulation and is undergoing tests with the operational hardware as part of the prelaunch system evaluation. Geometric accuracy specifications, geometric correction, and control point processing are discussed. Cross track and along track errors are tabulated for the thematic mapper, the spacecraft, and ground processing to show the temporal registration error budget in pixel (42.5 microrad) 90%.

Beyer, E.↗

NASA NTRS1986

Design of an advanced two-phase capillary cold plate

The functional principles and implementation of capillary pumped loop (CPL) two phase heat transport system for various elements of the Space Station program are described. Circulation of the working fluid by the surface-tension forces in a fine-pore capillary wick is the core principle of CPL systems. The liquid, usually NH3 at the moment, is changed into a vapor by heat absorption at one end of the loop, and the vapor is carrried back along the wick by the surface tension within the wick. NASA specifications and the results of mechanical and thermal tests for prototype cold plate and the capillary pump designs are outlined. The CPL is targeted for installation on free-flying platforms, attached payloads, and power subsystem thermal control systems.

Chalmers, D. R.↗

NASA NTRS1988

Automated knowledge generation

The general objectives of the NASA/UCF Automated Knowledge Generation Project were the development of an intelligent software system that could access CAD design data bases, interpret them, and generate a diagnostic knowledge base in the form of a system model. The initial area of concentration is in the diagnosis of the process control system using the Knowledge-based Autonomous Test Engineer (KATE) diagnostic system. A secondary objective was the study of general problems of automated knowledge generation. A prototype was developed, based on object-oriented language (Flavors).

Myler, Harley R.↗

NASA NTRS1990

Automated electric power management and control for Space Station Freedom

A comprehensive automation design is being developed for Space Station Freedom's electric power system. It strives to increase station productivity by applying expert systems and conventional algorithms to automate power system operation. An integrated approach to the power system command and control problem is defined and used to direct technology development in: diagnosis, security monitoring and analysis, battery management, and cooperative problem-solving for resource allocation. The prototype automated power system is developed using simulations and test-beds.

Dolce, James L.↗

NASA NTRS1990

Automated electric power management and control for Space Station Freedom

Dolce, James L.↗

NASA NTRS1996

STS-76 Flight Day 1

On this first day of the STS-76 mission, the flight crew, Cmdr. Kevin P. Chilton, Pilot Richard A Searfoss, and Mission Specialists Shannon W. Lucid, Linda M. Godwin, Michael R. Clifford, and Ronald M. Sega, are shown performing prelaunch and launch activities for the night launch of the Space Shuttle Atlantis. The primary objective of this mission is the third docking between the Mir Space Station and Atlantis and a crew transfer. Lucid will remain onboard the Mir for about four months. Other activities include an EVA by Godwin and Clifford, logistics operations, and scientific research with a SPACEHAB module, some middeck experiments, and a Get Away Special (GAS) canister. Also, almost a ton of equipment and supplies will be transferred to the Mir. Experiments include the Mir Electric Field Characterization (MEFC), European Space Agency (ESA) Biorack life sciences experiment, Queens University Experiment in Liquid Diffusion (QUELD), Optizone Liquid Phase Sintering Experiment (OLIPSE), and a Naval Research Laboratory (NRL) GAS payload Trapped Ions in Space (TRIS), which will measure low-energy particle radiation in the inner magnetosphere. This mission also will include a KidSat, a prototype of Earth viewing cameras and instruments, that allow students in grades K-12 to see and direct the capture of pictures from space. Footage from Mission control is also included.

Source record↗

NASA NTRS2002

Adaptive Resource Management Technology for Satellite Constellations

This manuscript describes the Sensor Web Adaptive Resource Manager (SWARM) project. The primary focus of the project is on the design and prototyping of middleware for managing computing and network resources in a way that enables the information systems of satellite constellations to provide realtime performance within dynamic environments. The middleware has been prototyped, and it has been evaluated by employing it to manage a pool of distributed resources for the ITOS (Integrated Test and Operations System) satellite command and control software system. The design of the middleware is discussed and a summary of the evaluation effort is provided.

Welch, Lonnie↗

NASA NTRS2003

A Compact, Soft-Switching DC-DC Converter for Electric Propulsion

A hybrid, soft-switching, DC-DC converter has been developed with superior soft switching characteristics, high efficiency, and low electro-magnetic interference. This hybrid topology is comprised of an uncontrolled bridge operating at full pulse-width, and a controlled section operating as a conventional phase modulated converter. The unique topology is able to maintain zero voltage switching down to no load operating conditions. A breadboard prototype was developed and tested to demonstrate the benefits of the topology. Improvements were then made to reduce the size of passive components and increase efficiency in preparation for packaging. A packaged prototype was then designed and built, and several innovative packaging techniques are presented. Performance test data is presented that reveals deficiencies in the design of the power transformer. A simple redesign of the transformer windings eliminated the deficiency. Future plans to improve the converter and packaging design are presented along with several conclusions.

Button, Robert↗

NASA NTRS2004

Design, Fabrication, and Testing of SMA Enabled Adaptive Chevrons for Jet Noise Reduction

This study presents the status and results from an effort to design, fabricate, and test an adaptive jet engine chevron concept based upon embedding shape memory alloy (SMA) actuators in a composite laminate, termed a SMA hybrid composite (SMAHC). The approach for fabricating the adaptive SMAHC chevrons involves embedding prestrained Nitinol actuators on one side of the mid-plane of the composite laminate such that thermal excitation generates a thermal moment and deflects the structure. A glass-epoxy pre-preg/Nitinol ribbon material system and a vacuum hot press consolidation approach are employed. A versatile test system for control and measurement of the chevron deflection performance is described. Projection moire interferometry (PMI) is used for global deformation measurement and infrared (IR) thermography is used for 2-D temperature measurement and feedback control. A recently commercialized constitutive model for SMA and SMAHC materials is used in the finite element code ABAQUS to perform nonlinear static analysis of the chevron prototypes. Excellent agreement is achieved between the predicted and measured chevron deflection performance, thereby validating the design tool. Although the performance results presented in this paper fall short of the requirement, the concept is proven and an approach for achieving the performance objectives is evident.

Turner, Travis L.↗

NASA NTRS2011

Planar Rotary Motor Using Ultrasonic Horns

One of the first piezoelectric motor designs with significant rotational speeds was outlined by Barth. This device used extensional piezoelectric elements to produce a time varying force at a distance r from the center of a centrally supported disk. These extensional actuators produced micro-steps at a high frequency with the end result being macroscopic rotation of the disk and high torque. The rotation direction is controlled by the choice of the actuators and the direction of the extension about the rotor center. A recent advancement in producing pre-stressed power ultrasonic horns using flexures allows for the development of high torque ultrasonic motors based on the Barth's idea that can be fabricated in a 2D plate or in more complicated 3D structures. In addition to the pre-stress flexures the design also allows for the use of flexures to produce the rotor/horn normal force. The torque can be controlled by the number of actuators in the plane and the amplitude of the normal force. This paper will present analytical and experimental results obtained from testing prototype planar motors.

ultrasonic impacts.↗

NASA NTRSDate not supplied

TECHEDSAT-7 and 10: The Little Spacecraft That Could

The NOW (Nanosatellite Orbital Workshop) of NASA Ames Research Center (ARC) has two cubesats in orbit at this time: 6 U TechEdSat-10 (T-10) and the 3U TechEdSat-7 (T-7). T10 was jettisoned from the ISS via the NANORACKS system 7/13/2020, and T-7 was launched via Virgin Orbit 1/17/2021. Both were built by the Nano-satellite Orbital Workshop (NOW) at NASA ARC, and designed and fabricated by interns and students in collaboration with educational institutions. Prototyping novel technologies for non-powered re-entry and communications from orbit are primary research interests, however all subsystems including power generation and distribution, subsystem control, navigation, positioning, heat management etc. extend current technologies. Use of distributed processors using open software platforms and standards other based technologies and software is integral to all segments of spacecraft design. Here, we will present an overview of the spacecraft, experiments, and accomplishments – as well as the next three flight experiments. Some of these experiments include: The exo-brake re-entry system is being developed to enable sample return and end of life disposal; Internal communications for sensors, inter-subsystem and experiments uses both a Zigbee based PAN and internal Wi-Fi for high-speed inter-device communications; The Iridium small message LEO system (Short Burst Data) is used to both command the spacecraft and send data to the ground; Experimental use of the Global-Star system for L-band system comparison and back-up; Collaborative NOAA an experiment to communicate from LEO to the GOES geostationary satellite using the DCS (Data Collection System) with on-board Doppler correction; Mars and Lunar experimental communication systems for future cis-lunar and interplanetary nano-satellites; First demonstration of the NASA Near Earth Network systems with nano-satellites at NASA/Wallops Island; Solar array design and implementation for unique future flexible structures; Power distribution using Tardigrade rad-hard processor omni-board (designed by the team); Distributed processors with internal Wi-Fi connectivity; and Initial experiments with AI/Machine Learning.

M Murbach↗

DOE OSTI2024

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↗