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DOE OSTI2020

Deep anomaly detection for industrial systems: a case study

We explore the use of deep neural networks for anomaly detection of industrial systems where the data are multivariate time series measurements. We formulate the problem as a self-supervised learning where data under normal operation are used to train a deep neural network autoregressive model, i.e., use a window of time series data to predict future data values. The aim of such a model is to learn to represent the system dynamic behavior under normal conditions, while expect higher model vs. measurement discrepancies under faulty conditions. In real world applications, many control settings are discrete in nature. In this paper, vector embedding and joint losses are employed to deal with such situations. Both LSTM and CNN based deep neural network backbones are studied on the Secure Water Treatment (SWaT) testbed datasets. Also, Support Vector Data Description (SVDD) method is adapted to such anomaly detection settings with deep neural networks. Evaluation methods and results are discussed based on the SWaT dataset along with potential pitfalls.

anomaly detection, deep neural network↗

NASA NTRS1991

High resolution ultrasonic spectroscopy system for nondestructive evaluation

With increased demand for high resolution ultrasonic evaluation, computer based systems or work stations become essential. The ultrasonic spectroscopy method of nondestructive evaluation (NDE) was used to develop a high resolution ultrasonic inspection system supported by modern signal processing, pattern recognition, and neural network technologies. The basic system which was completed consists of a 386/20 MHz PC (IBM AT compatible), a pulser/receiver, a digital oscilloscope with serial and parallel communications to the computer, an immersion tank with motor control of X-Y axis movement, and the supporting software package, IUNDE, for interactive ultrasonic evaluation. Although the hardware components are commercially available, the software development is entirely original. By integrating signal processing, pattern recognition, maximum entropy spectral analysis, and artificial neural network functions into the system, many NDE tasks can be performed. The high resolution graphics capability provides visualization of complex NDE problems. The phase 3 efforts involve intensive marketing of the software package and collaborative work with industrial sectors.

Chen, C. H.↗

NASA NTRS1993

Retention latch mechanism for the Wake Shield Facility

The Wake Shield Facility (WSF) is a space transportation system (STS) payload that is scheduled for launch on STS-60 in November, 1993. It is being designed, tested and integrated into the STS by Space Industries Inc. for the University of Houston's Space Vacuum Epitaxy Center, a NASA Center for the Commercial Development of Space. The WSF is composed of two main components: a cross-bay carrier and a free-flying experimental platform. The WSF's primary objective is the epitaxial growth of thin films by controlled beam techniques in the ultra-high vacuum that exists in the wake of the free-flyer. The Retention Latch Mechanism (RLM) has been developed to act as the structural interface between the free-flyer and the carrier.

Vendrely, Timothy G.↗

NASA NTRS2004

A Spectrum of IV and V Modeling Techniques

The aerospace industry in general and NASA in particular is using more (semi-formal) model-based software development. Model-based development produces a collection of artifacts, for example, state diagrams, module diagrams (such as class diagrams), control-block diagrams, etc. These artifacts may than be used as a basis for auto code generation for production use. Therefore, these models must be properly evaluated in the IV and V process. IV and V practitioners know how assess standard procedural systems. But what can we du about IV and V of model-based systems? The goal of the work outlined in this proposal is to use cost effective automated techniques to the largest extent possible during the IV and V process. Our working hypotheses are: 1. There exists a range of validation techniques that can assess models built using a range of modeling techniques of increasing cost and complexity. Specifically, we hypotesize that the "cheaper" techniques can find faults cheaply and early in a project. These early results are then used to predict if this is a problem system and if a more elaborate and expensive IV and V effort is justified. 2. There exists a set of migration procedures that let us seamlessly move from simple models using cheaper techniques into more elaborate models suitable for a more expensive and detailed analysis. 3. We further hypothesize that this migration process is much cheaper than simply remodeling the system under investigation from scratch when moving to models needed for the more detailed and expensive IV and V assessments.

Heimdahl, Mats↗

NASA NTRS2000

Failure Accommodation Tested in Magnetic Suspension Systems for Rotating Machinery

The NASA Glenn Research Center at Lewis Field and Texas A&M University are developing techniques for accommodating certain types of failures in magnetic suspension systems used in rotating machinery. In recent years, magnetic bearings have become a viable alternative to rolling element bearings for many applications. For example, industrial machinery such as machine tool spindles and turbomolecular pumps can today be bought off the shelf with magnetically supported rotating components. Nova Gas Transmission Ltd. has large gas compressors in Canada that have been running flawlessly for years on magnetic bearings. To help mature this technology and quiet concerns over the reliability of magnetic bearings, NASA researchers have been investigating ways of making the bearing system tolerant to faults. Since the potential benefits from an oil-free, actively controlled bearing system are so attractive, research that is focused on assuring system reliability and safety is justifiable. With support from the Fast Quiet Engine program, Glenn's Structural Mechanics and Dynamics Branch is working to demonstrate fault-tolerant magnetic suspension systems targeted for aerospace engine applications. The Flywheel Energy Storage Program is also helping to fund this research.

Provenza, Andy J.↗

NASA NTRS2006

Brush Seals for Improved Steam Turbine Performance

GE Energy has retrofitted brush seals into more than 19 operating steam turbines. Brush seals offer superior leakage control compared to labyrinth seals, owing to their compliant nature and ability to maintain very tight clearances to the rotating shaft. Seal designs have been established for steam turbines ranging in size from 12 MW to over 1200 MW, including fossil, nuclear, combined-cycle and industrial applications. Steam turbines present unique design challenges that must be addressed to ensure that the potential performance benefits of brush seals are realized. Brush seals can have important effects on the overall turbine system that must be taken into account to assure reliable operation. Subscale rig tests are instrumental to understanding seal behavior under simulated steam-turbine operating conditions, prior to installing brush seals in the field. This presentation discusses the technical challenges of designing brush seals for steam turbines; subscale testing; performance benefits of brush seals; overall system effects; and field applications.

Turnquist, Norman↗

NASA NTRS2008

Measurement Assurance for End-Item Users

The goal of a Quality Management System (QMS) as specified in ISO 9001 and AS9100 is to assure the end product meets specifications and customer requirements. Measuring devices, often called measuring and test equipments (MTE), provide the evidence of product conformity to the prescribed requirements. Therefore the processes which employ MTE can become a weak link to the overall QMS if proper attention is not given to development and execution of these processes. Traditionally, calibration of MTE is given more focus in industry standards and process control efforts than the equally important proper usage of the same equipment. It is a common complaint of calibration laboratory personnel that MTE users are only interested in "a sticker." If the QMS requires the MTE "to demonstrate conformity of the product," then the quality of the measurement process must be adequate for the task. This leads to an ad hoc definition; measurement assurance is a discipline that assures that all processes, activities, environments, standards, and procedures involved in making a measurement produce a result that can be rigorously evaluated for validity and accuracy. To evaluate that the existing measurement processes are providing an adequate level of quality to support the decisions based upon this measurement data, an understanding of measurement assurance basics is essential. This topic is complimentary to the calibration standard, ANSI/NCSL Z540.3-2006, which targets the calibration of MTE at the organizational level. This paper will discuss general measurement assurance when MTE is used to provide evidence of product conformity, therefore the target audience of this paper is end item users of MTE. A central focus of the paper will be the verification of tolerances and the associated risks, so calibration professionals may find the paper useful in communication with their customers, MTE users.

Mimbs, Scott M.↗

NASA NTRS2020

Public Trust and Acceptance for Concepts of Remotely Operated Urban Air Mobility Transportation

There is building interest within industry and government to enable Urban Air Mobility (i.e., air-taxies). One concept envisions remotely piloted aircraft, yet it is unclear how this will impact public trust and acceptance. Method: Two hundred participants read vignettes describing remotely-piloted UAM operations and then responded to a series of questionnaires. The study employed a one-way between-subjects design manipulating five levels of Pilot-in-Command Distance: Onboard Pilot; Remote Control Pilot; Dedicated Remote Operator; Remote Operator; System Manager. Results: The Remote Control Pilot group indicated they would be less likely than the Onboard Pilot Group to use UAM, based on the mediating effect of trust in the automation. The Remote Control Pilot and Remote Operator groups indicated they would be less likely to use UAM than the Onboard Pilot group, based on the mediating effect of trust in the remote pilot/operator. Conclusion: Trust in UAM automation and remote pilots/operators will likely affect public acceptance of UAM.

MTurk↗

NASA NTRSDate not supplied

Systems Health Management and Prognostics Approaches for Electric Aircrafts

As more and more electric vehicles emerge in our daily operation progressively, a very critical challenge lies in the prediction of remaining driving flying time/distance for the flying vehicles. This information is important, particularly in the case of auto vehicles, because such vehicles can become self-aware, autonomously compute its own capabilities, and identify how to best plan and successfully complete vehicular missions safely. In case of electric aircrafts, computing the remaining flying time is also safety-critical, since an aircraft that runs out of power (battery charge) while in the air will eventually lose control leading to catastrophe. To facilitate and solve the prediction problem, awareness of the current health state of the system is key, since it is necessary to perform condition-based predictions. To accurately predict the future state of any system, it is required to possess knowledge of its current health state and future operational conditions. Latest achievements of data-driven algorithms in regression of complex nonlinear functions and classification tasks have generated a growing interest in artificial intelligence for industrial applications. Complex multi-physics models as well as digital twins, once purely built on physics and corresponding simplified lumped parameter iterations, can now benefit from machine learning algorithms to mitigate the lack of understanding of some complex behavior. Given models of the current and future system behavior, a general approach of model-based prognostics can solve the prediction problem and further decision-making. A systematic prediction framework is implemented to identify all possible sources of uncertainty, quantify each of them individually, and mathematically estimate their combined effect on the system-level quantity of interest, in this case, the remaining flying time/distance of the unmanned aircraft. Note - This presentation contains all previously published information.

Systems Health Managent↗

NASA NTRSDate not supplied

Health Monitoring and Prognostics for Electric Aircrafts

Systems Health Managent↗

NASA NTRSDate not supplied

Towards Sustainable Aviation With Efficient Airspace Operations

In November 2021, the Federal Aviation Administration published the United States Aviation Climate Action Plan to accelerate innovation across the U.S. aviation ecosystem. In response, NASA has established the Sustainable Flight National Partnership to engage with industry, academia, and other agencies to accomplish net-zero carbon emissions by 2050. As part of the SFNP Mission, NASA is conducting a series of real world operational demonstrations in the current National Airspace System with a focus on delivering real world sustainability benefits. This paper presents the current work and future plan for the SFNP Ops Demo Series and describes the cloud based infrastructure used for virtual deployment of decision support tools to flight operators and Air Traffic Controllers to help improve operational efficiency of the National Airspace System. Validation results are shared along with the key sustainability benefits such as jet fuel savings and reduction in CO2 emissions. The operational efficiency metrics such as delay savings are also reported.

Sustainable Flight National Partnership↗

DOE OSTI2024

Active Aerodynamic Load Control for Wind Turbines

The goal of this project was to develop and demonstrate an advanced dielectric barrier discharge (DBD) plasma actuator technology. We set out to demonstrate the efficacy and impact of the new actuator technology as a key component of an active load control system for wind turbines. A DBD plasma actuator consists of a thin layer of dielectric material separating a pair of offset electrodes. One of those electrodes is embedded between the dielectric layer and a non-conductive substrate, while the other is exposed to air. When driven by an appropriate high voltage waveform, the device ionizes the air near the surface of the dielectric and adjacent to the exposed electrode. Collisions between the ions in the plasma and neutral air molecules result in a wall-jet – a region of induced air velocity that can be used to modify the flow around a lifting body. Use of the device near the trailing edge of a wind turbine blade, designed in such a way as to amplify the effects of the flow-modifying device, can result in large changes to the global forces experienced by the blade. Because of the fast response time of the device, it can allow the turbine to react in real time to changes in the wind associated with turbulence, wind shear, gusts, and the like, when paired with appropriate sensors and control algorithms. The goal of this project was to increase the capacity of the device to induce velocity on its surface at the levels required by large, utility-scale wind turbines. The first technical goal was to increase the induced velocity from the current industry-best of about 4 m/s to 10 m/s by modifying the electrical waveform used to drive the device and by introducing a semi-conductive surface coating to control electrostatic charge build-up on the surface. The second goal was to use the device to modify the lift on a representative airfoil in a wind tunnel, demonstrating a reduction in lift coefficient of 0.2 or better. The third goal was to produce an actuator-induced velocity of 20 m/s. Alongside our partners at the University of Texas at Dallas, we also applied modern, advanced design methods to optimize the impact of the technology on the design of wind turbines. We also had planned to install a segmented, active load control system on a test turbine to demonstrate the ability to reduce unsteady aerodynamic forces on the turbine associated with changes in the wind. The highest induced velocity achieved during this research was 11 m/s. However, practical design constraints limited the change in lift coefficient to about 0.12 for a representative airfoil in the wind tunnel at a Reynolds number of 400,000. The primary conclusion is that the plasma actuator control authority remains insufficient for practical purposes when extrapolated to Reynolds numbers over 1 million. The potential impact of the active lift control concept was evaluated through detailed simulations for three wind turbine sizes: a 3.4MW onshore turbine, a 10MW offshore turbine, and a 15MW offshore turbine. A feedback control system was designed for each turbine within two scenarios: one where the active lift control is used as a retrofit capability on the baseline design, and the other where the designers were permitted to “upscale” the turbines in order increase annual energy production. The levelized cost of energy was then evaluated for the range of turbine sizes and design configuration. It was found that the LCOE reduction associated with active lift control fell in the range of 0.7% to 7.2%, with the highest reduction associated with upscaling the 3.4MW turbine.

17 WIND ENERGY↗

DOE OSTI2021

The causal relationship between melt pool geometry and energy absorption measured in real time during laser-based manufacturing

During laser powder bed fusion additive manufacturing, laser power absorption is governed by a pro -tean pool of molten metal that can present as a highly reflective surface, a deeply absorbing cavity, or some amalgamation thereof. These melt pool dynamics have been linked to defect creation, porosity, and surface finish quality. Although these are therefore critical for determining final part quality, their in-stantaneous influence on laser absorption have only been explored through simulation. To date, direct real-time observations have been elusive due to the locally extreme environment. In this work, we fo-cus a laser on Ti-6Al-4V powder and bare plate while quantifying the time-dependent, absolute energy absorption by monitoring omnidirectional backscattered laser intensity. We also simultaneously record the projective melt pool geometries with high-speed synchrotron x-ray imaging. We find that laser ab-sorption strongly reflects the stability of the vapor depression over a wide range of applied laser powers, oxygen content in the processing atmosphere, and with the presence of powder. During laser scanning of a powder bed surface, we find a significant absorption reduction after 400 mu s due to a dramatic change in the vapor depression aspect ratio-an event known to create porosity. Furthermore, as several industrial scan strate-gies necessitate thousands of these events during a build, their identification and control is of significant practical importance. Lastly, a normalized enthalpy model is demonstrated to be effective in quantifying the relationship between the laser absorption and cavity depth, even under transient conditions. In addi-tion to providing vital quantitative data for simulation calibration, the correlation of melt pool geometry with laser absorption during realistic processing conditions suggests the use of a total backscattered light detection system for real-time process control.

36 MATERIALS SCIENCE↗

DOE OSTI2020

FY2019 Energy Efficient Mobility Systems Annual Progress Report

EEMS Program activities during FY 2019 focused on analytical research to understand the impacts that new mobility technologies and services will have at the vehicle, traveler, and overall transportation system-level. This research included the development of vehicle and transportation system simulation models and tools to evaluate the complex interactions among the various actors within the mobility landscape, analysis of empirical data to characterize which solutions may provide the largest benefits, and development of new control systems and algorithms that use vehicle connectivity and automation to improve the performance and efficiency of individual vehicles as well as the overall traffic system. This document presents a brief overview of the EEMS Program and documents progress and results for projects within four of the five EEMS activity areas: (1) the SMART (Systems and Modeling for Accelerated Research in Transportation) Mobility Lab Consortium, (2) High Performance Computing and Big Data Solutions for Mobility Data, (3) Advanced R&D Projects conducted by industry and academia, and (4) Core Modeling, Simulation, and Evaluation, Similarly, the remaining EEMS activity area – (5) Living Labs (managed under VTO’s Technology Integration Program). Each of the individual progress reports provide a project overview and highlights of the technical results.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2025

Final Technical Report of a Feasibility Investigation of a Hydropower Flexibility Upgrade Kit

The project studied the feasibility of a concept for a flexibility upgrade kit called h-Dynamyk to improve the flexibility of U.S. hydropower plants and assessed its potential impact on the U.S. hydropower industry. This concept addresses the growing need for grid flexibility amid rising renewable energy adoption, such as wind and solar, which often introduce intermittency. The upgrade kit is intended to address challenges posed by aging turbine designs in meeting modern grid demands for flexibility services like frequency response, voltage control, spinning reserve, and black-start capabilities. Key features of the h-Dynamyk kit include siphon turbine assemblies, medium-voltage variable frequency drives (VFDs), and smart controls integrated with plant systems to optimize operations and extend equipment life. This nine-month discovery project successfully achieved its objectives by defining a baseline design and performance metrics for the h-Dynamyk flexibility upgrade kit, analyzing this baseline, and incorporating lessons learned from this analysis into a modified set of metrics and recommendations for future design and testing, which were further guided by field site studies.

13 HYDRO ENERGY↗

DOE OSTI2021

Slipstream Testing of Amine-Based Solvents at a Low-Rank Coal-Fired Power Plant

Conference presentation for 38th Annual International Pittsburgh Coal Conference, Virtual, September 20–23, 2021. To better assess mitigation strategies for aerosol reduction to extend solvent life, the University of North Dakota Energy & Environmental Research Center (EERC) installed a pilot-scale CO 2 absorption system at a lignite-fired plant in central North Dakota. The pilot-scale system was operated using both commercial KS-1™ solvent and advanced KS-21™ solvent provided by Mitsubishi Heavy Industries (MHI). MHI’s proprietary amine emission reduction unit (AERU™) technology was installed downstream of the absorber columns to reduce solvent losses by recovering amines at the system outlet. Fine particulate loading was measured throughout the capture system with and without a WESP operating and using both solvents. Captured particulate was brought back to the EERC to be analyzed for chemical composition and to be examined by scanning electron microscopy for particulate structure. These variables were then correlated to performance of particulate control devices in reducing aerosol formation and solvent losses.

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2023

Cybersecurity Framework Profile for Electric Vehicle Extreme Fast Charging Infrastructure

This document is the Cybersecurity Framework Profile (Profile) developed for the Electric Vehicle Extreme Fast Charging (EV/XFC) ecosystem, including the four domains that relies on the ecosystem (i) Electric Vehicles (EV); (ii) Extreme Fast Charging (XFC); (iii) XFC Cloud or Third-Party Operations; and (iv) Utility and Building Networks. This Profile utilizes the NIST Cybersecurity Framework Version 1.1 and provides voluntary guidance to help relevant parties develop Profiles specific to their organization to understand, assess, and communicate their cybersecurity posture as a part of their risk management process. The Profile is intended to supplement, not replace, an existing risk management program or cybersecurity standards, regulations, and industry guidelines that are in current use by the EV/XFC industry.

33 ADVANCED PROPULSION SYSTEMS↗

NASA NTRS1977

Space Resources and Space Settlements

This publication contains the technical papers from the five task groups that took part in the 1977 Ames Summer Study on Space Settlements and Industrialization Using Nonterrestrial Materials. The study was sponsored by the following NASA Headquarters organizations: Office of Space Science, Office of Aeronautics and Space Technology, and Office of Space Transportation Systems. The NASA Ames Research Center hosted the study and provided administrative support through its Life Sciences Directorate. Expert assistance in the many aspects of the study came from NASA Headquarters, NASA centers, universities, industry, and from individual consultants. This summer study was the largest and most comprehensive investigation of space manufacturing and habitation to date; forty senior research workers and ten students participated. The six-week study was preceded by several months of planning and preparation, and was followed by extensive work on manuscript checking, review, and assembly. The study topics reflected the research areas requiring the most intensive attention as ofrnid-1977; they were: Group I: Regenerative life-support systems and controlled environment agriculture. Group II: Parametric studies of efficient habitats in space. Time and cost analysis of a space manufacturing program plan. Group III: Detection and analysis of special classes of asteroids suitable as material resources for space manufacturing; studies of retrieval missions. Group IV: Electromagnetic mass drivers for use as interorbital engines, as devices to launch lunar material into space, and as tugs for the retrieval of asteroidal material. Group V: Chemical processing of non terrestrial material in space; manufacture of metals and glass fibers, beneficiation, and design of processing plants. These five task groups each produced two or more technical papers, signed by the contributing members. The papers were subjected to independent peer review by scientists not connected with the study. During the course of the study, frequent formal and informal exchanges of information occurred between task groups, so that the entire effort evolved in a coherent fashion and was directed toward common goals. However, each group remained responsible for the choice of its topics and for its conclusions. A listing of all the participants is given on pages vii-x. It would be inappropriate for me to single out particular people or groups for special mention, since all involved applied their skills with dedication and enthusiasm. Instead, I thank everyone for their contributions to the success of the study, and also for making it a united and warmly cooperative personal experience.

John Billingham↗