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All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Constellation's best estimate alternate source term methodology overview

Safety analyses for a nuclear power plants need to consider postulated accidents that results in at risk of accidental release of radiation. The regulations require plant specific safety analysis reports to include an evaluation of the requirements of 10CFR50.67. Such a safety analysis report mandates limits such that calculated radiological consequences relative to certain dose locations do not exceed a total effective dose equivalent (TEDE) limits following a postulated release of radioactivity. Calculations are performed to estimate the radiological consequences, in terms of dose, to people and equipment to ensure the estimated doses are within the prescribed limits. Analysis should demonstrate, with reasonable assurance, that these prescribed limits are complied with. Conventional methodologies utilize conservative approaches to address lack of uncertainty quantification in the utilized approaches, methods, and/or inputs. These built-in excess conservatisms often result in compounding effects and hence overly conservative results in the estimated radiological consequences, which leads to inaccurate margin evaluation for operation and accident mitigation. Therefore, evaluating accurate dose consequences is needed for both operational and safety reasons. The research documented in this paper provides an overview of Constellation's Best Estimate Alternate Source Term (BEAST) Methodology. BEAST methodology relies upon the use of realistic yet bounding input distributions for key analysis parameters, which replaces use of conservative deterministic singular inputs that bound overall analysis domain. This approach enables evaluating a more accurate accident analysis response, while enabling a bounding licensing basis envelope via more accurate quantification of uncertainty in the application. Therefore, built-in margin for a given scenario is more accurately evaluated.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
NASA NTRS2005

Reconfiguration of Analog Electronics for Extreme Environments: Problem or Solution?

This paper argues in favor of adaptive reconfiguration as a technique to expand the operational envelope of analog electronics for extreme environments (EE). In addition to hardening-by-process and hardening-by-design, "hardening-by-reconfiguration", when applicable, could be used to mitigate drifts, degradation, or damage on electronic devices (chips) in EE, by using re-configurable devices and an adaptive self-reconfiguration of their circuit topology. Conventional circuit design exploits device characteristics within a certain temperature/radiation range; when that is exceeded, the circuit function degrades. On a reconfigurable device, although component parameters change in EE, as long as devices still operate, albeit degraded, a new circuit design, suitable for new parameter values, may be mapped into the reconfigurable structure to recover the initial circuit function. Partly degraded resources are still used, while completely damaged resources are bypassed. Designs suitable for various environmental conditions can be determined prior to operation or can be determined in-situ, by adaptive reconfiguration algorithms running on built-in digital controllers. Laboratory demonstrations of this technique were performed by JPL in several independent experiments in which bulk CMOS reconfigurable devices were exposed to, and degraded by, low temperatures (approx. 196 C), high temperatures (approx.300 C) or radiation (300kRad TID), and then recovered by adaptive reconfiguration using evolutionary search algorithms. Taking this technology from Technology Readiness Level (TRL) 3 to TRL 5 is the target of a current NASA project.

Field Programmable Transistor Array (FPTA)↗
DOE OSTI2015

Scoping Study Investigating PWR Instrumentation during a Severe Accident Scenario

The accidents at the Three Mile Island Unit 2 (TMI-2) and Fukushima Daiichi Units 1, 2, and 3 nuclear power plants demonstrate the critical importance of accurate, relevant, and timely information on the status of reactor systems during a severe accident. These events also highlight the critical importance of understanding and focusing on the key elements of system status information in an environment where operators may be overwhelmed with superfluous and sometimes conflicting data. While progress in these areas has been made since TMI-2, the events at Fukushima suggests that there may still be a potential need to ensure that critical plant information is available to plant operators. Recognizing the significant technical and economic challenges associated with plant modifications, it is important to focus on instrumentation that can address these information critical needs. As part of a program initiated by the Department of Energy, Office of Nuclear Energy (DOE-NE), a scoping effort was initiated to assess critical information needs identified for severe accident management and mitigation in commercial Light Water Reactors (LWRs), to quantify the environment instruments monitoring this data would have to survive, and to identify gaps where predicted environments exceed instrumentation qualification envelop (QE) limits. Results from the Pressurized Water Reactor (PWR) scoping evaluations are documented in this report. The PWR evaluations were limited in this scoping evaluation to quantifying the environmental conditions for an unmitigated Short-Term Station BlackOut (STSBO) sequence in one unit at the Surry nuclear power station. Results were obtained using the MELCOR models developed for the US Nuclear Regulatory Commission (NRC)-sponsored State of the Art Consequence Assessment (SOARCA) program project. Results from this scoping evaluation indicate that some instrumentation identified to provide critical information would be exposed to conditions that significantly exceeded QE limits for extended time periods for the low frequency STSBO sequence evaluated in this study. It is recognized that the core damage frequency (CDF) of the sequence evaluated in this scoping effort would be considerably lower if evaluations considered new FLEX equipment being installed by industry. Nevertheless, because of uncertainties in instrumentation response when exposed to conditions beyond QE limits and alternate challenges associated with different sequences that may impact sensor performance, it is recommended that additional evaluations of instrumentation performance be completed to provide confidence that operators have access to accurate, relevant, and timely information on the status of reactor systems for a broad range of challenges associated with risk important severe accident sequences.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
NASA NTRS2016

Flow Characterization Studies of the 10-MW TP3 Arc-Jet Facility: Probe Sweeps

This paper reports computational simulations and analysis in support of calibration and flow characterization tests in a high enthalpy arc-jet facility at NASA Ames Research Center. These tests were conducted in the NASA Ames 10-MW TP3 facility using flat-faced stagnation calorimeters at six conditions corresponding to the steps of a simulated flight heating profile. Data were obtained using a conical nozzle test configuration in which the models were placed in a free jet downstream of the nozzle. Experimental surveys of arc-jet test flow with pitot pressure and heat flux probes were also performed at these arc-heater conditions, providing assessment of the flow uniformity and valuable data for the flow characterization. Two different sets of pitot pressure and heat probes were used: 9.1-mm sphere-cone probes (nose radius of 4.57 mm or 0.18 in) with null-point heat flux gages, and 15.9-mm (0.625 in) diameter hemisphere probes with Gardon gages. The probe survey data clearly show that the test flow in the TP3 facility is not uniform at most conditions (not even axisymmetric at some conditions), and the extent of non-uniformity is highly dependent on various arc-jet parameters such as arc current, mass flow rate, and the amount of cold-gas injection at the arc-heater plenum. The present analysis comprises computational fluid dynamics simulations of the nonequilibrium flowfield in the facility nozzle and test box, including the models tested. Comparisons of computations with the experimental measurements show reasonably good agreement except at the extreme low pressure conditions of the facility envelope.

Goekcen, Tahir↗
NASA NTRS2016

Flow Characterization Studies of the 10-MW TP3 Arc-Jet Facility: Probe Sweeps

This paper reports computational simulations and analysis in support of calibration and flow characterization tests in a high enthalpy arc-jet facility at NASA Ames Research Center. These tests were conducted in the NASA Ames 10-MW TP3 facility using flat-faced stagnation calorimeters at six conditions corresponding to the steps of a simulated flight heating profile. Data were obtained using a conical nozzle test configuration in which the models were placed in a free jet downstream of the nozzle. Experimental surveys of arc-jet test flow with pitot pressure and heat flux probes were also performed at these arc-heater conditions, providing assessment of the flow uniformity and valuable data for the flow characterization. Two different sets of pitot pressure and heat probes were used: 9.1-mm sphere-cone probes (nose radius of 4.57 mm or 0.18 in) with null-point heat flux gages, and 15.9-mm (0.625 in) diameter hemisphere probes with Gardon gages. The probe survey data clearly show that the test flow in the TP3 facility is not uniform at most conditions (not even axisymmetric at some conditions), and the extent of non-uniformity is highly dependent on various arc-jet parameters such as arc current, mass flow rate, and the amount of cold-gas injection at the arc-heater plenum. The present analysis comprises computational fluid dynamics simulations of the nonequilibrium flowfield in the facility nozzle and test box, including the models tested. Comparisons of computations with the experimental measurements show reasonably good agreement except at the extreme low pressure conditions of the facility envelope.

CFD↗
DOE OSTI2019

Investigating instabilities in a Rotating Detonation Combustor Operating with Natural Gas-Hydrogen Fuel Blend – Effect of Air Preheat and Annulus Width

Propagation characteristics of a detonation wave in an air-breathing Rotating Detonation Combustor (RDC) using natural gas-hydrogen fuel blends is presented in this paper. Short duration (~up to 6s) experiments were performed on a 152.4mm OD uncooled RDC with two different annulus gap widths (5.08mm and 7.62mm) over a range of equivalence ratios (0.6–1.0) at varying inlet air temperatures (~65°C-204°C) and natural gas content (up to 15%) with pre-combustion operating pressure slightly above ambient.It was observed that the RDC, with an annulus gap width of 5.08mm, was inherently unstable when natural gas (NG) was added to the hydrogen fuel while operating at pre-combustion pressures near ambient and at an inlet air temperature of 65°C. Increasing the annulus gap width to 7.62mm improved the stability of the detonation wave at similar temperatures and pressure permitting operation with as much as 5% NG by volume. While observed speeds of the detonation waves were still below theoretical values, an increase in inlet air temperature reduced the variability in wave speed. The frequency analysis thus explored in this study is an effort to quantify detonation instability in an RDC under varying operational envelope. The data presented is relevant towards developing strategies to sustain a stable detonation wave in an RDC using natural gas for land based power generation.

Roy, Arnab↗
NASA NTRS1985

Simulation evaluation of display/FLIR concepts for low-altitude, terrain-following helicopter operations

A piloted simulation of three head-down display (HDD) concepts with flight-director guidance superimposed on forward-looking infrared (FLIR) imagery was performed to evaluate the task of low-level, terrain-following (TF), manual helicopter flight. The three display concepts were examined for the purpose of finding ways by which aircraft flight-attitude and command symbols and FLIR imagery could be integrated onto one instrument. In all cases, the FLIR imagery was centered on the flight-path vector of the aircraft. The three displays were then characterized by having: (1) pitch attitude conformal to the FLIR imagery; (2) pitch attitude conformal to the FLIR imagery, but with an increase in the scaling; and (3) pitch attitude nonconformal to the FLIR imagery with the same pitch scaling as in (2). The simulation was conducted on the Vertical Motion Simulator (VMS) at Ames Research Center, using NASA and Air Force test pilots. The pilots indicated that the nonconformal pitch attitude and FLIR display was the preferred way to display information because of the absence of pitch-attitude information on displays (1) and (2) during some portions of the operational flight envelope.

Swenson, H. N.↗
DOE OSTI2014

Tracking the evolution of a coherent magnetic flux rope continuously from the inner to the outer corona

The magnetic flux rope (MFR) is believed to be the underlying magnetic structure of coronal mass ejections (CMEs). However, it remains unclear how an MFR evolves into and forms the multi-component structure of a CME. In this paper, we perform a comprehensive study of an extreme-ultraviolet (EUV) MFR eruption on 2013 May 22 by tracking its morphological evolution, studying its kinematics, and quantifying its thermal property. As EUV brightenings begin, the MFR starts to rise slowly and shows helical threads winding around an axis. Meanwhile, cool filamentary materials descend spirally down to the chromosphere. These features provide direct observational evidence of intrinsically helical structure of the MFR. Through detailed kinematical analysis, we find that the MFR evolution has two distinct phases: a slow rise phase and an impulsive acceleration phase. We attribute the first phase to the magnetic reconnection within the quasi-separatrix layers surrounding the MFR, and the much more energetic second phase to the fast magnetic reconnection underneath the MFR. We suggest that the transition between these two phases is caused by the torus instability. Moreover, we identify that the MFR evolves smoothly into the outer corona and appears as a coherent structure within the white-light CME volume. The MFR in the outer corona was enveloped by bright fronts that originated from plasma pile-up in front of the expanding MFR. The fronts are also associated with the preceding sheath region followed by the outmost MFR-driven shock.

79 ASTRONOMY AND ASTROPHYSICS↗
NASA NTRS1992

A burst from a thermonuclear runaway on an ONeMg white dwarf

Studies which examine the consequences of accretion, at rates of 10(exp -9) solar mass/yr and 10(exp -10) solar mass/yr, onto an ONeMg white dwarf with a mass of 1.35 solar masses are performed. In these studies, a Lagrangian, hydrodynamic, one-dimensional computer code was used. The code now includes a network with 89 nuclei up to Ca-40, elemental diffusion, new opacities, and new equation of state. The initial abundance distribution corresponded to a mixture that was enriched to either 25, 50, or 75 percent in products of carbon burning. The remaining material in each case is assumed to have a solar composition. The evolution of the thermonuclear runaway in the 1.35 solar mass white dwarf, with M = 10(exp -9) solar mass, produced peak temperatures in the shell source exceeding 300 million degrees. The sequence produced significant amounts of Na-22 from proton captures onto Ne-20 and significant amounts of Al-26 from proton captures on Mg-24. This sequence ejected 5.2 x 10(exp -6) solar mass moving with speeds from approximately 100 km/s to 2300 km/s. When the mass accretion rate was decreased to 10(exp -10) solar mass, the resulting thermonuclear runaway produced a shock that moved through the outer envelope of the white dwarf and raised the surface luminosity to L greater than 10(exp 7) solar luminosity and the effective temperature to values exceeding 10(exp 7) K. The interaction of the material expanding from off of the white dwarf with the accretion disk should produce a burst of gamma-rays.

Starrfield, S.↗
NASA NTRS1995

Lithospheric bending at subduction zones based on depth soundings and satellite gravity

A global study of trench flexure was performed by simultaneously modeling 117 bathymetric profiles (original depth soundings) and satellite-derived gravity profiles. A thin, elastic plate flexure model was fit to each bathymetry/gravity profile by minimization of the L(sub 1) norm. The six model parameters were regional depth, regional gravity, trench axis location, flexural wavelength, flexural amplitude, and lithospheric density. A regional tilt parameter was not required after correcting for age-related trend using a new high-resolution age map. Estimates of the density parameter confirm that most outer rises are uncompensated. We find that flexural wavelength is not an accurate estimate of plate thickness because of the high curvatures observed at a majority of trenches. As in previous studies, we find that the gravity data favor a longer-wavelength flexure than the bathymetry data. A joint topography-gravity modeling scheme and fit criteria are used to limit acceptable parameter values to models for which topography and gravity yield consistent results. Even after the elastic thicknesses are converted to mechanical thicknesses using the yield strength envelope model, residual scatter obscures the systematic increase of mechanical thickness with age; perhaps this reflects the combination of uncertainties inherent in estimating flexural wavelength, such as extreme inelastic bending and accumulated thermoelastic stress. The bending moment needed to support the trench and outer rise topography increases by a factor of 10 as lithospheric age increases from 20 to 150 Ma; this reflects the increase in saturation bending moment that the lithosphere can maintain. Using a stiff, dry-olivine rheology, we find that the lithosphere of the GDH1 thermal model (Stein and Stein, 1992) is too hot and thin to maintain the observed bending moments. Moreover, the regional depth seaward of the oldest trenches (approximately 150 Ma) exceeds the GDH1 model depths by about 400 m.

Levitt, Daniel A.↗
DOE OSTI2022

Smart, Connected Manufactured Housing Solutions through High-Performance Design. Final CRADA report

This report focuses on HVAC, domestic hot water, and miscellaneous electric loads via voluntary opportunities that may arise from partnerships with utilities, as well as future US Environmental Protection Agency ENERGY STAR and DOE Zero Energy Ready Manufactured Home programs. Phase I of this project has begun the technical dialogue toward developing an implementation plan among DOE’s Oak Ridge National Laboratory, Clayton Manufactured Homes, and US Department of Housing and Urban Development Code manufactured housing stakeholders. These activities have focused on delivering high-performance design through integration of technology. Project tasks include the following: Identifying baseline energy analysis resources opportunities from a variety of DOE and utility stakeholders; Developing a smart home and business solution by leveraging existing utility programs working with Smart Homes Partners resources such as ACE IoT Solutions, Google Nest, and Ecobee; Developing improved smarter ventilation systems with industry ventilation partners such as the Madison Group; Developing improved building science QA/QC testing equipment with manufacturers such as The Energy Conservatory, and supporting other feasible concepts vetted under DOE’s Advanced Buildings Collaborative with Slipstream, reinventing HVAC in manufactured housing; and, Developing smart home short- and long-term viable technical solutions in coordination with Clayton Manufactured Homes in new and/or revitalized community scales for future Phase II prototype demonstrations, which may include design (and perhaps construction) of single-section homes targeting rental property developers and multi-section homes targeting low- to middle-income affordable housing community developers Given the ongoing US Department of Energy (DOE) rulemaking activities, baseline energy analysis assessments of envelope prescriptive and Uo (i.e., the overall thermal energy efficiency of the home in British thermal units per square foot of exterior heat loss/gain surfaces) measures were removed from the scope of Phase I of this project.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
NASA NTRSDate not supplied

Experimental Methods Using Force Application of A Single Boom for A 500-M²-Class Solar Sail

Solar sailing missions rely on deployable systems for large area-to-mass ratios once in space, while still being small enough for launcher envelopes in the stowed configuration. Many of these deployable systems feature booms that are flattened and subsequently coiled onto a spool / hub. As part of a collaborative deployable space structures research effort between the National Aeronautics and Space Administration (NASA) and German Aerospace Center (DLR), a boom deployment system for a future 500 m² solar sail has been developed. To achieve the respective solar sail size goal, 16.5-m-long booms produced by NASA were integrated into a DLR-designed deployer mechanism. This considerable size, as well as the lightweight construction of the booms and respective deployable systems makes testing on the ground a significant challenge. Some systems for gravity compensation as well as vertical testing to minimize the influence of gravity have been used in the past. However, an uncertainty factor remains towards the behaviour in the space environment. The focus of this paper is the load application testing of the integrated boom-deployment mechanism system under microgravity condition, as well as a comparison to vertical testing under gravity. Testing in microgravity was performed during a parabolic flight test inside an aircraft and it included stowage and full deployment of a single boom along the longitudinal axis of the aircraft. The load application was split into two categories: static testing, which induced a linear force ramp to the static boom for either compression or compression-bending; and dynamic testing, which applied a constant force to a boom during extension provided by the deployer mechanism. Both types of tests were performed multiple times at two distinct lengths of the boom, fully deployed (12.76 m) and ~28.6 % deployed (3.65 m). More parameters that are vital to the test philosophy are the angles of attack in the force application and the highest force applied. The data acquisition used for the applied load and deflection measurements of the boom is also presented.

Martin Richter↗
NASA NTRSDate not supplied

Experimental Methods Using Force Application of A Single Boom for A 500-M²-Class Solar Sail

Solar sailing missions rely on deployable systems for large area-to-mass ratios once in space, while still being small enough for launcher envelopes in the stowed configuration. Many of these deployable systems feature booms that are flattened and subsequently coiled onto a spool / hub. As part of a collaborative deployable space structures research effort between the National Aeronautics and Space Administration (NASA) and German Aerospace Center (DLR), a boom deployment system for a future 500 m² solar sail has been developed. To achieve the respective solar sail size goal, 16.5-m-long booms produced by NASA were integrated into a DLR-designed deployer mechanism. This considerable size, as well as the lightweight construction of the booms and respective deployable systems makes testing on the ground a significant challenge. Some systems for gravity compensation as well as vertical testing to minimize the influence of gravity have been used in the past. However, an uncertainty factor remains towards the behaviour in the space environment. The focus of this paper is the load application testing of the integrated boom-deployment mechanism system under microgravity condition, as well as a comparison to vertical testing under gravity. Testing in microgravity was performed during a parabolic flight test inside an aircraft and it included stowage and full deployment of a single boom along the longitudinal axis of the aircraft. The load application was split into two categories: static testing, which induced a linear force ramp to the static boom for either compression or compression-bending; and dynamic testing, which applied a constant force to a boom during extension provided by the deployer mechanism. Both types of tests were performed multiple times at two distinct lengths of the boom, fully deployed (12.76 m) and ~28.6 % deployed (3.65 m). More parameters that are vital to the test philosophy are the angles of attack in the force application and the highest force applied. The data acquisition used for the applied load and deflection measurements of the boom is also presented.

Martin Richter↗
NASA NTRS2008

2007 Research and Engineering Annual Report

Selected research and technology activities at NASA Dryden Flight Research Center are summarized. These following activities exemplify the Center's varied and productive research efforts: Developing a Requirements Development Guide for an Automatic Ground Collision Avoidance System; Digital Terrain Data Compression and Rendering for Automatic Ground Collision Avoidance Systems; Nonlinear Flutter/Limit Cycle Oscillations Prediction Tool; Nonlinear System Identification Using Orthonormal Bases: Application to Aeroelastic/Aeroservoelastic Systems; Critical Aerodynamic Flow Feature Indicators: Towards Application with the Aerostructures Test Wing; Multidisciplinary Design, Analysis, and Optimization Tool Development Using a Genetic Algorithm; Structural Model Tuning Capability in an Object-Oriented Multidisciplinary Design, Analysis, and Optimization Tool; Extension of Ko Straight-Beam Displacement Theory to the Deformed Shape Predictions of Curved Structures; F-15B with Phoenix Missile and Pylon Assembly--Drag Force Estimation; Mass Property Testing of Phoenix Missile Hypersonic Testbed Hardware; ARMD Hypersonics Project Materials and Structures: Testing of Scramjet Thermal Protection System Concepts; High-Temperature Modal Survey of the Ruddervator Subcomponent Test Article; ARMD Hypersonics Project Materials and Structures: C/SiC Ruddervator Subcomponent Test and Analysis Task; Ground Vibration Testing and Model Correlation of the Phoenix Missile Hypersonic Testbed; Phoenix Missile Hypersonic Testbed: Performance Design and Analysis; Crew Exploration Vehicle Launch Abort System-Pad Abort-1 (PA-1) Flight Test; Testing the Orion (Crew Exploration Vehicle) Launch Abort System-Ascent Abort-1 (AA-1) Flight Test; SOFIA Flight-Test Flutter Prediction Methodology; SOFIA Closed-Door Aerodynamic Analyses; SOFIA Handling Qualities Evaluation for Closed-Door Operations; C-17 Support of IRAC Engine Model Development; Current Capabilities and Future Upgrade Plans of the C-17 Data Rack; Intelligent Data Mining Capabilities as Applied to Integrated Vehicle Health Management; STARS Flight Demonstration No. 2 IP Data Formatter; Space-Based Telemetry and Range Safety (STARS) Flight Demonstration No. 2 Range User Flight Test Results; Aerodynamic Effects of the Quiet Spike(tm) on an F-15B Aircraft; F-15 Intelligent Flight Controls-Increased Destabilization Failure; F-15 Integrated Resilient Aircraft Control (IRAC) Improved Adaptive Controller; Aeroelastic Analysis of the Ikhana/Fire Pod System; Ikhana: Western States Fire Missions Utilizing the Ames Research Center Fire Sensor; Ikhana: Fiber-Optic Wing Shape Sensors; Ikhana: ARTS III; SOFIA Closed-Door Flutter Envelope Flight Testing; F-15B Quiet Spike(TM) Aeroservoelastic Flight Test Data Analysis; and UAVSAR Platform Precision Autopilot Flight Results.

Stoliker, Patrick↗
DOE OSTI2019

Predicting Home Thermal Dynamics Using a Reduced-Order Model and Automatied Real-Time Parameter Estimation

Although smart thermostats have increasingly provided homeowners with abundant operational data related to advanced HVAC control and energy usage management in homes, there is a lack of systematic frameworks that can utilize such data to generate actionable information for advanced home comfort system diagnosis and control. Recognizing that a home thermal model, which is capable of connecting weather and HVAC operational data, is crucial to this framework, this paper introduces a home thermal model that is built upon the standard RC (Resistor-Capacitor) approach and the one virtual envelope assumption to describe the thermal dynamics of a home. A parameter estimation scheme is also developed that enables automatic, sequential, and optimal estimation of the model parameters, i.e., the thermal properties, of a home. Finally, the home thermal model and its parameter estimation scheme are tested using data collected over 63 consecutive days from a test home. In the test, the length of data that can provide enough robustness for parameter estimation is investigated. It is found that 10 days of data are enough, although 20 or more days of data can provide more robust results. In addition, when the model is used to make 12-hour-ahead predictions of indoor temperature the resulting mean, maximum, and 95%-confidence-interval absolute are 0.31 °C, 1.72 °C, and 0.90 °C, respectively, if the model is trained using 10 consecutive days of data, and 0.27 °C, 1.19 °C, and 0.72 °C, respectively, if 20 consecutive days are used. Therefore, the proposed home thermal model requires only a modest amount of training data to yield fairly accurate prediction and is able to perform better with more data.

home thermal model, Building thermal dynamics, ind↗
DOE OSTI2021

Regal Beloit Final Technical Report

The original project proposal submitted from NovaTorque Inc (NovaTorque) in 2016 was to improve the existing motor with 95% efficiency by reducing the losses by 21% to achieve 96%. A few months after the proposal was submitted, NovaTorque lost funding and went out of business. The assets of NovaTorque were then acquired by Regal Beloit Corporation (“Regal Beloit” or “Regal”). When the NovaTorque proposal was selected, the project was transferred to Regal Beloit. Once we had production samples from the new Regal production line, they were tested at the Regal Beloit test lab in Wausau, WI. The original NovaTorque motor had an efficiency of 95%, but when the technology was transferred to Regal Beloit, there were multiple manufacturing improvements made, even though the basic electromagnetic design did not change. The test results in Wausau showed that the motors made at the Regal Beloit plant had an efficiency of 96%. Since the goal of the project was to reduce the losses by 21%, a new efficiency target of 96.8% became the project objective. In the first budget period, motors were tested to get the baseline performance. We then used FEA modeling with ANSYS Maxwell to model the existing motor to get correlation between the FEA simulations and the actual test results. Once the model was validated, we evaluated some changes that could be made to the stator to reduce the losses and improve efficiency without changing the rotor or stator housing, keeping the modifications easy to implement. The changes were primarily in the area of making the stator axially shorter and adding Soft Magnetic Composite (SMC) tooth tips. In the second budget period, we proceeded to design and build the new stator that was identified above and identified additional improvements in the process that included a stator machining modification and the use of rectangular wire. When we actually built the motor, the choice of rectangular wire turned out to be a problem. The wire was made by squishing round wire to get the rectangular shape, which caused work hardening, making the wire too stiff to make the desired coils. We shifted to annealed square wire which was better, but we still could not maintain the proper coil envelope. The result was that we had reduced cross section area for stator laminations. We also had to have a radial offset resulting in a radial misalignment between the stator and rotor because of the oversized coils. After the motor was completed, it was shipped to Texas A&M University for testing. With the loss of flux from these issues, the measured motor efficiency was only 96.3%. The primary focus of this motor was to make sure our FEA simulation model predicted the measured losses and overall efficiency, this we moved on to the FEA simulation. The FEA simulations of the motor “as built” with misalignments had good correlation with the test results, so the next step was to use that model to optimize the design of the motor for a final build. This time we considered changes to the stator and rotor and also minor changes to the housing diameter. In the third budget period, we did the detailed design and construction of the final prototypes. The final prototypes had a slight increase in the stator diameter to fit in a standard Regal Beloit housing. We shortened the stator and use more layers of wire in the coils. We also increased the cone angle of the rotor and stator from the original 110 degrees to 130 degrees to get some additional efficiency and optimized the stator cross section. The predicted efficiency from the FEA simulations was 96.9%. When completed, the motors were tested. We were a little short of reaching our target efficiency goal of 96.8%. We were only able to get to 96.7% efficiency. While it may be possible with additional iterations in designs and future builds to gain that additional 0.1%, we believe that we are close to the best we can achieve from a practical viewpoint, and additional iterations would be more work than the potential gains would be worth. No other motor in this class can even reach the 96% that we started with.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
NASA NTRS2013

2013 NASA Range Safety Annual Report

Welcome to the 2013 edition of the NASA Range Safety Annual Report. Funded by NASA Headquarters, this report provides an Agency overview for current and potential range users. This report contains articles which cover a variety of subject areas, summaries of various activities performed during the past year, links to past reports, and information on several projects that may have a profound impact on the way business will be conducted in the future. Specific topics discussed in the 2013 NASA Range Safety Annual Report include a program overview and 2013 highlights, Range Safety Training, Independent Assessments, support to Program Operations at all ranges conducting NASA launch/flight operations, a continuing overview of emerging range safety-related technologies, and status reports from all of the NASA Centers that have Range Safety responsibilities. Every effort has been made to include the most current information available. We recommend this report be used only for guidance and that the validity and accuracy of all articles be verified for updates. As is the case each year, we had a wide variety of contributors to this report from across our NASA Centers and the national range safety community at large, and I wish to thank them all. On a sad note, we lost one of our close colleagues, Dr. Jim Simpson, due to his sudden passing in December. His work advancing the envelope of autonomous flight safety systems software/hardware development leaves a lasting impression on our community. Such systems are being flight tested today and may one day be considered routine in the range safety business. The NASA family has lost a pioneer in our field, and he will surely be missed. In conclusion, it has been a very busy and productive year, and I look forward to working with all of you in NASA Centers/Programs/Projects and with the national Range Safety community in making Flight/Space activities as safe as they can be in the upcoming year.

Center Status↗