Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “Design for reliability”

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.

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

At least 1,639 records · Page 91
All sourcesNASA NTRSDOE OSTI
NASA NTRSDate not supplied

NASA Physics of Failure (PoF) for Reliability

An item’s reliability or longevity is dependent not only on its design but also on how it is used, manufactured, tested, and the stresses it has or will experience. Stresses include operational and environmental exposures to thermal, voltage, current, age/exposure, mechanical, and radiation mechanisms. Therefore, in reliability analysis, it is important to consider the contributions of all these factors when predicting the failure rates of components. Historically, there has been a reliance on handbook data (e.g., MIL-HDBK-217), but experience has shown that these values and distributions are not representative of actual performance. Therefore, to make more credible reliability and risk assessments for its missions, NASA must transition to estimating likelihoods of failure based on an item’s reliability or longevity factors (or the physical susceptibilities and strengths impacting the design’s performance) has or will experience, whenever possible. To facilitate this transition, a Handbook on Methodology for Physics of Failure Based Reliability Assessments has been developed by NASA to assist in applying physics experiences or experimental physics for empirical analysis and conceptualized physics exposures or theoretical physics for deterministic analysis, to develop and aggregate realistic likelihoods of failure leading to more credible forecasts of item performance and longevity. In addition, since it is NASA’s intention that this document continues to evolve based on community lessons learned and the introduction of new assessment methodologies, NASA is encouraging and appreciates the contributions of current and future authors to maintain and enhance this handbook and its supporting case studies.

PoF↗
DOE OSTI2022

Wind Turbine Drivetrain Reliability [Slides]

Pitch bearings, main bearings, and gearboxes in conventional wind turbine drivetrains often do not meet their 20-year minimum specified lifetime, resulting in turbine downtime as well as expensive, time-consuming repairs or replacements. The dominant failure modes of the drivetrain components and the conditions that lead to their failure are not fully accounted for during product design or routinely modeled for life management. Drivetrain reliability improvements and O&M cost reductions remain top priorities for both land-based and offshore wind turbines, especially as wind turbines continue to be deployed in increasingly remote and offshore locations, continue to increase in size, and are becoming expected to be in service beyond their original design life, all of which correspond to an increase in the impact of any reliability issues on O&M costs. This presentation summarizes the most recent activities by NREL and ANL on drivetrain reliability.

17 WIND ENERGY↗
NASA NTRS2009

Towards Behavioral Reflexion Models

Software architecture has become essential in the struggle to manage today s increasingly large and complex systems. Software architecture views are created to capture important system characteristics on an abstract and, thus, comprehensible level. As the system is implemented and later maintained, it often deviates from the original design specification. Such deviations can have implication for the quality of the system, such as reliability, security, and maintainability. Software architecture compliance checking approaches, such as the reflexion model technique, have been proposed to address this issue by comparing the implementation to a model of the systems architecture design. However, architecture compliance checking approaches focus solely on structural characteristics and ignore behavioral conformance. This is especially an issue in Systems-of- Systems. Systems-of-Systems (SoS) are decompositions of large systems, into smaller systems for the sake of flexibility. Deviations of the implementation to its behavioral design often reduce the reliability of the entire SoS. An approach is needed that supports the reasoning about behavioral conformance on architecture level. In order to address this issue, we have developed an approach for comparing the implementation of a SoS to an architecture model of its behavioral design. The approach follows the idea of reflexion models and adopts it to support the compliance checking of behaviors. In this paper, we focus on sequencing properties as they play an important role in many SoS. Sequencing deviations potentially have a severe impact on the SoS correctness and qualities. The desired behavioral specification is defined in UML sequence diagram notation and behaviors are extracted from the SoS implementation. The behaviors are then mapped to the model of the desired behavior and the two are compared. Finally, a reflexion model is constructed that shows the deviations between behavioral design and implementation. This paper discusses the approach and shows how it can be applied to investigate reliability issues in SoS.

Ackermann, Christopher↗
NASA NTRS1991

Design, optimization, and analysis of a self-deploying PV tent array

A tent shaped PV array was designed and the design was optimized for maximum specific power. In order to minimize output power variation a tent angle of 60 deg was chosen. Based on the chosen tent angle an array structure was designed. The design considerations were minimal deployment time, high reliability, and small stowage volume. To meet these considerations the array was chosen to be self-deployable, form a compact storage configuration, using a passive pressurized gas deployment mechanism. Each structural component of the design was analyzed to determine the size necessary to withstand the various forces to which it would be subjected. Through this analysis the component weights were determined. An optimization was performed to determine the array dimensions and blanket geometry which produce the maximum specific power for a given PV blanket. This optimization was performed for both lunar and Martian environmental conditions. Other factors such as PV blanket types, structural material, and wind velocity (for Mars array), were varied to determine what influence they had on the design point. The performance specifications for the array at both locations and with each type of PV blanket were determined. These specifications were calculated using the Arimid fiber composite as the structural material. The four PV blanket types considered were silicon, GaAs/Ge, GaAsCLEFT, and amorphous silicon. The specifications used for each blanket represented either present day or near term technology. For both the Moon and Mars the amorphous silicon arrays produced the highest specific power.

Collozza, Anthony J.↗
NASA NTRS1990

ALS turbomachinery technology

Advanced Development Programs are being pursued by Rocketdyne, Aerojet, and Pratt and Whitney to define and validate design approaches toward producing low-cost, reliable liquid-hydrogen and liquid-oxygen turbopumps for a 2580 kN (580 klb) thrust Advanced Launch System. The generic approach, which is evolving after 18 months of trade studies and conceptual and preliminary design efforts, is explained. In addition, the preliminary liquid-hydrogen turbopump designs produced in parallel tasks by Rocketdyne and Aerojet and the liquid-oxygen turbopump design produced by Pratt and Whitney are described, and technology features and issues are discussed.

Csomor, A.↗
NASA NTRS2021

Relocatable 10 kW Solar Array for Lunar South Pole Missions

Deployable, relocatable, free-standing solar arrays are being developed to provide modular power for future lunar South Pole missions. Major design requirements for these arrays will be low mass, compact launch stowage, and highly reliable deployment and retraction. This paper presents a novel conceptual design for a10 kW solar array to address these requirements referred to as the Relocatable Solar Array (RSA).Simply stated, the concept is a pair of solar cell blankets freely hanging from a horizontal cross arm supported by a vertical, slender, telescoping mast resting on a deployable tripod base. A major factor in simplifying the design is that the force exerted by lunar gravity is used to deploy and maintain extension of the hanging array blankets. A second major factor in achieving the desired low mass and high volumetric efficiency is that the array operates in the vacuum, low-gravity, lunar environment with no deployed vibration frequency requirement. Such a low-load environment enables use of extraordinarily slender and low mass structural members to support the hanging array blankets. This concept was developed, in part, to serve as a NASA reference solar array concept against which other proposed arrays can be compared.

Lunar Surface Power↗
DOE OSTI2022

Review of Wave Energy Converter Power Take-Off Systems, Testing Practices, and Evaluation Metrics: Preprint

While the field of wave energy has been the subject of numerical simulation, scale model testing, and precommercial project testing for decades, wave energy technologies remain in the early stages of development and must continuing proving themselves as a promising modern renewable energy field. One of the difficulties that wave energy systems have been struggling to overcome is the design of highly efficient energy conversion systems that can convert the mechanical power, derived from the oscillation of wave activated bodies, into another useful product. Often the power take-off (PTO) is defined as the single unit responsible for converting mechanical power into another usable form such as electricity, pressurized fluid, compressed air, and others. The PTO, and the entire power conversion chain (PCC), is of great importance as it affects not only how efficient wave power is converted into electricity, but also contributes to the mass, size, structural dynamics, and levelized cost of energy (LCOE) of the wave energy converter (WEC). Unlike wind and solar, there is no industrial standard device, or devices, for wave energy conversion and this diversity is transferred to the PTO system. The majority of current WEC PTO systems incorporate a mechanical or hydraulic drive train, power generator, and an electrical control system. The challenge of WEC PTO designs is designing a mechanical-to-electrical component that can efficiently convert irregular, bi-directional, low frequency and low alternating velocity wave motions. While gross average power levels can be predicted in advance, the variable wave elevation input has to be converted into smooth electrical output and hence usually necessitates some type of energy storage system, such as battery storage, accumulator super capacitors, etc., or other means of compensation such as an array of devices. One of the primary challenges for wave energy converter systems is the fluctuating nature of wave resources, which require WEC components to be designed to handle loads (i.e. torques, forces, and powers) that are many times greater than the average load. This approach requires a much greater PTO capacity than the average power output and indicates a higher cost. In addition, supporting mechanical coupling and or gearing can be added to the PCC to help alleviate the difficulties with transmission and control of fluctuating large loads with low frequencies (indicative of wave forcing) into smaller loads at higher frequencies (optimum for conventional electrical machine design) can quickly increase the complexity of the PCC which could result in a greater number of failure modes and increased maintenance costs. All of the previous points demonstrate how the PTO influences WEC dynamics, reliability, performance and cost which are critical design factors. This paper further explores these topics by providing a review of the state-of-the-art PTO systems currently under development, how these novel PTO systems are tested and derisked prior to precommercial deployment, and the evaluation metrics historically used to differentiate between PTO designs and how they can be improved to support control co-design focused development of wave energy systems.

laboratory testing↗
DOE OSTI2022

Drivetrain Reliability Collaborative Update

Pitch bearings, main bearings, and gearboxes in conventional wind turbine drivetrains often do not meet their 20-year minimum specified lifetime, resulting in turbine downtime as well as expensive, time-consuming repairs or replacements. The dominant failure modes of the drivetrain components and the conditions that lead to their failure are not fully accounted for during product design or routinely modeled for life management. Drivetrain reliability improvements and O&M cost reductions remain top priorities for both land-based and offshore wind turbines, especially as wind turbines continue to be deployed in increasingly remote and offshore locations, continue to increase in size, and are becoming expected to be in service beyond their original design life, all of which correspond to an increase in the impact of any reliability issues on O&M costs. This presentation summarizes the most recent activities by NREL and ANL on drivetrain reliability.

bearing↗
NASA NTRS2000

Temperature Distribution Within a Defect-Free Silicon Carbide Diode Predicted by a Computational Model

Most solid-state electronic devices diodes, transistors, and integrated circuits are based on silicon. Although this material works well for many applications, its properties limit its ability to function under extreme high-temperature or high-power operating conditions. Silicon carbide (SiC), with its desirable physical properties, could someday replace silicon for these types of applications. A major roadblock to realizing this potential is the quality of SiC material that can currently be produced. Semiconductors require very uniform, high-quality material, and commercially available SiC tends to suffer from defects in the crystalline structure that have largely been eliminated in silicon. In some power circuits, these defects can focus energy into an extremely small area, leading to overheating that can damage the device. In an effort to better understand the way that these defects affect the electrical performance and reliability of an SiC device in a power circuit, the NASA Glenn Research Center at Lewis Field began an in-house three-dimensional computational modeling effort. The goal is to predict the temperature distributions within a SiC diode structure subjected to the various transient overvoltage breakdown stresses that occur in power management circuits. A commercial computational fluid dynamics computer program (FLUENT-Fluent, Inc., Lebanon, New Hampshire) was used to build a model of a defect-free SiC diode and generate a computational mesh. A typical breakdown power density was applied over 0.5 msec in a heated layer at the junction between the p-type SiC and n-type SiC, and the temperature distribution throughout the diode was then calculated. The peak temperature extracted from the computational model agreed well (within 6 percent) with previous first-order calculations of the maximum expected temperature at the end of the breakdown pulse. This level of agreement is excellent for a model of this type and indicates that three-dimensional computational modeling can provide useful predictions for this class of problem. The model is now being extended to include the effects of crystal defects. The model will provide unique insights into how high the temperature rises in the vicinity of the defects in a diode at various power densities and pulse durations. This information also will help researchers in understanding and designing SiC devices for safe and reliable operation in high-power circuits.

Kuczmarski, Maria A.↗
DOE OSTI2023

Passive Safety System Reliability Analysis: Methodology, Application, and Results

Many advanced reactor designs rely on passive systems to provide assurance that certain safety functions, such as reactivity control and reactor heat removal, are maintained during transient scenarios. The performance of these systems is sensitive to boundary and environmental conditions and can lead to functional failure, which is the inability of the system to perform as intended even without any physical failures. Additionally, conditions can cause the passive systems to operate in an intermediate or degraded state. These operational modes of passive systems and their overall reliability can be difficult to capture in traditional probabilistic frameworks where discrete operating modes are assumed or time-dependent boundary conditions are not accounted for. Novel strategies and methods are needed to be able to capture the reliability of these passive systems and their impact on facility safety. The current abstract provides a summary of such a methodology and examples of its use in a case study, the GE Hitachi (GEH) PRISM probabilistic safety assessment (PSA), and the U.S. Department of Energy (USDOE) Versatile Test Reactor (VTR) PSA.

Bucknor, M.↗
NASA NTRS2024

High Reliability at Minimum Cost

This paper investigates the minimum cost of improving the reliability of complex technical systems. The two major methods to improve reliability are redesigning the system for higher reliability or providing redundant components to replace failed elements. The costs of redesign for reliability or adding redundancy are estimated. The most cost-effective combination for high reliability can be identified. The cost of increasing the intrinsic reliability of a system can be modeled as cost proportional to 1/(system failure rate) a , where the exponent “a” measures the difficulty of increasing reliability. The “a” exponent can vary from 0.25 to about 2.5. Operational reliability can also be increased by using redundant systems. The failure rate for N parallel redundant units is (system failure rate) N . The cost of redundancy is N times the system cost. The total redundant system cost is proportional to N/(system failure rate) a . The cost of redundancy increases as N gets larger, but larger N allows a higher system failure rate, which reduces the system design cost. There is a certain N, a certain level of redundancy, that has the minimum cost to achieve the required overall redundant system failure rate. The minimum cost for the redundant system is achieved at the optimum level of redundancy. The N for minimum cost is equal to -a ln (redundant system failure rate). The minimum cost of the N redundant systems is proportional to N * (original system failure rate) a . The optimum redesigned individual system failure rate is proportional to exp (-1/a), so the greater the difficulty, the higher the optimum individual system failure rate. Increasing the intrinsic reliability of a system encounters diminishing returns and at some point it becomes more cost-effective to add redundancy. The difficulty of increasing intrinsic system reliability determines the optimum design for high reliability at minimum cost.

reliability↗
NASA NTRSDate not supplied

High Reliability at Minimum Cost

This paper investigates the minimum cost of improving the reliability of complex technical systems. The two major methods to improve reliability are redesigning the system for higher reliability or providing redundant components to replace failed elements. The costs of redesign for reliability or adding redundancy are estimated. The most cost-effective combination for high reliability can be identified. The cost of increasing the intrinsic reliability of a system can be modeled as cost proportional to 1/(system failure rate) a , where the exponent “a” measures the difficulty of increasing reliability. The “a” exponent can vary from 0.25 to about 2.5. Operational reliability can also be increased by using redundant systems. The failure rate for N parallel redundant units is (system failure rate) N . The cost of redundancy is N times the system cost. The total redundant system cost is proportional to N/(system failure rate) a . The cost of redundancy increases as N gets larger, but larger N allows a higher system failure rate, which reduces the system design cost. There is a certain N, a certain level of redundancy, that has the minimum cost to achieve the required overall redundant system failure rate. The minimum cost for the redundant system is achieved at the optimum level of redundancy. The N for minimum cost is equal to -a ln (redundant system failure rate). The minimum cost of the N redundant systems is proportional to N * (original system failure rate) a . The optimum redesigned individual system failure rate is proportional to exp (-1/a), so the greater the difficulty, the higher the optimum individual system failure rate. Increasing the intrinsic reliability of a system encounters diminishing returns and at some point it becomes more cost-effective to add redundancy. The difficulty of increasing intrinsic system reliability determines the optimum design for high reliability at minimum cost.

reliability↗
DOE OSTI2024

High–Performance NiCo 2 O 4 /Graphene Quantum Dots for Asymmetric and Symmetric Supercapacitors with Enhanced Energy Efficiency

For the sustainable growth of future generations, energy storage technologies like supercapacitors and batteries are becoming more and more common. However, reliable and high-performance materials’ design and development is the key for the widespread adoption of batteries and supercapacitors. Quantum dots with fascinating and unusual properties are expected to revolutionize future technologies. However, while the recent discovery of quantum dots honored with a Nobel prize in Chemistry, their benefits for the tenacious problem of energy are not realized yet. In this context, herein, chemical-composition tuning enabled exceptional performance of NiCo 2 O 4 (NCO)/graphene quantum dots (GQDs) is reported, which outperform the existing similar materials, in supercapacitors. A comprehensive study is performed on the synthesis, characterization, and electrochemical performance evaluation of highly functional NCO/GQDs in supercapacitors delivering enhanced energy efficiency. The high-performance, functional NCO/GQDs electrode materials are synthesized by the incorporation of GQDs into NCO. The effect of variable amount of GQDs on the energy performance characteristics of NCO/GQDs in supercapacitors is studied systematically. In-depth structural and chemical bonding analyses using X-ray diffraction (XRD) and Raman spectroscopic studies indicate that all the NCO/GQDs composites crystallize in the spinel cubic phase of NiCo 2 O 4 while graphene integration evident in all the NCO/GQDs. The scanning electron microscopy imaging analysis reveals homogeneously distributed spherical particles with a size distribution of 5–9 nm validating the formation of QDs. The high-resolution transmission electron microscopy analyses reveal that the NCOQDs are anchored on graphene sheets, which provide a high surface area of 42.27 m 2 g –1 and high mesoporosity for the composition of NCO/GQDs-10%. In addition to establishing reliable electrical connection to graphene sheets, the NCOQDs provide reliable 3D-conductive channels for rapid transport throughout the electrode as well as synergistic effects. Chemical-composition tuning, and optimization yields NCO/GQDs-10% to deliver the best specific capacitance of 3940 Fg –1 at 0.5 Ag –1 , where the electrodes retain ≈98% capacitance after 5000 cycles. The NCO/GQD-10%//AC asymmetric supercapacitor device demonstrates outstanding energy density and power density values of 118.04 Wh kg –1 and 798.76 W kg –1 , respectively. The NCO/GQDs-10%//NCO/GQDs-10% symmetric supercapacitor device delivers excellent energy and power density of 24.30 Wh kg –1 and 500 W kg –1 , respectively. These results demonstrate and conclude that NCO/GQDs are exceptional and prospective candidates for developing next-generation high-performance and sustainable energy storage devices.

25 ENERGY STORAGE↗
NASA NTRS1989

NASA-LaRc Flight-Critical Digital Systems Technology Workshop

The outcome is documented of a Flight-Critical Digital Systems Technology Workshop held at NASA-Langley December 13 to 15 1988. The purpose of the workshop was to elicit the aerospace industry's view of the issues which must be addressed for the practical realization of flight-critical digital systems. The workshop was divided into three parts: an overview session; three half-day meetings of seven working groups addressing aeronautical and space requirements, system design for validation, failure modes, system modeling, reliable software, and flight test; and a half-day summary of the research issues presented by the working group chairmen. Issues that generated the most consensus across the workshop were: (1) the lack of effective design and validation methods with support tools to enable engineering of highly-integrated, flight-critical digital systems, and (2) the lack of high quality laboratory and field data on system failures especially due to electromagnetic environment (EME).

Meissner, C. W., Jr.↗
DOE OSTI2024

Comparing Designed Training Sets to Optimize Multivariate Regression Models for Pr, Nd, and Nitric Acid Using Spectrophotometry

Chemometric regression models were developed for the quantification of praseodymium (Pr, 0–1000 µg/mL), neodymium (Nd, 0–1000 µg/mL), and nitric acid (HNO 3 , 0.1–5 M) using spectrophotometry. Designed calibration sets were composed of 20 samples each: 10 model points and 10 lack-of-fit (LOF) points. The D-optimal designs effectively minimized the number of samples required to build models, and each design resulted in similar prediction performance, suggesting that statistical design of experiments can provide a reliable framework for selecting training set samples in three-variable systems. Partial least squares regression (PLSR) models were validated against a one-factor-at-a-time validation set composed of 125 samples (three variables, five levels). The top PLS-1 models resulted in average percent root mean square error of prediction error values of 3.5%, 1.7%, and 1.2% for Pr(III), Nd(III), and HNO 3 , respectively. Power set augmentations of the model and LOF samples were investigated to optimize the number of training set samples. PLSR models built using just required model points (10) had similar predictive capabilities as models including the LOF points (20) but with fewer samples. The number of validation samples was also varied systematically to learn how many samples are needed to validate regression models. This work addresses long-standing questions in the field of chemometrics to help make this approach amenable to the near-real-time quantification of hazardous species in remote settings.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
NASA NTRS2003

Development of an Output-based Adaptive Method for Multi-Dimensional Euler and Navier-Stokes Simulations

The use of computational simulations in the prediction of complex aerodynamic flows is becoming increasingly prevalent in the design process within the aerospace industry. Continuing advancements in both computing technology and algorithmic development are ultimately leading to attempts at simulating ever-larger, more complex problems. However, by increasing the reliance on computational simulations in the design cycle, we must also increase the accuracy of these simulations in order to maintain or improve the reliability arid safety of the resulting aircraft. At the same time, large-scale computational simulations must be made more affordable so that their potential benefits can be fully realized within the design cycle. Thus, a continuing need exists for increasing the accuracy and efficiency of computational algorithms such that computational fluid dynamics can become a viable tool in the design of more reliable, safer aircraft. The objective of this research was the development of an error estimation and grid adaptive strategy for reducing simulation errors in integral outputs (functionals) such as lift or drag from from multi-dimensional Euler and Navier-Stokes simulations. In this final report, we summarize our work during this grant.

Darmofal, David L.↗
NASA NTRS1979

PEP solar array definition study

The conceptual design of a large, flexible, lightweight solar array is presented focusing on a solar array overview assessment, solar array blanket definition, structural-mechanical systems definition, and launch/reentry blanket protection features. The overview assessment includes a requirements and constraints review, the thermal environment assessment on the design selection, an evaluation of blanket integration sequence, a conceptual blanket/harness design, and a hot spot analysis considering the effects of shadowing and cell failures on overall array reliability. The solar array blanket definition includes the substrate design, hinge designs and blanket/harness flexibility assessment. The structural/mechanical systems definition includes an overall loads and deflection assessment, a frequency analysis of the deployed assembly, a components weights estimate, design of the blanket housing and tensioning mechanism. The launch/reentry blanket protection task includes assessment of solar cell/cover glass cushioning concepts during ascent and reentry flight condition.

Source record↗