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At least 1,711 records · Page 95

All sources NASA NTRS DOE OSTI

NASA NTRSDate not supplied

Automated Ply-by-Ply Lamination and In-Situ Consolidation of Thermoplastic Composite High-Contour Stiffeners for High-Rate Aircraft Manufacturing

To meet the future demand of the commercial aircraft market, composite aircraft manufacturing rates must significantly increase. NASA’s Hi-Rate Composites Aircraft Manufacturing (HiCAM) program addresses this need to advance aircraft composite manufacturing technologies. Thermoplastic composites offer a promising solution to these manufacturing demands and present an opportunity for Northrop Grumman to bring the benefits of its Automated Stiffener Forming (ASF) technology to thermoplastic processing. Within HiCAM, Northrop Grumman is evolving the ASF technology for ply-by-ply, in-situ processing of thermoplastic composite materials. The modular process accommodates flexibility in the laminate stacking, while allowing for ply drops, ply additions, and yaw, pitch, and roll in the laminate geometry. To adapt the ASF process for thermoplastics, heating technologies and roller compaction processes were investigated by manufacturing flat test coupons. These panels were evaluated by photo-microscopy, non-destructive inspection, and short beam shear tests and results were compared against baseline autoclave coupons. The results of the laminates fabricated via ASF are presented.

out of autoclave↗

NASA NTRSDate not supplied

Laser Angle of Incidence Effects on in-Situ Consolidation of Automated Fiber Placement of Polyaryletherketone Composites

NASA and Electroimpact, Inc. ®†† in conjunction with other U.S. industry partners are performing research as a part of the NASA High-rate Composites for Aircraft Manufacturing (HiCAM) Project to fabricate thermoplastic panels using automated fiber placement (AFP) to increase manufacturing rates of aircraft structural composites. This work focuses on evaluating the in-situ consolidation AFP of thermoplastics (ICAT) process. Previous studies of the ICAT process using semi-crystalline, polyaryletherketone (PAEK) slit-tape have resulted in an adequate degree of intimate contact between plies; however, the resulting interlaminar strength have been less than laminates fabricated in an autoclave. To improve these properties, the effect of reducing the laser angle of incidence (AoI) during placement to increase the degree of auto-hesion was evaluated. The AoI of the laser assisted AFP head was varied between 12° and 16° to fabricate multiple quasi- isotropic and unidirectional test panels. Physics-based thermal models developed at the NASA Langley Research Center were utilized to predict the temperature profile. Laminate processing temperature was measured experimentally, and panel quality was evaluated by both non- destructive evaluation (NDE) as well as destructively by photo-microscopy. The effect on interlaminar strength was determined by short beam strength testing. Test results of carbon fiber laminates fabricated by ICAT using polyetheretherketone (PEEK), polyetherketoneketone (PEKK), and low-melt polyaryletherketone (LM-PAEK) at various laser angles of incidence, placement temperatures and placement speeds are presented.

Laser↗

NASA NTRSDate not supplied

Thermal Modelling of the in-Situ Consolidation of Automated Fiber Placement of Thermoplastic Composites

NASA is developing carbon fiber reinforced thermoplastic composites processing methods under the Hi-rate Composites Aircraft Manufacturing (HiCAM) project. The in-situ consolidation automated fiber placement (AFP) of thermoplastics (ICAT) process has high potential to increase manufacturing throughput and lower costs as it combines the repeatability and fast lay down rates of AFP with the thermoformability of thermoplastic materials to achieve part consolidation out of the autoclave. Physics-based process models are employed in the ICAT process development to understand, fundamentally, the thermal response of the carbon fiber (CF)/polyaryletherketone (PAEK) material during the rapid heating and cooling associated with laser-assisted AFP. A one-dimensional (1-D) closed-form model was developed capable of predicting the temperature profile through-the-thickness of the tape material. In addition, a two-dimensional (2-D) model was developed to predict the heat transfer through-the-thickness and in the laydown x-direction of the AFP head motion. The solution of the Fourier heat-transfer equations in the 2-D model is approximated using the explicit finite difference numerical method. The temperature profile during placement of PAEK slit-tape materials at various laser target temperatures and placement speeds were measured during ICAT process development trials at Electroimpact®, Inc. †† and the resulting experimental data is compared with the predictions of the 1-D and 2-D models.

Thermoplastics↗

NASA NTRSDate not supplied

Automated Ply-By-Ply Lamination and in-Situ Consolidation of Dry Carbon Fiber Non-Crimp Fabrics for High-Rate Aircraft Manufacturing of Structural Aircraft Components

NASA’s Hi-Rate Composites Aircraft Manufacturing (HiCAM) program addresses market needs to advance structural aircraft composite manufacturing technologies to significantly increase production rates. Dry, non-crimp fabric (NCF) carbon materials infused with advanced resin systems offer a promising solution to these manufacturing demands. Northrop Grumman’s Automated Stiffener Forming (ASF) technology has been adapted for ply-by-ply, in-situ processing of NCF materials. The modular ASF process accommodates flexibility in the laminate stacking, while allowing for ply drops, ply additions, and yaw, pitch, and roll in the laminate geometry. To adapt the ASF process for NCF materials, heating technologies and roller compaction processes were designed and tested on representative structural aircraft part geometries. Key success criteria for the ASF process with NCF materials is forming quality and preform compaction. Trials were performed with multiple NCF materials: unidirectional up to quad-axial formats. The NCF constituents, veils, stitching, and binders, were evaluated with the ASF process. The material performance in the ASF process and the resulting preform quality are presented.

dry carbon fiber materials↗

NASA NTRSDate not supplied

An Automated Medical Inventory System (AMIS) to Enable Earth-Independent Medical Operations

BACKGROUND: Inventory of medical consumables and durables (medications, treatment aids, diagnostic equipment, etc.) aboard the International Space Station is a manual process whereby crewmembers reach out to their flight surgeon to relay when items are used. Performing a full medical system inventory is time intensive. However, as exploration progresses to long duration missions with little to no resupply or evacuation capabilities, maintaining an accurate account of inventory and location for medical systems across the mission will become increasingly critical. A new system must be developed for future exploration missions to meet the need for a crew-facing, real time method of managing medical inventory. OVERVIEW: NASA’s Exploration Medical Integrated Product Team (XMIPT) is funding the AMIS project to mature the technology readiness level and to conduct a flight demonstration of a medical inventory capability. AMIS will leverage lessons learned from a Medical Consumables Tracking project previously demonstrated aboard the ISS in 2016 and 2017. Key components of AMIS include a database, supporting hardware and software, and interfaces to power, communications, or other vehicle or medical systems. Some medical inventory capability may be provided by the vehicle inventory management system which relies upon RFID-based technology and can track larger items such as medical kits or medical hardware. AMIS will augment these capabilities to enable tracking of individual medical kit contents. Efforts are underway to characterize the optimal solution trade space by comparing system specifications (e.g. mass and volume, etc.) across maintenance and operational use cases (e.g. crew time saved, total inventory automated, etc). DISCUSSION: The contents of a Mars Medical System have not been fully defined which poses challenges to defining an inventory system and requires assumptions regarding medical kit contents and medical system design. Other important considerations include minimizing crew time required, avoiding access restrictions to medical inventory in the event of an emergency, and ensuring that data is accessible to other medical system elements to enable crew autonomy in provision of medical care.

Automated Medical Inventory System↗

NASA NTRSDate not supplied

Composites From in-Situ Consolidation Automated Fiber Placement of Thermoplastics for High-Rate Aircraft Manufacturing

The National Aeronautics and Space Administration (NASA) project Hi-Rate Composites Aircraft Manufacturing (HiCAM) aims to significantly increase commercial aircraft composite structures manufacturing rate. Thermoplastic composites offer attractive solutions to rapid manufacturing due to their ability to be formed and consolidated quickly. NASA has a particular interest in assessing composite structure manufacturing utilizing an in-situ consolidation automated fiber placement (AFP) of thermoplastics (ICAT) process employing current state-of-the-art laser heating systems. Three semi-crystalline polyaryletherketone (PAEK) thermoplastic tape materials were characterized to ascertain the ICAT process parameters. The required laser power settings were determined at Electroimpact, Inc., measuring material temperatures utilizing a forward looking infrared (FLIR) thermal imaging camera and thermocouples. The material temperature, tool temperature, and placement speed were varied for resulting consolidation quality assessment. The resulting temperature data were also utilized to calibrate thermal analysis models under development at NASA. The experimental temperature data confirmed analytical results. The quality of the resulting test panels was evaluated by both non-destructive evaluation as well as destructively by photo-microscopy. The effect on interlaminar strength was determined by short beam strength testing. Test results of carbon fiber laminates fabricated by ICAT using polyetheretherketone (PEEK), polyetherketoneketone (PEKK), and low-melt polyaryletherketone (LM-PAEK) at various placement temperatures and placement speeds are presented.

thermoplastic composites↗

NASA NTRSDate not supplied

Automated Ply-By-Ply Lamination and in-Situ Consolidation of Dry Carbon Fiber Non-Crimp Fabrics for High-Rate Aircraft Manufacturing of Structural Aircraft Components

dry carbon fiber materials↗

NASA NTRSDate not supplied

Laser Angle of Incidence Effects on in-Situ Consolidation of Automated Fiber Placement of Polyaryletherketone Composites

NASA and Electroimpact, Inc. ® in conjunction with other U.S. industry partners are performing research as a part of the NASA High-rate Composites for Aircraft Manufacturing (HiCAM) Project to fabricate thermoplastic panels using automated fiber placement (AFP) to increase manufacturing rates of aircraft structural composites. This work focuses on evaluating the in-situ consolidation AFP of thermoplastics (ICAT) process. Previous studies of the ICAT process using semi-crystalline, polyaryletherketone (PAEK) slit-tape have resulted in an adequate degree of intimate contact between plies; however, the resulting interlaminar strength have been less than laminates fabricated in an autoclave. To improve these properties, the effect of reducing the laser angle of incidence (AoI) during placement to increase the degree of auto-hesion was evaluated. The AoI of the laser assisted AFP head was varied between 12° and 16° to fabricate multiple quasi-isotropic and unidirectional test panels. Physics-based thermal models developed at the NASA Langley Research Center were utilized to predict the temperature profile. Laminate processing temperature was measured experimentally, and panel quality was evaluated by both non-destructive evaluation (NDE) as well as destructively by photo-microscopy. The effect on interlaminar strength was determined by short beam strength testing. Test results of carbon fiber laminates fabricated by ICAT using polyetheretherketone (PEEK), polyetherketoneketone (PEKK), and low-melt polyaryletherketone (LM-PAEK) at various laser angles of incidence, placement temperatures and placement speeds are presented.

Thermoplastic Composites↗

DOE OSTI2013

Automated Translation and Thermal Zoning of Digital Building Models for Energy Analysis

Building energy simulation is valuable during the early stages of design, when decisions can have the greatest impact on energy performance. However, preparing digital design models for building energy simulation typically requires tedious manual alteration. This paper describes a series of five automated steps to translate geometric data from an unzoned CAD model into a multi-zone building energy model. First, CAD input is interpreted as geometric surfaces with materials. Second, surface pairs defining walls of various thicknesses are identified. Third, normal directions of unpaired surfaces are determined. Fourth, space boundaries are defined. Fifth, optionally, settings from previous simulations are applied, and spaces are aggregated into a smaller number of thermal zones. Building energy models created quickly using this method can offer guidance throughout the design process.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2014

Using the BEopt Automated Residential Simulation Test Suite to Enable Comparative Analysis Between Energy Simulation Engines: Preprint

Verification and validation are crucial software quality control procedures when developing and implementing models. This is particularly important as a variety of stakeholders rely on accurate predictions from building simulation programs. This study uses the BEopt Automated Residential Simulation Test Suite (BARTS) to facilitate comparison of two energy simulation engines across various building components and includes models that isolate the impacts of specific building components on annual energy consumption. As a case study, BARTS has been used to identify important discrepancies between the engines for several components of the building models; these discrepancies are caused by differences in the models used by the engines or coding errors.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2016

Assessing the Energy Impact of Connected and Automated Vehicle (CAV) Technologies

This is a presentation on connected and automated vehicle energy analysis and off-cycle credits calculation that was given at the January 2016 SAE Government/Industry Meeting.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2016

Optimal Control and Coordination of Connected and Automated Vehicles at Urban Traffic Intersections

We address the problem of coordinating online a continuous flow of connected and automated vehicles (CAVs) crossing two adjacent intersections in an urban area. We present a decentralized optimal control framework whose solution yields for each vehicle the optimal acceleration/deceleration at any time in the sense of minimizing fuel consumption. The solu- tion, when it exists, allows the vehicles to cross the intersections without the use of traffic lights, without creating congestion on the connecting road, and under the hard safety constraint of collision avoidance. The effectiveness of the proposed solution is validated through simulation considering two intersections located in downtown Boston, and it is shown that coordination of CAVs can reduce significantly both fuel consumption and travel time.

Connected and automated vehicles↗

DOE OSTI2017

Automated Metrology System for Pu 238

Under a collaborative partnership between the NASA and DOE, a new automated measurement system developed by ORNL will ensure quality production of plutonium-238 while reducing handling by workers. NASA has funded ORNL and other national laboratories to develop a process that will restore US production capability of Pu-238 for the first time since the late 1980s when the Savannah River Plant ceased production. ORNL has produced and separated about 100 grams of the material and plans to scale up the process over the next several years to meet demand to power NASA deep space missions.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

DOE OSTI2017

Drones in Automation - Secured Unmanned Aerial Systems

Factories, refineries, utilities (water/wastewater, electric) and related industrial sites are complex systems and structures with inspection and maintenance procedures required for optimal operation and regulatory compliance. As a specific example, consider just the bulk electric power system which is comprised of more than 200,000 miles of highvoltage transmission lines, thousands of generation plants and millions of digital controls. More than 1,800 entities own and operate portions of the grid system, with thousands more involved in the operation of distribution networks across North America. The interconnected and interdependent nature of the bulk power system requires a consistent and systematic application of risk mitigation across the entire grid system to be truly effective. Similar situations are found throughout automation where frequently an aging infrastructure is in place too. Consider, for example, the situation present in a refinery or chemical processing setting with the requirement for leak detection inspection of pipes, interconnects and systems stretching across the plant. The current practices and challenges relating just to this task - leak detection and repair (LDAR) – of detecting any fugitive emissions present and documenting all measurements thereby meeting air compliance regulations are typically “handled” by a small army of individuals with handheld or backpack-sized detectors who crawl through piping racks conducting measurements at each flange. Such work is performed in difficult conditions (temperature, humidity, physically challenging) with frequently a high level of employee turnover. Finaly, enter low cost sensors and mobile platforms – in other words unmanned aerial systems (UASs, or drones) with enhanced sensing capabilities.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2018

Analysis of Tipping Points in Connected and Automated Vehicles (CAV) Adoption Scenarios

Challenges to deployment of connected and automated vehicle (CAV) technologies extend beyond the vehicle and systems engineering challenges, and arise from a set of technological, economic, demographic, and regulatory issues. Informed observers develop intuition about these challenges, but without analytic tools their understanding may be limited as a basis for considering possible actions. We moved beyond the limitations of such intuition to an integrated systems analysis capability to explore CAVs deployment potential. We analyzed the potential for large-scale adoption of CAVs and barriers to such adoption, using quantitative data and understandings of system relationships among stakeholders across the breadth of technological, economic, demographic, and regulatory issues.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2018

Quantifying the Mobility and Energy Benefits of Automated Mobility Districts Using Microscopic Traffic Simulation

This poster highlights a study quantifying the mobility and energy benefits of automated mobility districts (AMDs), with a focus on the district-scale implementation of advanced vehicle (AV) technologies, the benefits of an AV-shared-mobility service within a confined geographic region or district, and AMD models serving as 'special generators' in existing urban travel demand models. Through the study, leaders developed an AMD modeling and simulation toolkit.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2019

Automated Design and Analysis of a Variable Displacement Linkage Motor

Hydrostatic drives consisting of a variable displacement pump and a low speed high torque (LSHT) motor are frequently used in off-highway vehicles. A variable displacement traction motor is desirable because of the ability to downsize the pump and thereby run the hydrostat at higher efficiency, as well as the possibility of hybridization of the drivetrain. Currently on the market are fixed and discrete speed LSHT radial piston motors and high speed low torque variable displacement axial piston motors. The radial piston motors are displacement dense but are not continuously variable, whereas the axial piston motors are continuously variable but require gearboxes, introducing packaging and robustness concerns. The Variable Displacement Linkage Motor (VDLM) is a LSHT motor that is continuously variable. It offers several benefits over current LSHT motors in that it is highly efficient over its operating range, it has low torque ripple, and it is displacement dense due to its multi-lobed cam and radial packaging. As with the design of any motor, the process is iterative and must be performed whenever performance objectives change. This paper describes an automated method for rapid exploration of the solution space for a variable displacement motor with specific application to the VDLM. This method leads to a motor design that theoretically can achieve 97% efficiency with a torque ripple below 5% at full displacement.

42 ENGINEERING↗

DOE OSTI2021

Wind Turbine Blade Finishing Automation: Robotic Toolpath Generation

Wind turbine blades are now over 100 meters long and can reach heights of several meters while in the finishing area of the factory. Because of this, automation should be used to lower the manufacturing cost and make the process safer for blade manufacturing technicians. This session will present a novel method that generates a six degree of freedom robotic toolpath with 3D cameras for the finishing of wind turbine blades to drive down the levelized cost and make wind energy even more competitive in the utility scale energy generation industry.

3d imaging↗