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NASA NTRS2012

Focal Plane Alignment Utilizing Optical CMM

In many applications, an optical detector has to be located relative to mechanical reference points. One solution is to specify stringent requirements on (1) mounting the optical detector relative to the chip carrier, (2) soldering the chip carrier onto the printed circuit board (PCB), and (3) installing the PCB to the mechanical structure of the subsystem. Figure 1 shows a sketch of an optical detector mounted relative to mechanical reference with high positional accuracy. The optical detector is typically a fragile wafer that cannot be physically touched by any measurement tool. An optical coordinate measuring machine (CMM) can be used to position optical detectors relative to mechanical reference points. This approach will eliminate all requirements on positional tolerances. The only requirement is that the PCB is manufactured with oversized holes. An exaggerated sketch of this situation is shown in Figure 2. The sketch shows very loose tolerances on mounting the optical detector in the chip carrier, loose tolerance on soldering the chip carrier to the PCB, and finally large tolerance on where the mounting screws are located. The PCB is held with large screws and oversized holes. The PCB is mounted loosely so it can move freely around. The optical CMM measures the mechanical reference points. Based on these measurements, the required positions of the optical detector corners can be calculated. The optical CMM is commanded to go to the position where one detector corner is supposed to be. This is indicated with the cross-hairs in Figure 2(a). This figure is representative of the image of the optical CMM monitor. Using a suitable tapping tool, the PCB is manually tapped around until the corner of the optical detector is at the crosshairs of the optical CMM. The CMM is commanded to another corner, and the process is repeated a number of times until all corners of the optical detector are within a distance of 10 to 30 microns of the required position. The situation is sketched in Figure 2(b) (the figure also shows the tapping tool and where to tap). At this point the fasteners for the PCB are torqued slightly so the PCB can still move. The PCB location is adjusted again with the tapping tool. This process is repeated 3 to 4 times until the final torque is achieved. The oversized mounting holes are then filled with a liquid bonding agent to secure the board in position (not shown in the sketch). A 10- to 30-micron mounting accuracy has been achieved utilizing this method..

Liebe, Carl Christian↗

NASA NTRSDate not supplied

NASA's Efforts to Commercialize Communications Services for Mission in Near-Earth Space

The National Aeronautics and Space Administration (NASA) Space Communications and Navigation (SCaN)Program enables high speed, robust, secure and cost-effective space communications and navigation services to current and future science and exploration missions. Consistent with National Space Policy, NASA is pursuing the use of demonstrated commercial services for all its future near-Earth requirements through a flexible, multi-provider approach that minimizes risks to the user missions and ensures costs to user missions are reasonable. Progress toward this goal is advancing in multiple key areas including direct to Earth (DTE), space-based relay, technology investments, required spectrum regulatory changes and mission engagement and infusion. The transition to commercial DTE services is already underway, with a target for transition by 2024. The primary functions to execute SCaN’s DTE strategy include increasing commercial service allocations by leveraging current commercial network providers and enabling seamless onboarding of additional providers into the network. Furthermore, moving away from government DTE services will allow operational costs to be optimized. A more gradual approach is planned for the transition to commercial space-based relay services to allow for demonstration and operationalization of commercial services for future users by 2030. In June of 2022, six American SATCOM vendors were awarded a combined $278.5 million through Funded Space Act Agreements (FSAAs) for the first cycle of demonstration and validation activities. The end-to-end service capabilities being targeted are based on existing NASA mission operational needs. Accordingly, each company has proposed a technical approach to lower costs, increase flexibility, and improve performance for a broad range of missions. Successful user mission transition to commercial services, both DTE and space-based relay, are dependent on the technologies and capabilities that address gaps in commercial capability. NASA is investing in technology development and pursuing a new strategic approach to the creation or adoption of space communications standards to move the agency toward a commercial paradigm. Wideband and multi-lingual user terminals are being developed to bridge differences in industry services. Building on ground demonstrations completed in 2021, the Johns Hopkins Applied Physics Lab (APL) will be flight testing a multi-lingual wideband terminal (payload) and demonstrating connectivity to both government and commercial relay services. NASA holds a leadership role in multiple civil space standards bodies and international coordination groups to ensure that standards supporting interoperability are developed with defined functions, interfaces, and performance. However, to successfully meet commercialization objectives, NASA seeks to collaborate with industry, and as applicable adopt or adapt to commercially defined standards. As such, NASA joined the 3rd Generation Partnership Project (3GPP) as an official member in 2021 to advocate for the inclusion of space missions as a unique user segment in future 5G non-terrestrial networks, and to better understand the scope of 3GPP releases and implications for space users. Further, engagement in Spectrum regulatory bodies is being undertaken to augment existing space-Earth and inter-satellite frequency allocations available for both government and commercial space systems. This paper addresses the recent progress toward NASA’s commercial space communications transition objectives and how key challenges are being navigated.

Gregory W Heckler↗

NASA NTRS2009

An LED Approach for Measuring the Photocatalytic Breakdown of Crystal Violet Dye

A simple technique to assess the reactivity of photocatalytic coatings sprayed onto transmissive glass surfaces was developed. This new method uses ultraviolet (UV) gallium nitride (GaN) light-emitting diodes (LEDs) to drive a photocatalytic reaction (the photocatalytic breakdown of a UV-resistant dye applied to a surface coated with the semiconductor titanium dioxide); and then a combination of a stabilized white light LED and a spectrometer to track the dye degradation as a function of time. Simple, standardized evaluation techniques that assess photocatalytic materials over a variety of environmental conditions, including illumination level, are not generally available and are greatly needed prior to in situ application of photocatalytic technologies. To date, much research pertaining to this aspect of photocatalysis has been limited and has focused primarily on laboratory experiments using mercury lamps. Mercury lamp illumination levels are difficult to control over large ranges and are temporally modulated by line power, limiting their use in helping to understand and predict how photocatalytic materials will behave in natural environmental settings and conditions. The methodology described here, using steady-state LEDs and time series spectroradiometric techniques, is a novel approach to explore the effect of UV light on the photocatalytic degradation of a UV resistant dye (crystal violet). GaN UV LED arrays, centered around 365 nm with an adjustable DC power supply, are used to create a small, spatially uniform light field where the steady state light level can be varied over three to four orders of magnitude. For this study, a set of glass microscope slides was custom coated with a thinly sprayed layer of photocatalytic titanium dioxide. Crystal violet was then applied to these titanium-dioxide coated slides and to uncoated control slides. The slides were then illuminated at various light levels from the dye side of the slide by the UV LED array. To monitor dye degradation on the slides over time, a temperature-stabilized white light LED was used to illuminate the opposite side of the slides. As the dye degraded, the amount of light from the white light LED transmitted through the slide was monitored with a spectrometer and subsequently analyzed to determine and compare the rate of dye degradation for photocatalytically coated versus uncoated slide surfaces. The long-term stability of the spectrometer/white light LED combination, which required only a single reference spectra to be taken for a time series sequence of several hours, enabled accurate measurements of transmitted light over time. Time series transmission curves were generated and results demonstrated that over time the transmission increased much more rapidly on the coated slides than on the control slides. This experimental configuration and methodology for photocatalytic activity measurement minimizes many external variable effects and allows low light level studies to be performed. This study also compares the advantages of this novel LED light source design to traditional mercury lamp systems and non-LED lamp approaches that have conventionally been used. The methodology and experimental design research summarized in this abstract is partly funded by the Department of Homeland Security, Science and Technology Directorate, and by the NASA Stennis Space Center Innovative Partnerships Program.

Ryan, Robert E.↗

DOE OSTI2024

Liquid Piston with Spray Cooling Near-Isothermal Compressor

The goal of this project was to prototype and characterize the performance of a liquid-piston spray-cooled gas compressor. The working principle of the compressor enables optimized high-efficiency operation over a very wide range of operating conditions, unlike conventional compressors that are optimized for a narrow range of operating conditions. The compressor technology is suitable for many applications, such as gas pipeline transport, gas storage, and commercial and residential heat pumps. Both physical testing and computational fluid dynamics (CFD) modeling of the processes using the Oak Ridge National Laboratory high-performance computing center were completed. The experimental and CFD studies focused on a near-isothermal liquid-piston compressor (LPC) that uses propylene glycol to compress CO 2 . The first prototype demonstrated isothermal operation during several sequentially executed cycles of CO 2 compression and raised the temperature of the compressed CO 2 by only 2 K, compared with approximately 6 K when the gas was compressed non-isothermally. Isothermal operation was demonstrated at CO 2 flow rates of up to 2 L/min. The second prototype was designed with two compression chambers to allow continuous flow of high-pressure CO 2 . However, the design of the valve train to direct flow between the compression chambers was not sufficient to allow demonstration of CO 2 compression. Numerical simulations of the LPC in which the compression chamber was filled with propylene glycol injected from the bottom inlet were performed using large eddy simulation (LES) with the wall-adapting local eddy-viscosity subgrid-scale model coupled with the multiphase volume of fluid (VOF) model to simulate the transient interface between gas and liquid and to capture the heat and mass transfers within the compression chamber. In this effort, the effects of boundary conditions applied to the LES-VOF calculations (i.e., no wall, an adiabatic wall, and a wall with a heat flux subscribed) on the overall pressure and temperature of the CO 2 gas as well as the transient evolution of flow and heat transfer within the compression chamber were investigated and are discussed in this report. The LES calculation with no wall showed no dynamical flow patterns, and the volume-averaged temperature of CO 2 increased from 305 to 392.7 K, whereas LES calculations with a constant wall temperature or a wall heat flux had similar increases of CO 2 temperatures. The results of the LES simulation using a wall heat flux showed different stages in the compression process and revealed dynamical formation and interaction of CO 2 gas layers and circulation flow patterns within the chamber that contributed to the overall heat transfer between the solid wall, gas, and liquid surface in the compressor. Though an industrial partnership for commercializing the compressor was not secured, the technology was attractive for an industrial partner to use in two research proposals in response to US Department of Energy funding opportunity announcements.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

NASA NTRSDate not supplied

The Potential of Medical Drones: An Analysis of Current and Future Use Cases

Modern Application of Medical-Based Drone Delivery Drones have been used advantageously by militaries for nearly a century, but their uses in civilian life are still mostly cutting-edge, if not theoretical. After a decade of bold proclamations, Amazon’s “PrimeAir” drone delivery system is still in the stage of “preparing” for deliveries, while the public awaits for start ups like SkyDrop (formerly Flirtey) to follow through on impressive promises. Despite the well-publicized disappointment so far in commercial drone delivery, medical drone delivery has already proven itself practical and cheap in several countries, and it promises to expand in the coming years. Drones are uniquely suited to make valuable and urgent deliveries to remote areas, quickly transporting medical supplies where road transportation is prohibitively slow or not available at all. Drones have been used notably to deliver AEDs for out-of-hospital cardiac arrest, frequently beating first-responders to the scene; to deliver blood when there is none on hand at hospitals; to deliver vaccines to an island nation with little transportation infrastructure; and to respond flexibly to medical emergencies in a war zone. Economics make the delivery of food and other cheap goods by drone unattractive in the near-term, but the value and time-sensitivity of medical deliveries mean that drones are already saving lives in healthcare. “We believe the value of new technology is most valuable where it is clearly needed...that’s why we wanted to focus on drones delivering medicine and not delivering pizzas, ”said one executive of a drone system manufacturer. The immediate prospects for the expansion of medical drone use are many; however, they do not exist without their own drawbacks and challenges. Most obvious is the limited range of current commercially-available drones, most of which are isolated to a perimeter of roughly 18 miles. Technological know-how presents another barrier to integration of medical drones on a larger scale. Reports from the United Nations frequently cite a“skill deficit”—a prohibitively low number of qualified drone operators in low-and moderate-income countries (LMICs). Another perhaps more discreet speed bump in global drone development and usage are the various regulations on drone usage. Drone technology has developed so quickly that many states, out of an excess of caution, have nearly snuffed out the fledgling industry with regulation. There also exist significant concerns over the security of private citizens, the efficacy of medical deliveries, and the costs of drone operation. It is these last three barriers which this study will seek to overcome. Put simply, the prospect for human development in LMICs from drone-based medical delivery is far too great to disregard. As of 2020, 3.4 billion people live in rural communities, containing fewer than 5,000 people/km^2. Often lacking infrastructure, these communities are largely isolated from their more populated, urban counterparts. In drones lies the potential to reshape the geographic and developmental distinctions that divide the global population. This development must, therefore, begin first and foremost with advancement in regional well-being and life expectancy. Life expectancy makes up a key facet of human development. The United Nations relies on it as a key indicator of a state’s health. Lars Kunze of the Dortmund University Department of Economic sex plains this as a matter of physical capital accumulation. The longer people live, the more they save as opposed to spend. The more they save, the more which eventually gets invested in themselves and the community as a whole. In providing medical products via drone, it is the intention of this study to enable communities with the means and incentives for long-run savings and investment for future economic development. Through a close analysis of Vanuatu, Rwanda, Tanzania, and Ukraine—four states where drones are currently used to deliver medical supplies—this study develops a framework that LMICs in general and Mexico and particular can adopt and to use medical drones in difficult-to-reach communities for the sake of long-run human developmental initiatives.

Ryan Teoh↗

NASA NTRS2018

Urban Air Mobility (UAM) Market Study

The Booz Allen Team explored market size and potential barriers to Urban Air Mobility (UAM) by focusing on three potential markets – Airport Shuttle, Air Taxi, and Air Ambulance. We found that the Airport Shuttle and Air Taxi markets are viable, with a significant total available market value in the U.S. of $500 billion, for a fully unconstrained scenario. In this unconstrained best-case scenario, passengers would have the ability to access and fly a UAM at any time, from any location to any destination, without being hindered by constraints such as weather, infrastructure, or traffic volume. Significant legal and regulatory, weather, certification, public perception, and infrastructure constraints exist, which reduce the market potential for these applications to only about 0.5% of the total available market, or $2.5 billion, in the near term. However, we determined that these constraints can be addressed through ongoing intra-governmental partnerships, government and industry collaboration, strong industry commitment, and existing legal and regulatory enablers. We found that the Air Ambulance market is not a viable market if served by electric vertical takeoff and landing (eVTOL) vehicles due to technology constraints but may potentially be viable if a hybrid VTOL aircraft are utilized. The barriers and challenges we characterized in this study can be stratified according to their applicability or potential mitigation through technology as well as market maturity (Figure 1). In the near term, high cost of service will be a key economic challenge. We found potential for significant reduction in service cost through increased vehicle and component efficiency, and automation in a more mature market scenario. Weather conditions also pose a challenge to the UAM market, though there is potential for mitigation of some of these impacts through technology such as sensors enabling operations in low visibility. However, even in a mature market with advanced technology, disruptions are still likely to occur due to weather events such as thunderstorms and strong winds. High density operations will likely stress the current Air Traffic Management (ATM) system in the near term, but technology and new initiatives such as the Air Traffic Management -eXploration project (ATM-X) will enable safe and efficient integration of UAM into the National Airspace System (NAS). Current battery technology creates a barrier in the near term, especially for the Air Ambulance market, as battery weight and extensive recharging times would be needed for these operations. Advancements in battery technology, as well as use of hybrid VTOLs, could significantly reduce this barrier in the longer term. As UAM emerges as a viable mode of transportation in the near term, adverse energy and environmental impacts, particularly noise, may impact community acceptance and potentially persist as the market matures into larger-scale operations. For non-technology related challenges, we found that infrastructure constraints will create a significant barrier to UAM in the near term but could be addressed in the longer term through development and expansion of vertiports. Competition from existing modes of transportation such as ride-sharing (e.g., Lyft, Uber) and ground taxi’s pose a key barrier to UAM in the short term, which will likely evolve into competition from other emerging technologies such as autonomous cars and electric trains in the longer term. Weather events will influence other components of the operation such as passenger comfort (e.g., extreme temperatures, turbulence) and infrastructure (e.g., winter weather causing cracks and degradation in vertiports). There is also potential for these impacts to be heightened in the longer term from the increased frequency of adverse weather such as thunderstorms due to changing climatic conditions. We also found that the public has strong concerns about safety as a passenger in a piloted UAM, including “lasing” of pilots, unruly passengers, and sabotage. They would prefer that all passengers pass through a security screening process before boarding a vehicle. They would also prefer to use UAM for longer regional trips, such as flying from Washington, DC to Baltimore, MD or San Diego, CA to Los Angeles, CA. A longer term automated UAM vehicle market will face challenges due to public apprehension about automation and unmanned operations, and a preference to fly with passengers they know in an autonomous (unmanned) operational scenario.

Rohit Goyal↗

DOE OSTI2023

Cyber-Informed Engineering Implementation Guide

This Implementation Guide describes the principles of Cyber-Informed Engineering (CIE) and outlines questions that engineering teams should consider during each phase of a system’s lifecycle to effectively employ these principles. It describes what it means to engineer systems in a cyber-informed way, rather than offering a comprehensive, step-by-step process or procedure for CIE implementation. This guide complements—but does not replace—the application of cybersecurity standards or practices currently in place within an organization. Engineers and technicians that design critical energy infrastructure installations can use this Implementation Guide to integrate the 12 principles of CIE into each phase of the engineering lifecycle, from concept to retirement. The guide is aimed at system or design engineers, rather than software engineers or operational cybersecurity practitioners. The engineers who design, build, operate, and maintain the physical infrastructure are best positioned to leverage a system’s engineering design to diminish the severity of cyber attacks or digital technology failures. CIE expands cybersecurity decisions into the engineering space, not by asking engineers to become cyber experts, but by calling on engineers to apply engineering tools and make engineering decisions that improve cybersecurity outcomes. CIE examines the engineering consequences that a sophisticated cyber attacker could achieve and drives engineering changes that may provide deterministic mitigations to limit or eliminate those consequences.

42 ENGINEERING↗

DOE OSTI1995

Nuclear Safety [Vol. 36, No. 1, January-June 1995]

Nuclear Safety is a journal that covers significant issues in the field of nuclear safety. Its primary scope is safety in the design, construction, operation, and decommissioning of nuclear power reactors worldwide and the research and analysis activities that promote this goal, but it also encompasses the safety aspects of the entire nuclear fuel cycle, including fuel fabrication, spent-fuel processing and handling, and nuclear waste disposal, the handling of fissionable materials and radioisotopes, and the environmental effects of all these activities. Table of Contents for this issue follows. THE CHORNOBYL ACCIDENT: 1 The Chornobyl Accident Revisited, Part II: The State of the Nuclear Fuel Located Within the Chornobyl Sarcophagus, A A. Borovoi and A. R. Sich; GENERAL SAFETY CONSIDERATIONS: 33 Nuclear Power Safety in Central and Eastern Europe, R. Wilson; 46 Safety of Nuclear Power Reactors in the Former Eastern European Countries, S. Chakraborty; 53 Technical Note: On the Definition of Common-Cause Failures, H. Paula; ACCIDENT ANALYSIS: 58 Modeling and Analysis of Core-Debris Recriticality During Hypothetical Severe Accidents in the Advanced Neutron Source Reactor, S.-H. Kim, V. Georgevich, D. B. Simpson, C. O. Slater, and R. P. Taleyarkhan; 68 Ignitability of Hydrogen/Oxygen/Diluent Mixtures in the Presence of Hot Surfaces, R. K. Kumar and G. W. Koroll; 94 Coupled RELAP5 and CONTAIN Accident Analysis Using PVM, K. A. Smith, A. J. Baratta, and G. E. Robinson; CONTROL AND INSTRUMENTATION: 109 Application of Fuzzy Logic in Nuclear Reactor Control Part I: An Assessment of State-of-the-Art, A. S. Heger, N. K. Alang-Rashid, and M. Jamshidi; DESIGN FEATURES: 122 Twenty-Third DOE/NRC Nuclear Air-Cleaning and Treatment Conference, R. R. Bellamy, J. J. Hayes, and M. W. First; ENVIRONMENTAL EFFECTS: 135 Atmospheric Dispersion and the Radiological Consequences of Normal Airborne Effluents from a Nuclear Power Plant, D. Fang, C. Z. Sun, and L. Yang; 142 Calculation of Distribution Coefficients for Radionuclides in Soils and Sediments, I. Puigdomenech and U. Bergstrom: OPERATING EXPERIENCES: 155 Reactor Shutdown Experience, Compiled by J. W. Cletcher; U.S. NUCLEAR REGULATORY COMMISSION INFORMATION AND ANALYSES: 158 Operating Experience Feedback Report—Reliability of Safety-Related Steam Turbine-Driven Standby Pumps Used in U.S. Commercial Nuclear Power Plants, J. R. Boardman; 166 Turbine Building Hazards, H. L Ornstein; RECENT DEVELOPMENTS: 169 Reports, Standards, and Safety Guides, D. S. Queener; 175 Proposed Rule Changes as of Dec. 31,1994; ANNOUNCEMENTS: 32 Harvard School of Public Health In-Place Filter Testing Workshop; 134 International Conference on Advances in the Operational Safety of Nuclear Power Plants; 193 30th Tennessee Industries Week; 193 DOE Technical Standards Program 1995 Workshop; 194 Multiphase Flow Experiments and Instrumentation; 180 The Authors; 185 Indexes to Nuclear Safety, Volumes 34 and 35.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2020

Agent-Based Coordination Scheme for PV Integration (ABC4PV)

Renewables and especially photovoltaics (PV) have benefitted significantly from a host of incentives and policies targeted toward enhanced integration and adoption of specific energy technologies. However, with the push to move forward into a subsidy-free market framework, behind-the-meter residential PV applications have generally struggled to retain their value (unlike utility scale and commercial projects) [1]. This project focused on developing control-theoretic solutions aimed at improving the integration and interaction of behind-the-meter residential PV with other distribution system assets (controllable and non-controllable) to enhance the integrated value of residential PV. To this end, a suite of decentralized control methodologies have been developed to enable effective coordination and control of behind-the-meter residential load customers’ PV, battery storage systems (BSS), controllable loads and other similar assets within a distribution feeder. This interaction aims at procuring energy savings and, thus, energy bill savings. The main source of savings is drawn from reducing the effect of demand charge pricing and is realized at the feeder level, assuming community level interaction and management among the aforementioned assets. Optimal control of the assets is implemented with a distributed optimization methodology, leveraging consensus-based algorithms. The results gathered from the optimal control simulations demonstrates that the savings can be duly achieved and the algorithm decision times (to dynamically control asset set points, for example) are fast. As for the overall efficiency of PV+BSS systems, to procure energy savings from curtailment of the demand charge pricing effects, the optimal control is set up so as to minimize the variance of the load for all customers, throughout a feeder and throughout time in a rolling horizon scheduling with model predictive control. The control takes into account inter-temporal electrochemical storage (battery) degradation costs: specifically, we have developed a long-term lifetime model for the BSS that weighs in the effect of the degradation factor in the dispatch formulations, thus, a considerable operating cost that affects energy decision making. The levelized cost of energy (LCOE – redefined for the purpose of quantifying asset integration effectiveness through the customers’ energy cost) is shown to be below the threshold set for the combined PV+BSS topology of $ 0.14/kWh for multiple cases of PV penetration all the way up to 50%, provided that a policy of shared ownership of and savings is in place. Further, the LCOE calculated for the case before the deployment PV+BSS systems is also achievable, i.e. the deployment of PV+BSS, if planned and scheduled optimally. will have no effect on customers’ energy costs. From the control methodology viewpoint, the developed consensus-based algorithms are shown to converge for a wide range of problem cases (spanning normal operating scenarios and contingencies), guaranteeing dispatch solutions under forecasting errors, communication break-downs and cyber-security attacks. The proposed control solutions are scalable and real-time implementable, with dispatch computations and device set-point updates converging in less than 2s in most practical instances of the above events.

14 SOLAR ENERGY↗

DOE OSTI2024

Innovating the next generation of commercial smart building software

Nearly 30% of commercial building energy use is wasted due to equipment faults and HVAC controls problems. The result is increased emissions, compromised comfort and productivity, and less reliable coordination of building power needs with a clean grid. The energy impact alone represents $17 billion in potential savings. Today’s smart building software provides a robust solution to address these operational deficiencies. Energy management and information systems (EMIS) are saving up to 9% on average, with two-year paybacks. They are being incorporated into energy management processes, commissioning services, and utility programs. As effective as they are, two barriers prevent even deeper benefits; limited personnel to fix problems once they are identified, and the expense and time to manually implement changes in control systems. In partnership with the research community, the EMIS industry is developing new capabilities to overcome these barriers. Moving beyond siloed products for either fault detection and diagnostics, or optimal control, these new capabilities empower users to not only automatically identify faults, but also to push corrective action, and control improvements to their buildings. In this paper, several areas for enhancements are documented: ‘one-time’ correction of faults such as setpoints, schedules, and economizer lockouts; short-term active testing for automated proportional integral derivative (PID) loop tuning and functional testing; and continuous supervisory control for demand flexibility and year-round efficiency. Results are presented from a pair of partner implementations out of a dozen providers integrating these enhancements into their products, including field tests from across the country, and insights into operator acceptance and integration into operations and maintenance practices.

Casillas, Armando↗

DOE OSTI2025

Results of an interlaboratory study on the working curve in vat photopolymerization II: Towards a standardized method

The working curve measurement in photopolymer additive manufacturing is a ubiquitous measure of the cure depth of a printing resin as a function of radiant exposure of light. The fit parameters from this measurement (the depth of light penetration D p and the critical exposure E c ) are used to evaluate and report a resin’s printability, optimize processing parameters, and inform print and resin quality control. Despite its widespread use, the working curve lacks a standard measurement method. Here, following up on our paper “Results of an Interlaboratory Study on the Working Curve in Vat Photopolymerization” from last year, an interlaboratory study on the working curve was performed using calibrated, reproducible, bandpass filtered light sources. With these light sources, the variability between labs in measured working curves was dramatically reduced from the initial interlaboratory study. Aggregate data from this experiment produced reliable D p and E c measurements at 385 nm of 39.2 ± 3.7 µm and 12.3 ± 3.0 mJ cm −2 , respectively. At 405 nm the values of D p and E c are 69.3 ± 3.8 µm and 17.9 ± 2.3 mJ cm −2 , respectively. The results are agnostic to the thickness measurement tool utilized by participants, ensuring broad applicability across laboratories. We also tested the generalizability of the proposed method of using a filtered light source by filtering a commercial 405 nm light source and obtaining a working curve in agreement with the aggregate data from the interlaboratory study. This interlaboratory study provides a basis for a documentary standard for the working curve, so that the entire photopolymer additive manufacturing industry can share reproducible and interoperable working curve data.

36 MATERIALS SCIENCE↗

NASA NTRS2016

Compiling a Comprehensive EVA Training Dataset for NASA Astronauts

Training for a spacewalk or extravehicular activity (EVA) is considered a hazardous duty for NASA astronauts. This places astronauts at risk for decompression sickness as well as various musculoskeletal disorders from working in the spacesuit. As a result, the operational and research communities over the years have requested access to EVA training data to supplement their studies. The purpose of this paper is to document the comprehensive EVA training data set that was compiled from multiple sources by the Lifetime Surveillance of Astronaut Health (LSAH) epidemiologists to investigate musculoskeletal injuries. The EVA training dataset does not contain any medical data, rather it only documents when EVA training was performed, by whom and other details about the session. The first activities practicing EVA maneuvers in water were performed at the Neutral Buoyancy Simulator (NBS) at the Marshall Spaceflight Center in Huntsville, Alabama. This facility opened in 1967 and was used for EVA training until the early Space Shuttle program days. Although several photographs show astronauts performing EVA training in the NBS, records detailing who performed the training and the frequency of training are unavailable. Paper training records were stored within the NBS after it was designated as a National Historic Landmark in 1985 and closed in 1997, but significant resources would be needed to identify and secure these records, and at this time LSAH has not pursued acquisition of these early training records. Training in the NBS decreased when the Johnson Space Center in Houston, Texas, opened the Weightless Environment Training Facility (WETF) in 1980. Early training records from the WETF consist of 11 hand-written dive logbooks compiled by individual workers that were digitized at the request of LSAH. The WETF was integral in the training for Space Shuttle EVAs until its closure in 1998. The Neutral Buoyancy Laboratory (NBL) at the Sonny Carter Training Facility near JSC opened in March 1997 and is the current site for US EVA training. Other space agencies also have used water to simulate weightlessness and train for EVAs. Russia has a training facility similar to the NBL named the Hydro Lab. The Hydro Lab began operations at the Gagarin Cosmonaut Training Center (GCTC) in 1980 and has been used extensively to the present. Although a majority of training in the Hydro Lab uses the Russian Orlan suit, a small number of sessions have been conducted using a NASA suit. The Japanese Weightlessness Environment Test System (WETS) went into service at the Tsukuba Space Center in 1997 but was closed in 2011 due to extensive earthquake damage. Several sessions were performed using a NASA suit, but these sessions were short and considered "development" runs. LSAH has assembled records from the WETF, NBL and Hydro Lab. Recording of the EVA training data has changed considerably from 1967 to present. The goal of early record keeping was to track use of hardware components, and the person involved was treated as a suited operator, not as a focus of interest. Records from the past two decades are fairly precise with the person, date, suit type and size noted. On occasion the length of the session was listed, but this data is not included on all records. Records were merged from data sources and extensive cleaning of the records was required since the multiple sources frequently overlapped and duplicated records. To date the LSAH EVA training dataset includes over 12,500 EVA training sessions performed by NASA astronauts since 1981. The following variables are included for most records: Name, Sex, Event date, Event name, HUT type, HUT size, Facility, and Estimated run time. For a smaller subset of records, the following variables are available: Actual run time, Time inverted, and the suit components Waist bearing type, Shoulder harness, Shoulder pads, and Teflon inserts. The LSAH dataset is currently the most complete resource for data regarding EVA training sessions performed by NASA astronauts. However, it is not 100 percent complete since the WETS (Japan) and NBS (Marshall) training facility data were not included. This dataset has been compiled by LSAH to study the relationship of EVA training to musculoskeletal injuries but has many other non-medical applications. This dataset can be provided to other groups in order to respond to program and research questions with appropriate board approvals.

Laughlin, M. S.↗

DOE OSTI2025

Suppression of pair beam instabilities in a laboratory analogue of blazar pair cascades

The generation of dense electron–positron pair beams in the laboratory can enable direct tests of theoretical models of γ-ray bursts and active galactic nuclei. We have successfully achieved this using ultrarelativistic protons accelerated by the Super Proton Synchrotron at (CERN). In the first application of this experimental platform, the stability of the pair beam is studied as it propagates through a meter-length plasma, analogous to TeV γ-ray-induced pair cascades in the intergalactic medium. It has been argued that pair beam instabilities disrupt the cascade, thus accounting for the observed lack of reprocessed GeV emission from TeV blazars. If true, this would remove the need for a moderate strength intergalactic magnetic field to explain the observations. We find that the pair beam instability is suppressed if the beam is not perfectly collimated or monochromatic, hence the lower limit to the intergalactic magnetic field inferred from γ-ray observations of blazars is robust.

blazar jets↗

NASA NTRSDate not supplied

TOWARD A METHOD FOR SCALING HUMAN BODY MODELS IN AN IMU-BASED WORKFLOW

BACKGROUND Scaled biomechanical models can more accurately inform crew health decisions when tailored to the wide range of astronaut sizes. One component to improve scaling of existing models to better represent each unique astronaut’s size is the individual length scaling of limbs. Traditionally, these lengths are determined by motion capture or manual measurement. A new method is herein proposed for length scaling which can be done by measuring linear and angular accelerations at a desired point during isolated motion around a point of rotation, then calculating the distance between the desired point and point of rotation. When an Inertial Measurement Unit (IMU) device is placed at the distal point of a limb, the isolated motion is about that limb’s proximal joint. For example, to measure forearm length, an IMU is placed at the wrist, the point of rotation is at the elbow, and the isolated motion is forearm flexion and extension. These calculated lengths are then used to scale models to each unique astronaut’s size, thereby improving the applicability of the model. This method of scaling limb segments can be used for any limb that has an easily defined proximal joint for the limb to rotate around including hands, arms, legs, feet. Utilizing IMUs for data collection also provides the synergistic ability to record data without a dedicated space in a room with many cameras, therefore reducing the data collection footprint, or record data where optical motion capture is not possible, such as inside a spacesuit. METHODS AND RESULTS To test this method, upper body data collection was performed with 5 Xsens DOT IMUs on a single subject. IMUs consist of an accelerometer, a gyroscope, and a magnetometer which collect linear acceleration, angular velocity, and magnetic fluctuations, respectively. Before any ground-based laboratory collection, the magnetic fluctuations are used to correct the heading of the IMU in space relative to the Earth’s magnetic field. The direct measurement of angular velocity is integrated to calculate angular acceleration. Then the linear acceleration ( a ) and angular acceleration (α) are solved using r = at/α to calculate the radius, which in this case is the distance between the IMU and the point of rotation (i.e., segment length). The IMU must be placed at the most distal point of the limb being measured (i.e., ankle if measuring lower leg length) and the test plan must consist of an isolated motion about that limb’s proximal joint (i.e., knee flexion and extension if measuring lower leg length). The distances (radii) calculated at every time interval were filtered (bandpass filter keeping 5th-90th percentile data) to eliminate outliers and spurious data that occur when the isolated motion was stopped or nearly stopped. The remaining distances were averaged, resulting in the calculated limb length. Scaling factors were then computed by dividing the calculated limb length by the unscaled model’s length. These scale factors are plugged into the Scale Tool in OpenSim [1,2] to apply the scaling to the OpenSim Full Body Rajagopal Model [3,4]. Manual measurements of limb lengths were taken before data collection started and used for comparing against the calculated lengths. The Anthropometric Survey of US Army Personnel (ANSUR II) [5] was also used as a third source of reference for limb length measurements. The following measurements were retrieved from the subject before data collection: 34.5 cm from L1 to C7 (thorax), 25.7 cm from C7 Joint Center (JC) to head vertex (neck and head), 36.3 cm from shoulder JC to elbow JC (humerus), 29.5 cm from elbow JC to wrist JC (forearm), and 16.2 cm from clavicle to acromion (clavicle). Of those five, forearm and humerus lengths were calculated using this proposed method to obtain preliminary results. The forearm length after filtering and averaging was calculated to be 37.6 cm. This is a 28% overestimation from the measured forearm length (29.5 cm). The humerus length after filtering and averaging was calculated to be 47.8 cm. This is a 31% difference from the measured subject length (36.3 cm). Sources of error include imperfect isolated motion (method currently expects that motion should be perfectly circular in a 2D plane, include no rotation of the IMU, and be relatively smooth; a more secure IMU attachment method will help), unrefined filter techniques (removed highest and lowest values with 20% high and low pass filters and no smoothing filters), arbitrary removal of stopped or near stopped data (kept data for only a short range before and after the angular velocity peaking), and a more representative method for removing gravitational acceleration is needed (current method is to zero all accelerations against a baseline taken just before the isolated motion which does not account for the gravitational acceleration changed due to IMU rotation during movement). Addressing these error sources will improve the accuracy of the limb length calculation. Next steps include creating a method for whole-body scaling estimation using individual limb scale factors. Continued pursuit of these techniques is expected to enable acquiring anthropometric information using only IMUs in real-time.

E. K. Marecki↗

DOE OSTI2021

Markets and Economic Requirements for Fission Batteries and Other Nuclear Systems

Fission Batteries (FBs) are nuclear reactors defined by five characteristics which enable large-scale deployment: cost competitive, standardized sizes for economic mass production, easy installation and removal, secure and safe unattended operation with high reliability. FBs are not defined by technology or power level. Technical and market considerations suggest that most FBs will produce 20 to 30 MWt. This proceedings reports on the outcomes of two workshops that were held in January 2021 to better define markets and economic challenges for FBs. Three major markets were identified. The largest market is the industrial and commercial heat market. There are about 4000 industrial users (excluding utilities) that require more than one megawatt of heat. The number of customers versus size of heat demand was determined. In a low-carbon world there is the potential for many additional customers—including expanded biofuels production and district heat. The second market is for non-grid electricity. This includes co-generation plants that produce heat and electricity for a single customer. The third market is the maritime market with ~100,000 ships worldwide. In the United States, natural gas is the low-cost energy option today and will remain so unless constraints or taxes impact its use. If restrictions on greenhouse gas emissions, the FB competition includes natural gas with carbon capture, biofuels, hydrogen and grid electricity. Natural gas with carbon capture is not economically viable on a small scale. Biofuels may be expensive but may be the economically preferred option for locations with small energy demands of a few megawatts. Hydrogen is a potential competitor with many of the characteristics of natural gas. Grid electricity is not a competitive source of heat. For FBs to be economically competitive, the price of delivered heat must be $20-50/MWh ($6-15/million BTU). The economically competitive range for non-grid electricity is estimated at $70-100/MWh. These electricity prices are competitive with the retail prices of electricity in many parts of the United States for the customer. FBs are not expected to be competitive selling wholesale electricity to the grid. To achieve the aforementioned cost targets for heat and electricity markets, FB designers must (1) maximize the power output within the constraints of a FB (e.g., truck transportability, passive decay heat removal), (2) drastically reduce the size of onsite staff, (3) adopt core designs with low fuel costs (enrichment and fabrication), and (4) develop a system design that is efficiently manufactured in factories. The business case depends upon more than being just a replacement for natural gas. The largest incentives for adoption of FBs is where they create new markets and new sources of revenue. An example is the paper and pulp industry that burns biomass wastes to provide heat and electricity to make paper. An external heat source could meet the demand for heat and electricity by the paper process and enable converting waste biomass into liquid biofuels rather than burning to provide heat. Other markets, such as data centers, are driven by special energy requirements such as extreme reliability. Most customers are not in the energy business but need heat and electricity to produce a product—a manufactured good, education, retail sales (shopping malls), marine transport or some other product. As a consequence, there will be large incentives to lease rather than own FBs. Leasing avoids the regulatory challenges that remain with the owner of the FB. Leasing creates large incentives for FP standardization of sizes and transportability to maintain the value of the FB at the end of the lease—similar to the leasing of jet engines and aircraft. The economic constraints combined with technical constraints suggest competitive FBs will likely have outputs exceeding 10 MWt. There appear to be little incentives for very long-lived reactor cores because such machines require much larger inventories of fuel. Maintenance requirements and the options to provide technology updates may favor shorter lifetimes (~5 years). The assessment is that there is the potential for FBs to be economically viable and play a major role in global decarbonization in three markets: heat, non-grid electricity and maritime applications.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2022

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

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

24 POWER TRANSMISSION AND DISTRIBUTION↗

NASA NTRS2014

Robonaut 2 - IVA Experiments On-Board ISS and Development Towards EVA Capability

Robonaut 2 (R2) has completed its fixed base activities on-board the ISS and is scheduled to receive its climbing legs in early 2014. In its continuing line of firsts, the R2 torso finished up its on-orbit activities on its stanchion with the manipulation of space blanket materials and performed multiple tasks under teleoperation control by IVA astronauts. The successful completion of these two IVA experiments is a key step in Robonaut's progression towards an EVA capability. Integration with the legs and climbing inside the ISS will provide another important part of the experience that R2 will need prior to performing tasks on the outside of ISS. In support of these on-orbit activities, R2 has been traversing across handrails in simulated zero-g environments and working with EVA tools and equipment on the ground to determine manipulation strategies for an EVA Robonaut. R2 made significant advances in robotic manipulation of deformable materials in space while working with its softgoods task panel. This panel features quarter turn latches that secure a space blanket to the task panel structure. The space blanket covers two cloth cubes that are attached with Velcro to the structure. R2 was able to open and close the latches, pull back the blanket, and remove the cube underneath. R2 simulated cleaning up an EVA worksite as well, by replacing the cube and reattaching the blanket. In order to interact with the softgoods panel, R2 has both autonomously and with a human in the loop identified and localized these deformable objects. Using stereo color cameras, R2 identified characteristic elements on the softgoods panel then extracted the location and orientation of the object in its field of view using stereo disparity and kinematic transforms. R2 used both vision processing and supervisory control to successfully accomplish this important task. Teleoperation is a key capability for Robonaut's effectiveness as an EVA system. To build proficiency, crewmembers have attempted increasingly difficult tasks using R2 inside the Station. After donning motion capture equipment and a virtual reality visor, Expedition 34/35 flight engineer Tom Marshburn began operations with simple hand movements. Having gained confidence, Marshburn guided R2's arms in a leader-follower exercise with crewmate Chris Cassidy. He was also able to use the hand to grab a tumbling roll of tape, a task only demonstrable in microgravity. Later efforts saw Cassidy handle softgoods through shared control with ground operators, mimicking an activity previously achieved using only autonomy. Robotic climbing through the ISS on handrails requires both precision motion and compliant grasps in order to both position grippers on handrails/seat track and prevent large internal forces. R2 climbs using actively controlled compliance and torque limiting to meet both the precision and softness requirements. During a step, the attached leg is controlled to be strong and stiff in order to maintain precision trajectory tracking. The swing leg is controlled to be stiff but weak to minimize unintentional impact forces while maintaining precision. During a simulated dual limb grasp (as shown in Figure 1), the R2 controller maintains one limb rigid and one limb soft to prevent large internal forces from building up. R2's grippers also use a form of force control to limit grip force while not fully closed on either a handrail or seat track thus limiting unintentional forces on cables/objects that may be present in R2's translational path. The on-board torso R2 safety system relies on a single end-effector velocity limit to prevent potential impact forces from exceeding Station maximum load requirements. R2's mobile configuration required modifications to the velocity limiting safety function due to its large, dynamic inertia. R2's legs maneuver the robot's mass creating configuration dependent, joint-relative inertias. A single all-encompassing velocity limit to cover worst case inertia is prohibitively low. The upgraded R2 control and safety systems solve this problem using momentum limiting, momentum control, and kinetic energy minimization. Momentum and kinetic energy take the robot mass into account relieving low velocity restrictions on low inertia end-effectors while ensuring that the overall mass of R2 is limited from hazardous velocities. The momentum of R2's five safety nodes (each of the four end-effectors and the body) is monitored and compared to a single momentum limit. If any of the five nodes exceeds the safety limit, the motor power is removed and the robot comes to a stop. Momentum control/limiting also provides a simple, reliable method to integrate hand held tools into the safety system by providing the tool mass to the control system thus automatically reducing the allowable velocity of the end-effector with the tool. Work on the ground continues to build the skill set for an EVA Robonaut. Recent experiments (Figure 2) demonstrate how a teleoperator can use R2 to manipulate a tether hook, an important safety precaution on spacewalks. Another task displayed Robonaut's ability to pull back a protective jacket over a hose and search for damage, as well as inspect a quick-disconnect fitting for debris. Demonstrations such as these are indicative of EVA work done on ISS, specifically seen during a series of spacewalks over 2012 and 2013 where astronauts searched for an ammonia leak in one of the external cooling loops. Through experiments both on ISS and on the ground, R2 is evolving and providing the information needed to plan out the upgrades that will make an EVA Robonaut an effective tool. With the addition of legs, R2 will start climbing inside the space station and supply invaluable information on how the climbing strategies and task stabilization techniques must be refined. Ground R2 systems will continue to work with additional EVA tools and equipment in preparation for onboard IVA testing and future EVA applications.

Diftler, Myron↗