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Mechanical Solutions Scan Report

Power lines, poles, and towers are the backbone of the United States (U.S.) electric-power grid. These transmission and distribution networks route electricity from generator to loads. The characteristics of these routes are rapidly changing -- trending towards decentralized renewable generation, electric heating, vehicle charging, and large data-center loads. Coupled with aging infrastructure and the increased frequency of extreme weather events, there is concern about the future reliability and transmission capacity of conductors and adjacent components. This scan report seeks to provide an overview of mechanical solutions to challenges caused by extreme weather events associated with components of transmission and distribution infrastructure, including conductor heat sag, ice accumulation, wind, and wildfire. Many options could increase transmission capacity or reliability, and these are at various stages of technological readiness. Some have only been lab tested, while some have been widely deployed in the U.S. or overseas for decades. The solution categories and providers featured in this report are intended to be comprehensive at the time of publication and to serve as a reference for decision-makers concerned about transmission and distribution reliability. There are two other categories of large, complex solutions, which are not covered in this report: replacing existing conductors with advanced conductors and implementing digital grid enhancing technologies. A separate scan report titled “Advanced Conductor Scan Report,” which discusses advanced carbon-core conductors, was published by the Idaho National Laboratory (INL) in 2023. Information on digital technologies, such as dynamic line ratings, power-flow controllers, and other power electronics and communications-based devices, can be found on the Grid- Enhancing Technologies landing page. Mechanical grid-enhancing technologies, or solutions covered in this report, often do not require full equipment replacement and do not rely on digital components. Mechanical technologies are overlooked because they may be older, simpler, or seemingly “more obvious” than digital or carbon-core technologies. However, it is wise to consider mechanical solutions in a thorough evaluation of grid enhancing technology solutions.

24 - POWER TRANSMISSION AND DISTRIBUTION

Novel Problem Solving - The NASA Solution Mechanism Guide

Over the past five years, the Human Health and Performance (HH&P) Directorate at the NASA Johnson Space Center (JSC) has conducted a number of pilot and ongoing projects in collaboration and open innovation. These projects involved the use of novel open innovation competitions that sought solutions from "the crowd", non-traditional problem solvers. The projects expanded to include virtual collaboration centers such as the NASA Human Health and Performance Center (NHHPC) and more recently a collaborative research project between NASA and the National Science Foundation (NSF). These novel problem-solving tools produced effective results and the HH&P wanted to capture the knowledge from these new tools, to teach the results to the directorate, and to implement new project management tools and coursework. The need to capture and teach the results of these novel problem solving tools, the HH&P decided to create a web-based tool to capture best practices and case studies, to teach novice users how to use new problem solving tools and to change project management training/. This web-based tool was developed with a small, multi-disciplinary group and named the Solution Mechanism Guide (SMG). An alpha version was developed that was tested against several sessions of user groups to get feedback on the SMG and determine a future course for development. The feedback was very positive and the HH&P decided to move to the beta-phase of development. To develop the web-based tool, the HH&P utilized the NASA Tournament Lab (NTL) to develop the software with TopCoder under an existing contract. In this way, the HH&P is using one new tool (the NTL and TopCoder) to develop the next generation tool, the SMG. The beta-phase of the SMG is planed for release in the spring of 2014 and results of the beta-phase testing will be available for the IAC meeting in September. The SMG is intended to disrupt the way problem solvers and project managers approach problem solving and to increase the use of novel and more cost and time effective problem solving tools such as open innovation, collaborative research, and virtual collaborative project centers. The HH&P envisions changing project management coursework by including the SMG in the teaching of project management problem solving tools.

Keeton, Kathryn E.

Mechanical Solution for Existing Conductors

The rapid growth in energy demand, driven by advancements in AI technology, renewable energy integration, and increased industrial activity, highlights the need for innovative solutions to improve the resiliency and efficiency of the power grid. This report details the fire testing of GridWrap’s Composite WiRe Wrap, to evaluate the wrap's ability to enhance conductor performance under wildfire-simulated conditions. Conductors were prepared and tested in a controlled environment at 400°C for 18 minutes, during which sag and temperature data were recorded. The results demonstrated that the unwrapped conductor sagged 3/16ths of an inch, while the WiRe Wrapped conductor sagged only 1/16th of an inch under identical conditions, indicating a significant improvement in mechanical performance. This project, conducted as part of a collaborative effort between BEA (Idaho National Laboratory’s managing contractor) and GridWrap, Inc., demonstrates the potential of grid-enhancing technologies like WiRe Wrap to reduce sag, increase grid resiliency, and support the future energy landscape. By validating the performance of such technologies in real-world scenarios, this work provides critical insights for industry adoption, benefiting both grid operators and U.S. taxpayers through improved reliability, reduced emissions, and enhanced energy delivery.

24 - POWER TRANSMISSION AND DISTRIBUTION

SCARLET I: Mechanization solutions for deployable concentrator optics integrated with rigid array technology

The SCARLET I (Solar Concentrator Army with Refractive Linear Element Technology) solar array wing was designed and built to demonstrate, in flight, the feasibility of integrating deployable concentrator optics within the design envelope of typical rigid array technology. Innovative mechanism designs were used throughout the array, and a full series of qualification tests were successfully performed in anticipation of a flight on the Multiple Experiment Transporter to Earth Orbit and Return (METEOR) spacecraft. Even though the Conestoga launch vehicle was unable to place the spacecraft in orbit, the program effort was successful in achieving the milestones of analytical and design development functional validation, and flight qualification, thus leading to a future flight evaluation for the SCARLET technology.

Wachholz, James J.

Iterative Mechanism Solutions with Scenario and ADAMS

This slide presentation reviews the use of iterative solutions using Scenario for Motion (UG NX 2 Motion) to assist in designing the Mars Science Laboratory (MSL). The MSL will have very unique design requirements, and in order to meet these requirements the system must have the ability to design for static stability, simulate mechanism kinematics, simulate dynamic behaviour and be capable of reconfiguration, and iterations as designed. The legacy process used on the Mars Exploration rovers worked, but it was cumbersome using multiple tools, limited configuration control, with manual process and communication, and multiple steps. The aim is to develop a mechanism that would reduce turn around time, and make more reiterations possible, to improve the quality and quantity of data, and to enhance configuration control. Currently for NX Scenario for Motion uses are in the articulation studies, the simulations of traverse motions,and subsystem simulations. The design of the Rover landing model requires accurate results, flexible elements, such as beams, and the use of the full ADAMS solver has been used. In order to achieve this, when required, there has been a direct translation from Scenario to ADAMS, with additional data in ascii format. The process that has been designed to move from Scenario to ADAMS is reviewed.

Mars Science Laboratory (MSL)

Focal mechanism of deep moonquakes

To elucidate the focal mechanism of deep moonquakes, S-wave polarizations of deep moonquake signals from the A(1) source region are analyzed. At station 12, where the available data are of the highest quality, the variation of polarization angle with the anomalistic phase of the moon indicates agreement with that expected from the focal mechanism model of Nakamura (1978). Focal mechanism solutions were derived for eight A(1) moonquakes assuming that moonquakes are, like earthquakes, caused by a shear fracture on a fault plane. The mechanism solutions generally indicate a nearly horizontal or almost vertical faulting. The slip directions estimated from the solutions are different from one another, again suggesting variation of focal mechanisms as a function of the tidal phase of the moon.

Koyama, J.

Performance Degradation of Amine-Infused Fiber Sorbents for Direct Air Capture: Mechanisms and Solutions

Sorbent stability poses significant impacts on longterm performance of direct air capture (DAC) of CO 2 and levelized cost of capture (LCOC). We report the DAC performance degradation of amine-infused fiber sorbents based on poly(ethylenimine) (PEI), mesoporous SiO 2 , and cellulose acetate (CA) over CO 2 cyclic sorption cycles in a nonoxidative environment. Infrared and nuclear magnetic resonance spectra indicate that the aminolysis reactions between CA ester moieties and PEI amine sites lead to the formation of acetamides and hence lower CO 2 affinities of the sorbents. This stability issue can be remedied by hydrolysis treatment of the CA fiber sorbents before PEI impregnation or replacing CA with poly(ether sulfone). This study underscores the importance of selecting proper support or additive materials of DAC contactors that are compatible with active species of CO 2 capture.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH

Mechanical Agitation For Aqueous Cleaning

Cleaning basket placed in aqueous cleaning solution mechanically agitated by air spring. Compressed air at oscillating pressure supplied to air spring to produce repeated vertical motion of cleaning basket.

Morgan, Gene E.

A Generalized Power System Architecture Sizing and Analysis Framework

The aeronautics industry has been challenged to increase efficiency, reduce noise and emissions, and decrease dependency on carbon-based fuels. To address these needs, NASA has identified and begun to pursue electrified aircraft as a possible solution. The power system for an electric aircraft can exist in many different forms, however; at the early design stage the engineer(s) must identify whether a hybrid- or turbo- electric solution may be best, whether the power transmission system is to be AC or DC, and to ultimately answer the question: does the electric solution provide a net system benefit compared to the fully mechanical solution? This paper describes a generalized power system architecture sizing and analysis framework to provide a mechanism to answering these questions, along with an example based on the STARC-ABL Architecture.

Turbo-Electric

Working toward a three-dimensional fatigue closure model for surface cracks

The first reliable elastic fracture mechanics solutions for a surface crack in a plate were obtained by Newman and Raju. The authors, both from the Mechanics of Materials Branch at NASA-Langley, used a highly detailed finite element solution requiring substantial computational resources. Computers have since become more powerful and available; however, many important related problems remain computationally expensive. The problem of three-dimensional fatigue crack growth taking into account plasticity-induced crack closure is one such problem. It is the goal of this research to provide an efficient method to account for three-dimensional crack closure in fatigue. Newman developed a two-dimensional plasticity-induced crack closure model for center cracked specimens. This model requires iterations to determine both the contact solution at each growth step and the extent of the plastic zone at the crack tip. A three-dimensional version of this model would require obtaining these nonlinear variables all along the crack front. This model must be efficient so that repeated calculations can be performed during crack growth simulations. The highly versatile line spring model (LSM) with contact, fatigue, and plasticity will form the basis of the closure model. There are several required additions to past work to address the three-dimensional crack closure problem. Initially, these additions will include (1) an improved LSM to more accurately obtain the crack opening displacement, stress intensity factors, and elastic T-stress near the ends of the surface crack; (2) a method to determine the extent of the plastic zone all along the crack front; (3) a method to determine the contact zone given a perfectly plastic layer of material on the crack surfaces; (4) a method to determine the magnitude of the compressive contact stress; and (5) a way to implement the degree of constraint along the curved crack front. During the summer ASEE program an enhanced LSM was developed. A method similar to that of 'strip synthesis' first introduced by Fujimoto was used. Briefly, the crack opening displacements of 'slices' of the surface crack in a direction parallel to the plate surface are considered in addition to the standard LSM approach that makes use of springs obtained from slices perpendicular to the plate surface. This enhancement is necessary so that an accurate three-dimensional representation of quantities such as contact zone size, plastic zone size, stress intensity factors, T-stress, and crack opening displacement can be determined. By combining results of previous investigations with the LSM, the problem of three-dimensional crack closure will be addressed. In addition to a closure model, the enhanced LSM can be used for many other problems including interacting surface cracks and fatigue crack growth of a through crack with a curved crack front.

Joseph, Paul F.

Pointing/roll mechanism for the ultraviolet coronagraph spectrometer

A pointing/roll mechanism for the Ultraviolet Coronagraph Spectrometer (UVCS) is presented along with a description of the mechanism control algorithm. The mechanism, operating in space, will position the 2.1 meter long, 0.7 meter diameter UVCS instrument in pitch and yaw, within a 54 arc-minute half angle cone, and will also allow it to rotate + or - 179.75 deg. After considerable design effort, an optimum mechanical solution was achieved, which meets all scientific requirements as well as weight, volume, and power budgets. Evolution of the mechanism is presented along with the design status.

Ostaszewski, Miroslaw A.

Device For Controlling Crystallization Of Protein

Variable sandwich spacer enables optimization of evaporative driving force that governs crystallization of protein from solution. Mechanically more rigid than hanging-drop and sitting-drop devices. Large oscillations and dislodgment of drop of solution in response to vibrations suppressed by glass plates. Other advantages include: suitable for automated delivery, stable handling, and programmable evaporation of protein solution; controlled configuration enables simple and accurate determination of volume of solution without disrupting crystallization; pH and concentration of precipitant controlled dynamically because pH and concentration coupled to rate of evaporation, controllable via adjustment of gap between plates; and enables variation of ratio between surface area and volume of protein solution. Alternative version, plates oriented vertically instead of horizontally.

Noever, David A.

Calculating Mode Mixity in Interlaminar Fracture of Composite Laminates

To accurately predict delamination under mixed-mode loading, cohesive elements must partition the energies dissipated in Mode I and Mode II correctly. The ability of cohesive models to predict mode mixity was evaluated by performing analyses of the single leg bending (SLB) test, which exhibits a variable mode mixity with crack length. Accordingly, two numerical integration methods were developed to compute the energy partitioning: (i) a local calculation of the accumulated work of tractions at each point along the crack path, and (ii) a global J-integral “snapshot” calculation along a contour around the process zone. In the case of a composite laminate with properties characterized by short fracture process zone (FPZ), the results of these two methods correlate well with each other and with a linear elastic fracture mechanics solution. However, FPZscan be long due to fiber bridging or due to the intrinsic toughness of the material. Then, the results of mode-mixity calculations obtained with various methods vary widely from each other. It is argued that the global J-integral calculation is the most accurate interpretation of the energy release rate and mode mixity for either short or long process zones. This solution will provide a more accurate characterization of resistance curves and mode mixity in experimental results, and it will also guide the development of more accurate mixed-mode cohesive laws for tougher materials characterized by strong R-curve responses, such as thermo-plastic composites.

cohesive zone analysis

Adhesive-bonded scarf and stepped-lap joints

Continuum mechanics solutions are derived for the static load-carrying capacity of scarf and stepped-lap adhesive-bonded joints. The analyses account for adhesive plasticity and adherend stiffness imbalance and thermal mismatch. The scarf joint solutions include a simple algebraic formula which serves as a close lower bound, within a small fraction of a per cent of the true answer for most practical geometries and materials. Digital computer programs were developed and, for the stepped-lap joints, the critical adherend and adhesive stresses are computed for each step. The scarf joint solutions exhibit grossly different behavior from that for double-lap joints for long overlaps inasmuch as that the potential bond shear strength continues to increase with indefinitely long overlaps on the scarf joints. The stepped-lap joint solutions exhibit some characteristics of both the scarf and double-lap joints. The stepped-lap computer program handles arbitrary (different) step lengths and thickness and the solutions obtained have clarified potentially weak design details and the remedies. The program has been used effectively to optimize the joint proportions.

Hart-Smith, L. J.

Design, evaluation and recommedation effort relating to the modification of a residential 3-ton absorption cycle cooling unit for operation with solar energy

The possible use of solar energy powered absorption units to provide cooling and heating of residential buildings is studied. Both, the ammonia-water and the water-lithium bromide cycles, are considered. It is shown that the air cooled ammonia water unit does not meet the criteria for COP and pump power on the cooling cycle and the heat obtained from it acting as a heat pump is at too low a temperature. If the ammonia machine is water cooled it will meet the design criteria for cooling but can not supply the heating needs. The water cooled lithium bromide unit meets the specified performance for cooling with appreciably lower generator temperatures and without a mechanical solution pump. It is recommeded that in the demonstration project a direct expansion lithium bromide unit be used for cooling and an auxiliary duct coil using the solar heated water be employed for heating.

Merrick, R. H.