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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 19 records

The design, fabrication and installation of cable routing mockups in support of Spacelab 2

From flight and mockup drawings of Spacelab 2 (SL 2) experiments and hardware, shop ready mockup drawings were produced. Floor panels were the first items considered for fabrication. Cold plate and orthogrid mockups were designed and fabricated. Experiment and other hardware mockups were fabricated of aluminum or plywood, depending on size and configuration. Eighty-three cable routing bracket mockups were fabricated of aluminum and delivered for painting.

Source record↗

Reference floating wind array designs for three representative regions

This work presents the systematic development of three open-source reference floating wind array designs. The designs are tailored to representative site conditions for three regions of the United States: Humboldt Bay off the coast of California, the Gulf of Maine, and the Gulf of America. We adopted existing reference designs for the individual 15 MW turbines, semisubmersible floating platforms, substations, mooring systems, and power cables – integrating and adapting them as needed for each location. We adapted existing dynamic cable designs to use larger conductor sizes to meet the arrays' power transmission requirements, and we set up redundant mooring systems for each substation. The layout of each array is a uniform-grid design optimized to approximately minimize the levelized cost of energy (LCOE) within a square lease area while satisfying spatial constraints. These constraints ensure adequate clearances between adjacent turbines and between underwater components during the layout optimization to prevent clashing and ensure that all components reside within the lease boundaries. Substations are included to allow accounting for intra-array cable costs. They are placed within the uniform grid to maintain the navigability of the arrays. For each feasible layout considered, annual energy production and cable routing costs are calculated and updated in the LCOE objective function. After the optimization, we refined the cable routing with a mix of algorithmic and manual methods to ensure that the cables avoid mooring system components and approach the substation with adequate clearances. We confirmed the suitability of each reference array's layout by comparing the wake losses at each wind heading angle to the wind rose, observing that the optimized layouts largely avoid wake losses in the predominant wind directions. These reference arrays provide open-source baseline designs to enable future research and innovation of floating wind technology at the array scale.

17 WIND ENERGY↗

Robotic Software Architecture for in-Space Outfitting Operations

Space exploration is expanding into longer missions, larger payloads, and more complex operations. To make these larger scale missions a reality, it is necessary to perform assembly, construction, and maintenance tasks via a robotic workforce in addition to crewed operations. While there has been significant research into in-space assembly and manufacturing, it is primarily focused on rigid structural elements, such as ISRU printing or truss construction. Outfitting tasks, such as cable routing, are a critical step to a fully operational in-space facility. This paper seeks to provide a reduced order state model and an optimized combination of state-of-the-art robotics algorithms applied to a cable routing scenario. Simulation results are expected to advance approaches to online autonomous robotic manipulation of non-rigid elements.

Amy M Quartaro↗

Robotic Software Architecture for In-Space Outfitting Operations

Space exploration is expanding into longer missions, larger payloads, and more complex operations. To make these larger scale missions a reality, it is necessary to perform assembly, construction, and maintenance tasks via a robotic workforce in addition to crewed operations. While there has been significant research into in-space assembly and manufacturing, it is primarily focused on rigid structural elements, such as ISRU printing or truss construction. Outfitting tasks, such as cable routing, are a critical step to a fully operational in-space facility. This paper seeks to provide a reduced order state model and an optimized combination of state-of-the-art robotics algorithms applied to a cable routing scenario. Simulation results are expected to advance approaches to online autonomous robotic manipulation of non-rigid elements.

Amy Quartaro↗

Improved Testing Capability and Adaptability Through the Use of Wireless Sensors

From the first Saturn V rocket booster (S-II-T) testing in 1966 and the routine Space Shuttle Main Engine (SSME) testing beginning in 1975, to more recent test programs such as the X-33 Aerospike Engine, the Integrated Powerhead Development (IPD) program, and the Hybrid Sounding Rocket (HYSR), Stennis Space Center (SSC) continues to be a premier location for conducting large-scale testing. Central to each test program is the capability for sensor systems to deliver reliable measurements and high quality data, while also providing a means to monitor the test stand area to the highest degree of safety and sustainability. Sensor wiring is routed along piping and through cable trenches, making its way from the engine test area, through the test stand area and to the signal conditioning building before final transfer to the test control center. When sensor requirements lie outside the reach of the routine sensor cable routing, the use of wireless sensor networks becomes particularly attractive due to their versatility and ease of installation. As part of an on-going effort to enhance the testing capabilities of Stennis Space Center, the Test Technology and Development group has found numerous applications for its sensor-adaptable wireless sensor suite. While not intended for critical engine measurements or control loops, in-house hardware and software development of the sensor suite can provide improved testing capability for a range of applications including the safety monitoring of propellant storage barrels and as an experimental test-bed for embedded health monitoring paradigms.

Solano, Wanda M.↗

Atlantic Offshore Wind Transmission Study

The Atlantic Offshore Wind Transmission Study (AOSWTS) is part of the U.S. Department of Energy's (DOE) efforts to understand and facilitate the transmission of electricity from wind in the Atlantic Ocean. It was informed by the Atlantic Offshore Wind Transmission Literature Review and Gaps Analysis (Bothwell et al. 2021) and the convening workshops hosted in 2022-2023 by DOE and the U.S. Department of the Interior's Bureau of Ocean Energy Management. The study results help to inform An Action Plan for Offshore Wind Transmission Development in the U.S. Atlantic Region (Baker et al. 2023). DOE's Wind Energy Technologies Office funded AOSWTS. The AOSWTS identifies and evaluates pathways to enable offshore wind energy deployment in the Atlantic Ocean through coordinated offshore transmission solutions in the near term (by 2030) and long term (by 2050). The study fills gaps in prior analyses by providing a multiregional planning perspective that evaluates offshore wind generation development with transmission planning. It incorporates environmental, ocean co-use, and other siting considerations into defining potential offshore transmission routes. The study also compares different multiregional offshore transmission topologies and their associated costs (using potential cable routes) and benefits (in terms of production cost savings and enhanced resource adequacy). In addition, the AOSWTS analyzes reliability impacts from a multiregional perspective. The study provides guidance for policymakers and transmission stakeholders on possible outcomes resulting from a proactive, coordinated, and interregional approach to transmission planning for offshore wind energy development in the Atlantic. While this study presents possibilities, additional work following system operator methods and procedures can help build on this analysis.

17 WIND ENERGY↗

Atlantic Offshore Wind Transmission Study: Executive Summary

The Atlantic Offshore Wind Transmission Study (AOSWTS) is part of the U.S. Department of Energy's (DOE) efforts to understand and facilitate the transmission of electricity from wind in the Atlantic Ocean. It was informed by the Atlantic Offshore Wind Transmission Literature Review and Gaps Analysis (Bothwell et al. 2021) and the convening workshops hosted in 2022-2023 by DOE and the U.S. Department of the Interior's Bureau of Ocean Energy Management. The study results help to inform An Action Plan for Offshore Wind Transmission Development in the U.S. Atlantic Region (Baker et al. 2023). DOE's Wind Energy Technologies Office funded AOSWTS. The AOSWTS identifies and evaluates pathways to enable offshore wind energy deployment in the Atlantic Ocean through coordinated offshore transmission solutions in the near term (by 2030) and long term (by 2050). The study fills gaps in prior analyses by providing a multiregional planning perspective that evaluates offshore wind generation development with transmission planning. It incorporates environmental, ocean co-use, and other siting considerations into defining potential offshore transmission routes. The study also compares different multiregional offshore transmission topologies and their associated costs (using potential cable routes) and benefits (in terms of production cost savings and enhanced resource adequacy). In addition, the AOSWTS analyzes reliability impacts from a multiregional perspective. The study provides guidance for policymakers and transmission stakeholders on possible outcomes resulting from a proactive, coordinated, and interregional approach to transmission planning for offshore wind energy development in the Atlantic. While this study presents possibilities, additional work following system operator methods and procedures can help build on this analysis.

17 WIND ENERGY↗

Autonomous Stabilization and Orientation Control of Hoisted Payloads

An orientation control system prototype has been developed for hoisted payloads. This system will allow payloads to be lifted off inclined surfaces while maintaining orientation control, allowing removal of tightly packed payloads without colliding with adjacent objects. For this concept, the payload is hoisted with a crane using a rigging system composed of a cable routed through two capstans and three or four attachment points on the payload. Motors rotate the capstans to adjust the cable lengths to the payload, and thereby control the orientation of the payload. Initial testing of the prototype was completed using manual control, however the algorithms necessary to fully automate the system are presented in this paper.

control↗

Cryogenic Pressure Seal for Wires

High-pressure-seal formed by forcing polyurethane into space surrounding wire or cable in special fitting. Wire or cable routed through fitting then through a tightly fitting cap. Wire insulation left intact. Cap filled with sealant and forced onto the fitting: this pushes sealant into fitting so it seals wire or cable in fitting as well as in cap.

Ciana, J. J.↗

Modeling Deformable Linear Objects for Autonomous Robotic Outfitting of Lunar Surface Systems

This paper presents structural models of deformable linear objects (DLOs). DLOs are a subclass of deformable objects that encompasses common outfitting elements such as cables and ropes. Models are validated through hardware experiments, and integration in a robotic autonomy architecture for space environments is discussed. A persistent human presence on the lunar surface is one of the next major milestones in space exploration. This requires the development of robust extraplanetary construction technologies including structures and materials modeling and robotic systems. Previous robotic construction technology development has primarily focused on structural assembly, with significantly less focus on robotically performed outfitting tasks to instantiate subsystems providing power, data, life support, etc. These tasks involve manipulation of highly flexible elements, which are difficult to model, such as cable harnesses, ropes, and hoses. Robotic manipulation of DLOs, especially cable harnesses, is an active area of research as cable harnesses are essential for providing power and data to space assets. DLO models that can be used for robot manipulator trajectory generation are necessary for autonomous operation of lunar infrastructure. There are many proposed methods for modeling DLOs, and they primarily fall into three types: 1) discrete model-based, 2) continuum model-based, and 3) Neural Network-based. These types each have pros and cons, and the tradeoff between model accuracy and computational speed informs which type should be used. An understanding of this trade-off is imperative for real-time control of autonomous systems. High computational requirements reduce the speed of the model, making real-time control difficult, while accuracy is critical to preventing collisions. Discrete models, such as a mass-spring multibody representation, require relatively few calculations, and accuracy is directly tied to the step size of the discretization. Continuum models, such as a B-spline representation or a Cosserat rod model (a mix of continuous and discrete), are more informed of the structural properties of the cable and are much more accurate than a rigid body mass-spring model, but at significant computational cost. A Neural Network approach can provide an online solution with very few computational steps, but properly generating training data can be difficult and validation for an in-space application is not trivial. This paper explores the trade-off between different modeling approaches and compares accuracy and computational speed/complexity of the three types mentioned above. Model accuracy is evaluated using a cable in a static configuration. True cable shape is obtained using a depth camera for RGB images and point-cloud segmentation. The purpose of this experiment is to evaluate the trade-offs of different approaches to the DLO modeling problem. Understanding the tradeoffs between different cable modeling techniques paves the way for developing robotic control and planning architectures necessary for real-time manipulation of DLOs for lunar infrastructure outfitting. Real-time control is required for robotic systems to be able to actively manipulate a cable in a harsh environment where model and sensor errors compound, and environmental conditions can cause significant disturbances. Cable routing must be performed in areas with high density of objects/obstacles: through truss structures, near solar panels or mirror arrays, next to bundles of electrical equipment. Understanding the best way to plan and manipulate a cable without disrupting the environment or damaging the cable is imperative to robotic outfitting operations on the lunar surface.

Amy M Quartaro↗

Space Station Freedom secondary power wiring requirements

Secondary power is produced by DDCU's (direct current to direct current converter units) and routed to and through secondary power distribution assemblies (SPDA's) to loads or tertiary distribution assemblies. This presentation outlines requirements of Space Station Freedom (SSF) EEE (electrical, electronic, and electromechanical) parts wire and the approved electrical wire and cable. The SSF PDRD (Program Definition and Requirements Document) language problems and resolution are reviewed. The cable routing to and from the SPDA's is presented as diagrams and the wire recommendations and characteristics are given.

Sawyer, C. R.↗

FAD-Toolset (Floating Array Design Toolset) [SWR-26-056]

The Floating Array Design (FAD) Toolset is a collection of tools for modeling and designing arrays of floating offshore structures. It was originally designed for floating wind systems but has applicability for many offshore applications. A core part of the FAD Toolset is the floating array model, which serves as a high-level library for efficiently modeling a floating array, such as a floating wind array. It combines site condition information and a description of the floating array design, and contains functions for evaluating the array's behavior considering the site conditions. For example, it combines information about site soil conditions, mooring line loads, and an array's anchor characteristics to estimate the holding capacity of each anchor. The library works in conjunction with the tools RAFT, MoorPy, and FLORIS to model floating platforms, wind turbines, mooring systems, power cables, and array wakes respectively. Layered on top of the floating array model is a set of design tools that can be used for algorithmically adjusting or optimizing parts of the a floating array. Specific tools existing for mooring lines, shared mooring systems, dynamic power cables, static power cable routing, and overall array layout. These capabilities work with the design representation and evaluation functions in the floating array model, and they can be applied by users in various combinations to suit different purposes. In addition to standalone uses of the FAD Toolset, a coupling has been made with Ard, (https://github.com/NLRWindSystems/Ard) a sophisticated and flexible wind farm optimization tool. This coupling allows Ard to use certain mooring system capabilities from FAD to perform layout optimization of floating wind farms with Ard's more advanced layout optimization capabilities. The FAD Toolset works with the IEA Wind Task 49 Ontology (https://github.com/IEAWindTask49/Ontology), which provides a standardized format for describing floating wind farm sites and designs. See example use cases in our examples folder (https://github.com/NLRWindSystems/FAD-Toolset/blob/main/examples/README.md) For working with the library, it is important to understand the floating array model structure, which is described more here: https://github.com/NLRWindSystems/FAD-Toolset/blob/main/fad/README.md.

Sirkis, Leah [National Laboratory of the Rockies (↗

Fork Union EPC Installation Observation Report

On June 22nd and 23rd, a representative from Savannah River National Lab (SRNL) traveled to the Fork Union substation in Fork Union, Virginia (owned and operated by Dominion Energy) to observe the installation, calibration, and commissioning of three Electric Phenomena Cluster (EPC) sensors. The installation in its entirety included the physical securing of the EPC sensors by Dominion Energy, fiber optic cable (furnished by SmartSenseComm) being run in conduits and cable trays from the EPC sensor to the Optical Processing Unit (OPU) located in the substation switch house. The location of the EPC sensors, OPU, and cable routing can be seen in the figures included.

47 OTHER INSTRUMENTATION↗

PIP-II LB650 Cryomodule Mockup

Fermilab’s PIP-II project requires accurate cable routing in the LB650 cryomodule, a confined and difficult-to-access system. We designed a full-scale mockup using a 15-ft, 7-ft 8020 frame and twenty-three PLA interfaces. CAD modeling and lifting analysis has been verified for safe assembly With all components ordered, the mockup will allow technicians to rehearse routing and identify issues before working on the real cryomodule.

Oribello, Francis [Northern Illinois U.]↗

The design and fabrication of the Centaur neutral buoyancy trainer and related hardware

Two full scale mockups of the Centaur upper stage were designed, fabricated and delivered to NASA. One was the Centaur Weightless Environment Training Facility (WETF) trainer and the other was the Centaur 1-G mockup. The Centaur upper stage booster is designed to carry the spacecraft Galileo to Jupiter, and the spacecraft Ulysses to an orbit around the Sun after launch from the Space Shuttle. The flight vehicle has several Extravehicular Activity (EVA) contingency tasks that require crew training. This need for crew training generated the requirement for the Centaur WETF crew trainer, which is high fidelity in areas of expected crew interface. During the production of the Centaur WETF crew trainer, the need for a jumper cable from Centaur to the Orbiter was identified. This EVA contingency task would be the installation of a cable from the Orbiter cargo bay sill to various command data boxes on Centaur to allow crew control deployment should a failure occur. This task required the upgrading of volumetric boxes on the trainer to a high fidelity configuration including electrical connector installation and cable routing.

Ware, Alan S.↗

Layout and cabling considerations for a large communications antenna array

Layout considerations for a large deep space communications antenna array are discussed. A fractal geometry for the antenna layout is described that provides optimal packing of antenna elements, efficient cable routing, and logical division of the array into identical sub-arrays.

Logan, R. T., Jr.↗

Cammp Team

The International Space Station (ISS) Configuration Analysis Modeling and Mass Properties (CAMMP) Team is presenting a demo of certain CAMMP capabilities at a Booz Allen Hamilton conference in San Antonio. The team will be showing pictures of low fidelity, simplified ISS models, but no dimensions or technical data. The presentation will include a brief description of the contract and task, description and picture of the Topology, description of Generic Ground Rules and Constraints (GGR&C), description of Stage Analysis with constraints applied, and wrap up with description of other tasks such as Special Studies, Cable Routing, etc. The models include conceptual Crew Exploration Vehicle (CEV) and Lunar Lander images and animations created for promotional purposes, which are based entirely on public domain conceptual images from public NASA web sites and publicly available magazine articles and are not based on any actual designs, measurements, or 3D models. Conceptual Mars rover and lander are completely conceptual and are not based on any NASA designs or data. The demonstration includes High Fidelity Computer Aided Design (CAD) models of ISS provided by the ISS 3D CAD Team which will be used in a visual display to demonstrate the capabilities of the Teamcenter Visualization software. The demonstration will include 3D views of the CAD models including random measurements that will be taken to demonstrate the measurement tool. A 3D PDF file will be demonstrated of the Blue Book fidelity assembly complete model with no vehicles attached. The 3D zoom and rotation will be displayed as well as random measurements from the measurement tool. The External Configuration Analysis and Tracking Tool (ExCATT) Microsoft Access Database will be demonstrated to show its capabilities to organize and track hardware on ISS. The data included will be part numbers, serial numbers, historical, current, and future locations, of external hardware components on station. It includes dates of all external ISS events and flights and the associated hardware changes for each event. The hardware location information does not always reveal the exact location of the hardware, only the general location. In some cases the location is a module or carrier, in other cases it is a WIF socket, handrail, or attach point. Only small portions of the data will be displayed for demonstration purposes.

Evertt, Shonn F.↗

Miniature Six-Axis Load Sensor for Robotic Fingertip

A miniature load sensor has been developed as a prototype of tactile sensors that could fit within fingertips of anthropomorphic robot hands. The sensor includes a force-and-torque transducer in the form of a spring instrumented with at least six semiconductor strain gauges. The strain-gauge wires are secured to one side of an interface circuit board mounted at the base of the spring. This board protects the strain-gauge wires from damage that could otherwise occur as a result of finger motions. On the opposite side of the interface board, cables routed along the neutral axis of the finger route the strain-gauge output voltages to an analog-to-digital converter (A/D) board. The A/D board is mounted as close as possible to the strain gauges to minimize electromagnetic noise and other interference effects. The outputs of the A/D board are fed to a controller, wherein, by means of a predetermined calibration matrix, the digitized strain-gauge output voltages are converted to three vector components of force and three of torque exerted by or on the fingertip.

Diftler, Myron A.↗