Engineering topics

Stewart, Michael

Publications and source records attributed to Stewart, Michael.

8 records

DOE OSTI2019

Vertical Axis Wind Turbine (VAWT) with Thermoplastic Composite Blades

Rising concerns about global climate change, planet pollution and increasing use of energy have accelerated wider utilization of renewable energy sources. A recent trend in energy system development is decentralization of power generation systems. The opportunity for individuals or organizations to generate electricity locally decreases losses and part of the electricity price caused by the long-distance power transmission. Vertical axis wind turbines (VAWTs) cannot compete with traditional horizontal axis wind turbines (HAWTs) on the basis of aerodynamic performance or maximum power output generated for a given footprint. However, their ability to perform at a wide range of wind speeds, indifference to wind direction, simplicity of fabrication, transportability and maintainability make them ideal candidates for decentralized installations in urban and residential areas. The project team including Steelhead Composites (SHC), Colorado State University (CSU), National Renewable Energy Laboratory (NREL) and Arkema Inc. designed and fabricated a VAWT rotor assembly with thermoplastic composite blades using novel infusion and fabrication techniques. This full-scale VAWT rotor assembly was designed for a rated power output of 0.5-1 kW, as estimated through analytical computational fluid dynamics (CFD) methods. Those CFD simulations were combined with structural finite element analysis (FEA) to optimize the shape and composite layup of the wind blades. Much of the emphasis of this program was to characterize the recyclable thermoplastic material and composite structural design, in order to take full advantage of the material properties of such composites. Additionally, this project examined the potential of thermoplastic resin systems to transform the way VAWT rotor assemblies are joined both in the factory in in the field, by utilizing thermally welded joints to minimize field failure. The infused composite blades manufactured during this program are an excellent example of these benefits made possible by the Arkema thermoplastic resin system. This prototype blade manufacturing also provided the groundwork to inform decisions for larger scale manufacturing techniques applicable to a commercialization strategy. There is specific commercial interest for small scale VAWT’s that are competitively priced, perform to expectations, and have environmentally conscious end-of-life characteristics. Economic analysis was also conducted to compare designs and material usage, providing an estimated levelized cost of energy (LCOE) for the VAWT. The next steps for commercialization would include testing of the rotor assembly to verify predicted performance, specification of the balance of plant components (generator, inverter, etc.), and identification of a manufacturing partner with capability to scale-up production. This program has showed the potential for a commercially viable product through detailed analysis, material characterization and prototype fabrication.

17 WIND ENERGY↗

NASA NTRS2018

Variables Influencing RNAV STAR Adherence

In this study we investigated how variables in the aviation domain impact adherence levels of aircraft flying area navigation arrivals with optimized profile descents (RNAV OPDs) (RNAV STARs: aRea NAVigation Standard Terminal Arrival Routes). Variable categories were: weather, aircraft, procedure, and traffic. Non-adherence events analyzed were: miss above, miss below, skip before merge, and skip after merge. Miss below and miss above describe when a flight does not comply vertically with a procedure. Skips refer to a flight leaving a procedure, then returning. Findings of this work reveal that vertical events are most impacted by altitude restriction size, steepness of flight paths, and merging routes. Lateral events were impacted by merging flight conflicts, number of speed restrictions, and the flow rate of the arrival traffic. This study helps increase understanding of how the system is functioning and identifies where procedures are not flexible enough to handle the variability in normal operations.major airports, procedure design, and recommendations for future work.

RNAV OPD↗

NASA NTRS2018

Thermal Protection Systems Technology Transfer from Apollo and Space Shuttle to the Orion Program

This paper describes how the Orion program is utilizing the Thermal Protection System (TPS) experience from the Apollo and Space Shuttle programs to reduce program risk and improve affordability to meet NASA's future manned exploration missions. The Orion program successfully completed the Exploration Flight Test (EFT-1) mission in 2014 and is currently assembling, integrating, and testing the next spacecraft for the Exploration Mission (EM-1) to meet the flight test objectives of an unmanned orbital mission to the moon and return to earth in 2019. The Orion spacecraft production operations are located in the Neil Armstrong Operations and Checkout (O&C) facility at the Kennedy Space Center (KSC) providing an affordable and seamless delivery approach of vehicles directly to the launch site eliminating spacecraft transportation and additional checkout testing. Innovative vehicle design, manufacturing and test operations approaches are maturing and evolving with each Orion vehicle build to support the challenging NASA exploration mission requirements beyond Low Earth Orbit (LEO) while reducing program cost and schedule impacts. An example of Orion's evolution is the incorporation of an improved heat shield design, assembly and testing approach to meet the higher re-entry velocities for a lunar return for the EM-1 mission. The EFT- 1 heat shield was based on the Apollo heat shield manufacturing processes and was assembled at a supplier location and then transported to KSC for final integration. The EM-1 heat shield is now manufactured, assembled, tested, and installed into the spacecraft at the O&C facility reducing program cost and production schedules. The transition of the Space Shuttle TPS capabilities has enabled Orion to provide a human rated capsule design using proven materials and processes established over years of orbiter re-entry missions. The Orion Crew Module (CM) TPS configuration is derived from the Apollo CM approach utilizing improved materials and processes developed from the Space Shuttle program. The Orion EFT-1 heat shield utilized the Avcoat ablative material from Apollo which was injected into a honeycomb substrate and has been updated for EM-1 incorporating a block configuration bonded to a composite shell structure. This approach utilizes the proven Avcoat material for the heat shield ablator and is utilizing derived bonding and inspection methods and techniques from the Space Shuttle tile experience. The Orion back shell TPS configuration is based on Space Shuttle tile designs using proven tile materials and coatings. The Orion forward bay cover utilizes the high temperature tiles similar to the back shell tiles and low temperature blankets derived from the Space Shuttle program reducing weight impacts. Space Shuttle Multi-Layer Insulation (MLI) is installed in the Orion capsule to control the interior temperature environment providing a light weight design. These TPS design approaches have performed successfully on the Orion first flight test on EFT-1 and are incorporated in the configuration for the next flight test for EM-1. Completion of these two flight tests will certify the TPS for the Orion program for human rated exploration missions and has reduced the development cost to the Orion program. In addition to transitioning the Space Shuttle TPS design configurations to Orion, the supporting manufacturing infrastructure, manufacturing processes, and inspection methods are also incorporated into the Orion assembly operations at KSC. This has avoided significant startup schedule and costs impacts of new capabilities and development of support operations necessary to fabricate, install, inspect, and validate the TPS installations for the Orion spacecraft. The Thermal Protection System Facility (TPSF) which supported the Space Shuttle program provides the heat shield Avcoat blocks and the back shell AETB-8 tiles for Orion program. Extending the existing Space Shuttle TPS operations at KSC provides onsite support to the Orion spacecraft assembly operations. A significant benefit to the Orion program is the transition of the Space Shuttle technician work force at KSC. This highly skilled workforce was able to transition to the Orion program and immediately support the TPS installation operations. They brought with them the human rated manufacturing and assembly operations culture that was critical to the Space Shuttle success avoiding the retraining cost and schedule impacts of a new workforce to Orion. The technician skills certification program from the Space Shuttle was found to be compatible with the Lockheed Martin technician certification programs enabling a seamless training process utilizing process similarity avoiding the cost of retraining the work force to Orion standards. The existing workforce is certificated for multiple processes enabling reassignment of technicians to other tasks in the Orion AI&P operations reducing the overall touch labor manpower requirements. Additional benefits of using the Space Shuttle workforce is the incorporation of the lessons learned from Space Shuttle processes to improve the Orion TPS processes. This has resulted in a continuous evolution of TPS processes to improve the producibility and reduce the program cost for the TPS for the Orion program. Transitioning the Apollo and Space Shuttle TPS designs, processes, and technician workforce has been instrumental in enabling Orion to successfully meet the program challenges for NASA's exploration missions of the future.

Stewart, Michael↗

NASA NTRS2018

Orion Heat Shield Manufacturing Producibility Improvements for the EM-1 Flight Test Program

This paper describes how the ORION program is incorporating improvements in the heat shield design and manufacturing processes reducing programmatic risk and ensuring crew safety in support of NASA's Exploration missions. The approach for the EFT-1 heat shield utilized a low risk Apollo heritage design and manufacturing process using an Avcoat TPS ablator with a honeycomb substrate to provide a one piece heat shield to meet the mission re-entry heating environments. The EM-1 mission will have additional flight systems installed to fly to the moon and return to Earth. Heat shield design and producibility improvements have been incorporated in the EM-1 vehicle to meet deep space mission requirements. The design continues to use the Avcoat material, but in a block configuration to enable improvements in consistant and repeatable application processes using tile bonding experience developed on the Space Shuttle Transportation System Program.

Producibility↗

DOE OSTI2017

Interpreting Mobile and Handheld Air Sensor Readings in Relation to Air Quality Standards and Health Effect Reference Values: Tackling the Challenges

The US Environmental Protection Agency (EPA) and other federal agencies face a number of challenges in interpreting and reconciling short-duration (seconds to minutes) readings from mobile and handheld air sensors with the longer duration averages (hours to days) associated with the National Ambient Air Quality Standards (NAAQS) for the criteria pollutants-particulate matter (PM), ozone, carbon monoxide, lead, nitrogen oxides, and sulfur oxides. Similar issues are equally relevant to the hazardous air pollutants (HAPs) where chemical-specific health effect reference values are the best indicators of exposure limits; values which are often based on a lifetime of continuous exposure. A multi-agency, staff-level Air Sensors Health Group (ASHG) was convened in 2013. ASHG represents a multi-institutional collaboration of Federal agencies devoted to discovery and discussion of sensor technologies, interpretation of sensor data, defining the state of sensor-related science across each institution, and provides consultation on how sensors might effectively be used to meet a wide range of research and decision support needs. ASHG focuses on several fronts: improving the understanding of what hand-held sensor technologies may be able to deliver; communicating what hand-held sensor readings can provide to a number of audiences; the challenges of how to integrate data generated by multiple entities using new and unproven technologies; and defining best practices in communicating health-related messages to various audiences. This review summarizes the challenges, successes, and promising tools of those initial ASHG efforts and Federal agency progress on crafting similar products for use with other NAAQS pollutants and the HAPs.

54 ENVIRONMENTAL SCIENCES↗

NASA NTRS2017

Objective Assessment Method for RNAV STAR Adherence

Flight crews and air traffic controllers have reported many safety concerns regarding area navigation standard terminal arrival routes (RNAV STARs). Specifically, optimized profile descents (OPDs). However, our information sources to quantify these issues are limited to subjective reporting and time consuming case-by-case investigations. This work is a preliminary study into the objective performance of instrument procedures and provides a framework to track procedural concepts and assess design specifications. We created a tool and analysis methods for gauging aircraft adherence as it relates to RNAV STARs. This information is vital for comprehensive understanding of how our air traffic behaves. In this study, we mined the performance of 24 major US airports over the preceding three years. Overlaying 4D radar track data onto RNAV STAR routes provided a comparison between aircraft flight paths and the waypoint positions and altitude restrictions. NASA Ames Supercomputing resources were utilized to perform the data mining and processing. We assessed STARs by lateral transition path (full-lateral), vertical restrictions (full-lateral/full-vertical), and skipped waypoints (skips). In addition, we graphed frequencies of aircraft altitudes relative to the altitude restrictions. Full-lateral adherence was always greater than Full-lateral/ full- vertical, as it is a subset, but the difference between the rates was not consistent. Full-lateral/full-vertical adherence medians of the 2016 procedures ranged from 0% in KDEN (Denver) to 21% in KMEM (Memphis). Waypoint skips ranged from 0% to nearly 100% for specific waypoints. Altitudes restrictions were sometimes missed by systematic amounts in 1,000 ft. increments from the restriction, creating multi-modal distributions. Other times, altitude misses looked to be more normally distributed around the restriction. This tool may aid in providing acceptability metrics as well as risk assessment information.

Stewart, Michael↗

NASA NTRS2016

Understanding Current Safety Issues for Trajectory Based Operations

Increases in procedural complexity were investigated as a possible contributor to flight path deviations in airline operations. Understanding current operational issues and their causes must be embraced to maintain current safety standards while increasing future functionality. ASRS data and expert narratives were used to discover factors relating to pilot deviations. Our investigation pointed to ATC intervention, automation confusion, procedure design, and mixed equipment as primary issues. Future work will need to include objective data and mitigation strategies.

RNAV STAR↗

NASA NTRS1994

Field and data analysis studies related to the atmospheric environment

This report summarizes work on a broad array of projects including: (1) applications of meteorological and/or oceanographic satellites; (2) improvement of the current set of NASA/USAF lightning related launch commit criteria rules; (3) the design, building, testing and deployment of a set of cylindrical field mills for aircraft use; (4) the study of marginal electrification storm conditions in relationship to the current launch commit rules for the space shuttle and various other launch vehicles using an instrumented aircraft; (5) support of the DC-8 and ER-2 lightning instrument package as part of both the Tropical Ocean - Global Atmospheric/Coupled Ocean-Atmospheric Response Experiment and the Convection and Moisture Experiment; (6) design of electronic circuitry and microprocessor firmware for the NASA Advanced Ground Based Field Mill; (7) design and testing of electronic and computer instrumentation for atmospheric electricity measurements; (8) simulating observations from a lightning imaging sensor on the Tropical Rainfall Measuring satellite; and (9) supporting scientific visualization and the development of computer software tools.

Kidder, Stanley↗