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Oversimplification of Systems Engineering Goals, Processes, and Criteria in NASA Space Life Support

This paper investigates the oversimplification of the inherently complex systems engineering process in space life support. The standard systems engineering process steps are described. The International Space Station (ISS) life support system is explained with its goals and performance criteria. Although it is not usually emphasized, the essential function of developing a hierarchy of systems and subsystems is to simplify the design process. The System Complexity Metric (SCM) shows how this di-vide-and-conquer approach also reduces the system complexity. The complete systems engineering process has many detailed steps. It is often simplified because of the effort required and the human limitations on working memory and decision span. Systems analysis demands slow, logical, and fo-cused thinking but is often bypassed in favor of quick, intuitive, subconscious “gut feel.” A study of 100 system designs found examples of 12 specific mental mistakes, such as ignoring stakeholder needs, and these mistakes are essentially oversimplifications of the systems engineering process. An analysis of space life support goals, options, criteria, and processes found 11 examples of oversimplifications in systems engineering, such as neglecting safety and cost. All these 11 oversimplifications could be traced to one or more of the 12 previously identified mental mistakes or other well-known ones, such as ig-noring sunk costs. Oversimplification of the systems engineering process is rarely noticed but is a common and harmful problem. A study of failures in 50 different space systems found that problems in systems engineering caused failures and often led to errors in design, development, and test that further contributed to failure. It seems that more diligent systems engineering could prevent many project problems and failures, but projects seem to be more guided by “gut feel” based on tradition, authority, and consensus than on the logical, rational systems engineering approach.

Simplified systems engineering↗

NASA NTRS2022

National Campaign (NC)-1 Strategic Conflict Management Simulation (X4) Final Report

Urban Air Mobility (UAM) enables highly automated, cooperative, passenger or cargo-carrying air transportation services in and around urban areas. UAM is a subset of the Advanced Air Mobility (AAM) concept under development by the National Aeronautics and Space Administration (NASA), the Federal Aviation Administration (FAA), and industry. The Strategic Conflict Management (SCM) Simulation, dubbed “X4”, was conducted between July 2021 and June 2022 by NASA with the FAA and industry to evolve the Provider of Services for UAM (PSU) that will be needed to ensure initial UAM operations can scale in the National Airspace System (NAS). The FAA UAM Concept of Operations (ConOps) v1 [1] served as an initial guiding document for the X4 airspace management system design to ensure the architecture supports testing of services provided by third-party service providers. To that end, the X4 architecture leveraged concepts and technologies developed for Unmanned Aircraft System (UAS) Traffic Management (UTM) while also developing and testing new capabilities and services needed for UAM. The architecture included an initial prototype of the FAA-Industry Exchange Protocol (FIDXP), third-party services such as the PSUs, and Discovery and Synchronization Service (DSS), and other new services such as Demand-Capacity Balancing (DCB) to facilitate UAM strategic conflict management. During X4, NASA led discussions and collaborated with seven industry airspace partners to develop initial airspace management concepts for UAM that drove what would be tested and evaluated during the simulations. The initial capabilities defined for PSU leveraged UTM UAS Service Supplier (USS) as a starting point and evolved to meet UAM requirements. These discussions were also an opportunity for NASA to collaborate with industry to develop a set of initial Community-Based Rules (CBRs). These CBRs enabled how UAM traffic would be cooperatively managed among UAM operators. The collaborative, iterative process of developing CBRs with industry during X4 provided insight into the challenges involved and identified the need for a suitable and effective forum for future CBR development. In parallel with these discussions, NASA conducted a series of seven software sprints and two collaborative simulations with the airspace partners that built up in complexity. Over the course of the year, all seven partners successfully completed all the sprints by demonstrating the required capabilities. They also participated in the two collaborative simulations to demonstrate how multiple PSUs could work together in a collaborative, more complex environment with higher traffic density. The X4 simulation accomplished NASA's objectives and helped advance the development of the seven participating PSUs. The lessons learned provided insight into key elements of the UAM Notional Architecture from the FAA ConOps v1 [1] and UTM technologies when applied to UAM: - Having a Concept of Use (ConUse) defined prior to the activity would accelerate the time and effort from concept development to testing. - While the UAM Notional Architecture provided a starting point for a federated architecture that support services provided by third-party providers, the USS and PSU differed in their capability definitions for operational intent submission and sharing, conformance monitoring, airspace authorization, strategic conflict management, airspace constraints and dynamic replanning. - While existing DSS developed for UTM provided a way for PSU and other UAM services (such as DCB) to discover relevant operations from each other, additional complexity and challenges were found during X4 testing and illuminated the need for a more suitable solution for UAM. Industry can leverage the results of this demonstration to accelerate UAM requirements, CBRs, and standards development. The FAA and other government municipalities and agencies will be able to leverage results to inform future policies and identify additional gaps that require further analysis, moving toward operationalization of UAM.

Urban Air Mobility↗

DOE OSTI2023

EVs@Scale Next-Gen Profiles - EV Profile Capture 2023

As part of the U.S. DOE EVs@Scale consortium Next-Gen Profiles (NGP) project, the profile capture of production electric vehicles undergoing high power charging (HPC) is conducted over a wide range of conditions to explore variance and performance. Charge session parameters are collected from both the electric vehicle (EV) and electric vehicle supply equipment (EVSE) at a rate of 10Hz and entered into a time-series database for analysis. These charge profiles are captured under nominal and off-nominal conditions, exploring the impact of battery state of charge (SOC), battery temperature, vehicle condition, smart charge management (SCM), and EVSE limitations. Nominal conditions are defined to be ideal conditions that should transfer the maximum allowable energy in the minimum possible amount of time. Nominal condition profiles are compared across EVs to characterize state-of-the-art EV charging performance against one another. Off-nominal condition profiles are compared against its nominal condition profile counterpart to highlight the variance across less desirable starting conditions within a single EV. Under nominal conditions, most EVs can achieve the original equipment manufacturer (OEM) rated peak-power and charge times. Peak power across EVs has variance due to the vehicle design, battery topology, charging strategy, etc. These 10-100% nominal preconditioned charge profiles across 13 EVs (11 light-duty (LD), 2 heavy-duty (HD)) were used for analysis in power curve analysis, power distribution, SOC and range comparison, thermal impacts of current draw, battery pack size and energy charged, and ramp rates. Power curve analysis show the uniqueness in power vs time curves across all EVs, breaking down the features of a typical profile and where variation is typically seen. Power distribution results showed that over 50% of charge time is spent below 50kW and only 12.1% is spent above 200kW. SOC and range performance yielded different top performing EVs when exploring goals of performance from SOC and range gained after 10-min (EV2) and 20-min (EV8), and time-to-achieve 80% SOC (EV8) and 200 miles of range (EV1). Current draw from 400-volt EVs had a higher thermal impact to cable/connector temperatures when compared to 800-volt EVs, due to a higher current requirement to achieve similar power levels. There was high variance in C rating, a useful metric when comparing the relationship between peak/average charge session power and relative battery pack size, across EVs under test. Ramp rates during initial power transfer were examined, fastest and slowest speeds ranging from 192.5kW/second to 2.6kW/second respectively. A similar analysis of ramp rates was also conducted for OCPP curtailment testing, where EVs underwent a 2-minute 65A curtailment request before returning to full-power charge. Under off-nominal conditions, most EVs experienced variation from the nominal condition profiles. EVs that underwent the full set of NGP defined testing conditions were compared, analysis of which was categorized by 800-volt and 400-volt EVs. It should be noted that the 800-volt EVs had significantly higher peak power ratings than the 400-volt EVs, and thus were more prone to variance. Initial state of charge, battery temperature, and vehicle condition had a considerable impact on peak power levels and charge time for the 800-volt vehicles under test. EVSE limited tests lowered achievable power down to 200kW, greatly impacted 800-volt charging power, and had little to no effect on 400-volt charging power. Adapter testing was performed on a single 400-volt EV, where power and current limitations were found but overall charge time was not significantly impacted. Adapter and boost converter testing was performed on a single 800-volt EV, where both charge power and charge time were greatly impacted. Charge profiles are unique, and comparing such requires analysis that examines starting conditions, vehicle and battery topologies,

Charging↗

DOE OSTI2024

Flexible Charging to Unify the Grid and Transportation Sectors for EVs at Scale (FUSE)

Electric vehicle (EV) adoption will expand beyond light-duty vehicles charging at lower-power public locations and family residences to include medium- and heavy-duty applications with more powerful charging at public stations and private depots. The Vehicle Grid Integration (VGI) and Smart Charge Management (SCM) pillar in EVs@Scale supports multiple projects. The FUSE project is developing and evaluating enabling technologies, charging solutions, and infrastructure design approaches to investigate the intricacies and potential benefits of vehicle grid integration and the application of smart charge management to charging of electric vehicles at scale. This presentation summarizes the findings of this research in 2024.

ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2024

EVs@Scale FUSE Fall '24 Deep Dive

ADVANCED PROPULSION SYSTEMS,DIRECT ENERGY CONVERSI↗

DOE OSTI2025

EVs@Scale Next-Gen Profiles - EV Profile Capture 2024

As part of the U.S. DOE EVs@Scale consortium Next-Gen Profiles (NGP) project, the profile capture and analysis of production electric vehicles undergoing high power charging (HPC) is conducted over a wide range of conditions to explore variance and performance. Charge session parameters are collected from both the electric vehicle (EV) and electric vehicle supply equipment (EVSE) at a rate of 10Hz and entered into a time-series database for analysis. These charge profiles are captured under nominal and off-nominal conditions, exploring the impact of battery state of charge (SOC), battery temperature, vehicle condition, smart charge management (SCM), and EVSE limitations. Nominal conditions are defined to be ideal conditions that should transfer the maximum allowable energy in the minimum possible amount of time. Nominal condition profiles are compared across EVs to characterize state-of-the-art EV charging performance against one another. Off-nominal condition profiles are compared against its nominal condition profile counterpart to highlight the variance across less desirable starting conditions within a single EV. This EV Profile Capture 2024 report stands as an update from the EV Profile Capture 2023 report to include the additional EV & EVSE assets tested and analyzed in 2024. The major updates within this report include the addition of three next-generation electric vehicles, added test cases, and further analysis. This expansion of analysis includes power profiles, power distribution, quantifying SOC, energy and range performance, EVSE limitation impacts, boost converter performance, etc. Additionally, NGP time-series data has been used as input towards three national laboratory-led grid modelling efforts: ANL’s IEEE-37 HIL model, INL’s Caldera model, and NREL’s EVI-X model. A summary of these platforms and how NGP has worked to improve their effectiveness has also been added to this years’ report.

Thurston, Sam↗

DOE OSTI2025

Dehydroxylation kinetics of kaolinite and montmorillonite examined using isoconversional methods

The use of calcined clays as supplementary cementitious materials (SCMs) in concrete is a promising strategy towards decarbonizing the cement and concrete industry. This is especially relevant considering the ever-increasing demand for concrete. Comprehensive understanding of the kinetics of calcination is essential towards maximizing the potential reactivity of clay minerals while ensuring energy efficiency. In this study, the kinetics of the dehydroxylation of kaolinite and montmorillonite are investigated under non-isothermal conditions at constant heating rate. Activation energies ( E a ) are determined via Friedman differential and advanced Vyazovkin incremental methods over the isoconversional range; these are devoid of computational approximations, thus allowing kinetic analysis without assuming a specific reaction model. Kinetic equations—in the differential form as well as a combination of differential and integral forms are compared against the experimentally determined reaction models to identify the most probable dehydroxylation mechanism for kaolinite and montmorillonite. A reaction order mechanism is established for dehydroxylation of kaolinite, while montmorillonite is noted to undergo dehydroxylation via a single-step reversible diffusion-controlled process. Kinetic triplet—comprising activation energy, reaction model and pre-exponential factor—is used to predict isothermal calcination conditions, which is further verified using analytical techniques. Heat release rates of clay-portlandite blends from isothermal calorimetry are used within a thermodynamic framework to quantify reactivity of the calcined clays. Here, the study demonstrates a general approach based on isoconversional methods to predict calcination conditions for different clays that can be used in efficient and optimized production of blended cements or SCMs.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Validation of MOOSE’s subchannel module using the AREVA FCTF heated bundle benchmark

Not Available

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2026

Modeling Flow in a Microreactor Core: From High-Fidelity CFD to Subchannel Analysis

The accurate prediction of pressure drop in tightly packed, low–Reynolds number (Re) bare rod bundles is essential for the thermal-hydraulic design of the Microreactor Applications Research Validation and EvaLuation (MARVEL) reactor and other microreactor concepts. However, existing friction factor correlations, particularly the upgraded Cheng-Todreas (UCTD) correlation, have limited validation for the small pitch-to-diameter ratios (P/Ds) and transitional flow conditions characteristic of these systems. In this work, we perform high-fidelity large-eddy simulations (LESs) of both an infinite bare rod bundle and a finite bare 37-pin scalloped rod bundle across the range 1000≤ 𝑅𝑒 ≤5500. The simulations reveal strong gap vortex–driven transitional behavior and indicate that the UCTD may underpredict the friction factor by up to 28% at 𝑃/𝐷 = 1.05. Using the LES-calculated pressure drops, we formulate a new friction factor correlation that follows the Cheng-Todreas functional form but is calibrated for low-Re and tightly packed geometries representative of a MARVEL-like reactor. The correlation is implemented in the MOOSE (Multiphysics Object-Oriented Simulation Environment) subchannel module and compared against both the LES and UCTD predictions. Across all subchannel types, the proposed model reduces the streamwise velocity differences from as high as 44% (UCTD) to below 9%, and decreases the pressure gradient differences from 13% to 25% (UCTD) to 0.7% to 7% relative to the LES results. These results suggest that the new correlation has the potential to improve the pressure drop and flow field predictions for such geometries, highlighting the importance of high-fidelity simulations in supporting microreactor thermal-hydraulic model development and motivating future pressure drop experiments for compact rod bundles to further validate these findings.

21 - SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLAN↗

DOE OSTI2024

Understanding Processes Controlling the Temporal and Spatial Variations of PBL Structures Over the ARM SGP Site

The surface heat, moisture, and momentum fluxes are transferred to the atmosphere above through the planetary boundary layer (PBL), where vertical mixing due to turbulent eddies of different sizes plays critical roles. Therefore, reliably representing PBL processes in numerical models is critical for weather, climate, and air quality prediction. Currently, there are over ten PBL schemes that are selectable within the advanced research version of the Weather Research and Forecasting (WRF) model, indicative of the challenges in capturing the impacts of turbulence within the PBL in models. Further improvements in PBL parameterizations are needed for both weather and climate models, as emphasized in many recent national reports, but require an advanced understanding of the underlying boundary layer processes from observations. This project takes advantage of Department of Energy (DOE) Atmospheric Radiation Measurement (ARM) investments in the atmospheric boundary layer observations and Large-Eddy Simulation (LES) ARM Symbiotic Simulation and Observation (LASSO) simulations to characterize PBL structures, understand key physical processes controlling the mixed layer development, and to evaluate PBL parameterization.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2023

Electrification 2022 Annual Progress Report

The Electric Drive Technologies (EDT) program's mission is to conduct early-stage research and development on transportation electrification technologies that accelerate the development of cost-effective and compact electric traction drive systems that meet or exceed performance and reliability requirements of internal combustion engine (ICE)-based vehicles, thereby enabling electrification across all light-duty vehicle types. The Grid and Charging Infrastructure (G&I) program's mission is to conduct early-stage research and development on transportation electrification technologies that enable reduced petroleum consumption by light, medium, and heavy-duty vehicles. The program identifies and enables the role of vehicles in the future electrical grid.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2023

Advancing Federal Infrastructure Through Innovation: Selecting Electric Vehicle Charging Infrastructure Wisely

The Biden Administration's issuance of Executive Orders directly addressing and accelerating Federal fleet electrification places an onus on both fleet and facility managers. This panel will help fleet and facility personnel understand how to select EVSE infrastructure in terms of implementation, energy management, and costs of procurement, installation/deployment, and electricity. The panel will cover technology aspects to include managed EVSE, bi-directional charging, implications on local electrical systems and storage needs in certain cases to buffer power demand. Discussion will include various considerations relevant to ensuring adequate EVSE, balancing infrastructure needs, and upgrades with fleet needs. The panelists will discuss how to provide sufficient infrastructure support, including which stakeholders to involve, procurement impediments, easement locations, and requirements that arise during the design and implementation process.

ADVANCED PROPULSION SYSTEMS,ENERGY PLANNING, POLIC↗

DOE OSTI2025

Smart Charge Management

This session will discuss "on-board" electric vehicle (EV) technology, its availability, and benefits. Learn about how these tools can empower agencies to further adopt EVs and aid in fleet electrification efforts. We will explore the evolving advancements of managed charging, available telematics, on-board technology and how to incorporate them into your overall EV adoption strategy. Furthermore, we'll discuss what to expect in the near future; and how to future proof your investments to make the technology work for you.

ADVANCED PROPULSION SYSTEMS,ENGINEERING↗