Control technology applied to production problems
Computer process control applications with emphasis on oil and chemical industries
Foster, C. V.↗
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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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Optimal Discounted Stochastic Control for Diffusion Processes
Optimal cost discounted stochastic control for diffusion processes
Kushner, H. J.↗
Statistical porcess control in Deep Space Network operation
This report describes how the Deep Space Mission System (DSMS) Operations Program Office at the Jet Propulsion Laboratory's (EL) uses Statistical Process Control (SPC) to monitor performance and evaluate initiatives for improving processes on the National Aeronautics and Space Administration's (NASA) Deep Space Network (DSN).
Deep Space Network operations statistical process ↗
Myna: Connecting powder bed fusion build data to simulation tools for digital twin applications
Additive manufacturing (AM), as a digital process, can generate a detailed digital thread linking a part’s design and manufacturing to its operational performance. As AM systems advance, an increasing amount of process data is stored in manufacturing databases. In principle, this data can be utilized by simulation-based digital twin approaches, such as real-time process control and asynchronous post-processing guidance. However, few tools currently exist for systematically integrating digital thread data with computational tools. Here, in this study, we propose a software package, called Myna, for connecting data from powder bed fusion processes to simulation tools. The utility of such a platform is demonstrated using build data from the Oak Ridge National Laboratory Manufacturing Demonstration Facility “Peregrine v2023-10” public dataset to automatically configure and run 54 semi-analytical 3DThesis melt pool simulations, 78 numerical Additive FOAM melt pool simulations, and 3 ExaCA microstructure simulations. The simulated, spatially registered microstructures are then compared directly with electron backscatter diffraction characterization of the corresponding as-built part locations. The resulting simulated microstructure showed variation as a function of process parameters, particularly stripe width; however, the experimental data had little variation between the microstructure texture and grain size resulting from different processing conditions. Analysis of the discrepancies suggest that it is possible a two-phase ferritic-austenitic solidification model is needed to accurately predict grain size and texture for certain stainless steel 316L feedstock compositions under powder bed fusion conditions, providing direction for future research. As illustrated here, due to the number and complexity of the simulations involved in AM process-structure–property predictions, automated methods to connect process data and simulations will remain necessary tools for testing hypotheses and implementing digital twin applications.
Knapp, Gerald L. [Oak Ridge National Laboratory (O↗
Multilevel Analysis of Electrochemically Mediated Methanolysis of Poly(ethylene terephthalate) (PET)
Here, this study presents a multilevel analysis of electrochemically mediated methanolysis as a promising method for reducing the environmental impacts of plastic recycling, with a focus on depolymerizing poly(ethylene terephthalate) (PET) into dimethyl terephthalate (DMT). Instead of conventional chemical PET depolymerization, this electrochemical approach provides distinct technical advantages in process control and efficiency. At the process level, key operational parameters, including applied current and reaction time, were systematically investigated to optimize PET conversion and DMT selectivity. The electrochemical approach was directly compared to equivalent chemical methanolysis systems and demonstrated superior performance in terms of PET conversion and DMT selectivity. Building on these findings, a technoeconomic assessment identified the current economic bottlenecks and revealed that improvements in process design, DMT selectivity, PET conversion, and energy efficiency are key to reducing the overall process cost and enabling future implementation. While further optimization is required for market competitiveness, these results establish a performance baseline for the electrochemically mediated PET methanolysis process and underscore the importance of combining process-level innovation with systems-level evaluation in the development of sustainable recycling technologies.
chemical recycling↗
Software Control Program For Transportable Microgrid State-of-charge Balancing And Frequency Stability Controls
A deterministic state-of-charge (SOC) balancing approach software control code is introduced as an integral secondary management to primary control layer of an islanded small microgrid or nanogrid system made up of multiple grid-forming inverter/battery/solar combination systems, where each set of batteries with each inverter are on independent DC buses (i.e. non-paralleled on the DC sides). A DERMS-level control approach, algorithm and automation controller program was developed to improve coordination and enable microgrid asset compliance and SOC balancing, enabling provision of a system-level power stability support architecture, load support, and asset scalability. The architecture is configured to treat each unit or micro/nano-grid as a node in a microgrid network, allowing for autonomous DERMS control regarding load and SOC balancing and power stability. As the network grows with the addition of units, greater coordination efforts may be required. The ideal small network microgrid ranges from 2-10 inverter/battery units before additional control parameters must be considered in the existing architecture. The control approach focuses on a deterministic state-of-charge analysis as the primary level control process followed by a secondary control loop using a forced frequency-watt droop strategy to conform off-the-shelf components into behaving under a leader-follower configuration. Adopting this control scheme has been shown to allow for a balanced, unit-coordinated microgrid network, enabling stable power flow. The deterministic state-of-charge approach is introduced as an integral primary control layer of an islanded small network microgrid. A standard strategy for SOC balancing is implementing a battery management system (BMS) to control SOC on the DC side. An alternative approach is to determine how to coordinate sending and receiving power on the AC side with multiple units. The latter approach assesses all the integrated units in the microgrid network. Once the individual units are identified, further system data is required to calculate each unit's total kWh, provided information about its capability to supply or consume kWh and availability. The secondary control layer in the multi-layered small network microgrid methodology uses the primary layer’s decision to initiate frequency setpoint changes, initializing the SOC balancing. The secondary control layer considers numerous system-dependent variables to enable a charging and discharging profile based on adjustable frequency setpoints. The combined architecture will result in stable, coordinated power flow enhancing an AC microgrid's functionalities.
Myers, KurtS [Idaho National Laboratory (INL), Ida↗
The comparative weldability of refractory metal alloys.
Refractory metal alloys rating on basis of weldability emphasizing metallurgical considerations, taking into account process control and welding as thermal process
REFRACTORY ALLOY↗
An automated oxide and diffusion facility for IC's
Report discusses totally-automated oxidation and diffusion facility for fabricating IC's. Several innovations are demonstrated: process controller specifically designed for semiconductor processing; automatic loading system to accept wafers from air track, insert them in quartz carrier, and place carrier on paddle for insertion into furnace; automatic unloading of wafers back onto air track; and boron diffusion using diborane.
Kennedy, B. W.↗
The Effect of Entrainment Through Atmospheric Boundary Layer Growth on Observed and Modeled Surface Ozone in the Colorado Front Range
Ozone concentrations at the Earth's surface are controlled by meteorological and chemical processes and are a function of advection, entrainment, deposition, and net chemical production/loss. The relative contributions of these processes vary in time and space. Understanding the relative importance of these processes controlling surface ozone concentrations is an essential component for designing effective regulatory strategies. Here we focus on the diurnal cycle of entrainment through atmospheric boundary layer (ABL) growth in the Colorado Front Range. Aircraft soundings and surface observations collected in July/August 2014 during the DISCOVER-AQ/FRAPPÉ (Deriving Information on Surface conditions from Column and Vertically Resolved Observations Relevant to Air Quality/Front Range Air Pollution and Photochemistry Éxperiment) campaigns and equivalent data simulated by a regional chemical transport model are analyzed. Entrainment through ABL growth is most important in the early morning, fumigating the surface at a rate of ~5 ppbv/h. The fumigation effect weakens near noon and changes sign to become a small dilution effect in the afternoon on the order of -1 ppbv/h. The chemical transport model WRF-Chem (Weather Research and Forecasting Model with chemistry) underestimates ozone at all altitudes during this study on the order of 10-15 ppbv. The entrainment through ABL growth is overestimated by the model in the order of 0.6-0.8 ppbv/h. This results from differences in boundary layer growth in the morning and ozone concentration jump across the ABL top in the afternoon. This implicates stronger modeled fumigation in the morning and weaker modeled dilution after 11:00 LT.
Entrainment through ABL Growth↗
Application of programmable logic controllers to space simulation
Incorporating a state-of-the-art process control and instrumentation system into a complex system for thermal vacuum testing is discussed. The challenge was to connect several independent control systems provided by various vendors to a supervisory computer. This combination will sequentially control and monitor the process, collect the data, and transmit it to color a graphic system for subsequent manipulation. The vacuum system upgrade included: replacement of seventeen diffusion pumps with eight cryogenic pumps and one turbomolecular pump, replacing a relay based control system, replacing vacuum instrumentation, and upgrading the data acquisition system.
Sushon, Janet↗
Recent Advances in LIBS for Real-Time Detection of Silicone Contaminants on CFRP Surfaces
Laser induced breakdown spectroscopy (LIBS) is a materials characterization technique that has been advanced and refined to provide in situ, real-time quality control of carbon fiber reinforced polymer (CFRP) surfaces. As part of an effort to improve process control for adhesive bonding, a LIBS system was designed and assembled at NASA Langley Research Center (LaRC) to enable detection of ultralow concentrations of silicone contamination on CFRP adherends. The LIBS instrument provides high sensitivity detection and quasi-nondestructive surface characterization of CFRP adherends prior to adhesive bonding. This review focuses on the advancements at LaRC using LIBS as a quality control tool for the detection of silicone contaminants for improved adhesive bonding reliability of CFRP materials. This work describes how the LIBS technique was advanced by analyzing the laser parameters, studying the laser-matter interactions, and performing time-resolved measurements to determine the optimal plasma conditions for elemental detection. In addition, LIBS results were compared to X-ray photoelectron spectroscopy data to enable quantitative analysis from analytical calibration curves. Examples are shown of how to perform surface mapping of silicone contamination. Finally, a brief discussion is also presented on LIBS instrumentation, recommendations for laser parameters and instrumentation components, and LIBS technique maturity.
Surface characterization, Carbon fiber reinforced ↗
Test Capability Enhancements to the NASA Langley 8-Foot High Temperature Tunnel
The NASA Langley 8-Foot High Temperature Tunnel produces true enthalpy environments simulating flight from Mach 4 to Mach 7, primarily for airbreathing propulsion and aerothermal/thermo-structural testing. Flow conditions are achieved through a methane-air heater and nozzles producing aerodynamic Mach numbers of 4, 5 or 7 and have exit diameters of 8 feet or 4.5 feet. The 12-ft long free-jet test section, housed inside a 26-ft vacuum sphere, accommodates large test articles. Recently, the facility underwent significant upgrades to support hydrocarbon fueled scramjet engine testing and to expand flight simulation capability. The upgrades were required to meet engine system development and flight clearance verification requirements originally defined by the joint NASA-Air Force X-43C Hypersonic Flight Demonstrator Project and now the Air Force X-51A Program. Enhancements to the 8-Ft. HTT were made in four areas: 1) hydrocarbon fuel delivery; 2) flight simulation capability; 3) controls and communication; and 4) data acquisition/processing. The upgrades include the addition of systems to supply ethylene and liquid JP-7 to test articles; a Mach 5 nozzle with dynamic pressure simulation capability up to 3200 psf, the addition of a real-time model angle-of-attack system; a new programmable logic controller sub-system to improve process controls and communication with model controls; the addition of MIL-STD-1553B and high speed data acquisition systems and a classified data processing environment. These additions represent a significant increase to the already unique test capability and flexibility of the facility, and complement the existing array of test support hardware such as a model injection system, radiant heaters, six-component force measurement system, and optical flow field visualization hardware. The new systems support complex test programs that require sophisticated test sequences and precise management of process fluids. Furthermore, the new systems, such as the real-time angle of attack system and the new programmable logic controller enhance the test efficiency of the facility. The motivation for the upgrades and the expanded capabilities is described here.
Harvin, S. F.↗
Automated Subsystem Control for Life Support System (ASCLSS)
The Automated Subsystem Control for Life Support Systems (ASCLSS) program has successfully developed and demonstrated a generic approach to the automation and control of space station subsystems. The automation system features a hierarchical and distributed real-time control architecture which places maximum controls authority at the lowest or process control level which enhances system autonomy. The ASCLSS demonstration system pioneered many automation and control concepts currently being considered in the space station data management system (DMS). Heavy emphasis is placed on controls hardware and software commonality implemented in accepted standards. The approach demonstrates successfully the application of real-time process and accountability with the subsystem or process developer. The ASCLSS system completely automates a space station subsystem (air revitalization group of the ASCLSS) which moves the crew/operator into a role of supervisory control authority. The ASCLSS program developed over 50 lessons learned which will aide future space station developers in the area of automation and controls..
Block, Roger F.↗
Designing for Small Volume Assembly of Advanced Electronics Packages
We describe a general methodology to Design for Producibility and Reliability (DFPAR) for very small volume production runs. In cases where the entire volume for fabrication is less than five products, traditional Statistical Process Control (SPC) is inadequate due to reliance on statistics of much larger volumes and the Central Limit Theorem. Data acquisition for process parameter estimation from such a small sample size is difficult; however, it is critical to producing high reliability product.
Central Limit Theorem statistics high reliability ↗
Welding process modelling and control
The research and analysis performed, and software developed, and hardware/software recommendations made during 1992 in development of the PC-based data acquisition system for support of Welding Process Modeling and Control is reported. A need was identified by the Metals Processing Branch of NASA Marshall Space Flight Center, for a mobile data aquisition and analysis system, customized for welding measurement and calibration. Several hardware configurations were evaluated and a PC-based system was chosen. The Welding Measurement System (WMS) is a dedicated instrument, strictly for the use of data aquisition and analysis. Although the WMS supports many of the functions associated with the process control, it is not the intention for this system to be used for welding process control.
Romine, Peter L.↗
ON THE UNIQUENESS OF TIME-OPTIMAL CONTROL FOR LINEAR PROCESSES
Uniqueness of time-optimal control for linear processes
LINEAR SYSTEM↗
Intelligent Processing Equipment Projects at DLA
The Defense Logistics Agency is successfully incorporating Intelligent Processing Equipment (IPE) into each of its Manufacturing Technology thrust areas. Several IPE applications are addressed in the manufacturing of two 'soldier support' items: combat rations and military apparel. In combat rations, in-line sensors for food processing are being developed or modified from other industries. In addition, many process controls are being automated to achieve better quality and to gain higher use (soldier) acceptance. IPE applications in military apparel include: in-process quality controls for identification of sewing defects, use of robots in the manufacture of shirt collars, and automated handling of garments for pressing.
Obrien, Donald F.↗
Dynamic Model of a supercritical CO2 10MW Recompression Closed Brayton Cycle
This model of the 10MW recompression closed Brayton cycle (RCBC) was developed in conjunction with the DOE’s Supercritical Transformational Electric Power (STEP) project. A high-fidelity dynamic model was used extensively to study the dynamic characteristics of the cycle and develop the process control architecture and strategies for start-up and shutdown procedures. This version of the model has been simplified from the original version to be more accessible for a variety of applications and research. The controllers developed for the original model have been maintained for this version and tuned to give a similar performance to the original model. This model can be used to perform similar studies as those performed in Liese et al (2020). The overall cycle performance will not be identical but will perform similarly.
Controls,Power Cycles,Process Systems Engineering,↗