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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 37 records · Page 2
All sourcesNASA NTRSDOE OSTI
NASA NTRS1998

Crawlers as Robotic Scanner Platform for Miniature NDT Instruments

The current use of aging aircraft significantly longer than their design life added a great degree of urgency to the ongoing need for low-cost, rapid, simple-to-operate, reliable and efficient NDE methods for detection and characterization of flaws.

aging aircraft NDE flaws field inspection eddy cur↗
DOE OSTI2019

R and DE Robotic Sensor Intern Team: Sensor Suite Mock Up Testing

Assess sensor suite performance: - Mounted on crawler typical to what would be used in tunnel; - In test bed simulating the tunnel environment. The SuperDroid fiber tethered LT-F crawler is a general-purpose surveillance robot that our team has refurbished as a testing platform for the sensor suite. This crawler was selected because its dimensions are similar to the actual crawler that will be deployed in the field. Crawler preparation included: - Communicating with vendor to resolve software and platform issues; - Configuring a laptop with the crawler control software; - Reconfiguration of communication protocol between computer and crawler; - Resolution of control board checksum errors; - Installation of a mounting fixture on the base; - In progress: addition of lighting needed for total darkness. A solution for hosting the selected sensors onto a single unit that could function standalone or be mounted on the crawler was needed. Sensor mount requirements included: - Host Lidar, panospheric cameras and IMU sensors; - Cable management for rotating Lidar; - House on-board crawler computer; - Method for affixing to crawler; - Robust and vibration proof. The Lidar sensor required a sturdy mount that ensured the axis of rotation be centered with the LiDAR's desired laser path and included a slender profile in order to not block the scanning FOV. The mounting plate holds two 180-degree cameras on either side and the servo on the center. The servo mount is located so the axis of rotation is in the center of the plate. The mount features a set of guides that hold the wires and ensure they wrap around the spool area properly. The sensor box design features thick walls for added strength, holes for mounting the sensor suite to the crawler, notches on the bottom for the different components and holes for cable routing and management. The sensor mounts were designed using CREO and printed in the R and DE Additive Manufacturing Lab. To test the performance of the sensor suite for our application it was desired to design and build a test bed simulating the H-Canyon tunnel environment. Requirements included: - Dimensions similar to the tunnel; - Wall surfaces simulating the eroded tunnel walls; - Complete darkness; - Even and uneven crawler path; - Ability to change the tunnel width to simulate erosion. The HCAEX tunnel changes in height and includes several bends ranging from approximately 30 to 80 degrees, for that reason a test bed capable of easily being changed was needed. The final design includes two sections that can be connected to provide a 16' tunnel or placed at an angle to create a tunnel bend. The test bed features caster wheels for easy movement and has a sliding inner wall that enables tunnel width to be controlled. In order to simulate the tunnel walls without adding a lot of weight to the test bed, sheets of faux stone are to be used on the inner walls. To create a completely dark tunnel, 100% black-out film will be draped over the tunnel structure. Carpet remnants in the lab will enable folds to be introduced in the floor to generate uneven surface data.

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DOE OSTI2018

H-Canyon Ventilation System Exhaust Tunnel Inspection at the Savannah River Site - 18052

The Department of Energy (DOE) H-Canyon Facility at the Savannah River Site (SRS) is operated by Savannah River Nuclear Solutions (SRNS). The Facility Structural Integrity Program (SIP) performs periodic visual inspections to confirm the component is capable of performing its safety function. This Program provides the process to document the conditions of safety related structural systems and components, their damage mechanisms, and recommend repairs if required before there is impact on the safety envelope. The H-Canyon Exhaust Tunnel is part of the H-Canyon Exhaust Ventilation System and is periodically inspected under the Structural Integrity Program. The Tunnel performs a Safety Class passive design feature function that is available 100% of the time. The Tunnel directs Canyon process air from the Canyon to the Sand Filter System. The radiological and chemical airborne activity coupled with the physical configuration of the tunnel precludes a manned entry into the tunnel. Tunnel inspections have been performed using cameras on a stick, referred to as pole cameras prior to CY2003. Since CY2003, five camera equipped crawlers have been used with varying levels of inspection success. With each successive crawler inspection, expectations have increased to perform tasks beyond visual examinations. The 2017 crawler performed the visual inspection but also included improvements on crawler performance, such as testing the use of wireless capability and remediation of crawler travel route, to the addition of stationary cameras and lighting at key locations. The latest 2017 crawler successfully traveled the entire length of the tunnel between the Canyon and Sand Filter System for the second time since development, thus providing key visual data for the integrity program [2]. In addition, several access ports were installed in 2017 following the removal of concrete core samples that allow for new visual inspection of the Canyon Crossover tunnel, thus providing information for an area that was generally inaccessible for monitoring. Planning for the 2019 crawler inspection is underway with the expectations to improve upon inspection cameras and also introduce mapping technologies such as LIDAR. The challenge to obtain meaningful data from the remote inspections of a 60+ year operating Canyon Exhaust tunnel continues to be a complex endeavor requiring close coordination of multiple organizations, adherence to Conduct of Operations, Radiological Safety, Worker Safety, etc. principles as well as alignment with Facility Safety Basis requirements. This paper discusses the continuing improvements in inspection techniques and the challenges associated these inspections. (authors)

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DOE OSTI2019

H-Canyon Tunnel Inspection System

Cable Analysis: The crawlers is controlled remotely via a long coax cable. In order to make sure we do not damage the cable which could cut our contact (data/power/control), we had to determine the bend radius of it at certain locations. This was done with dimensional analysis in Creo and inputting the information into a MATLAB program. Engineering Drawings: Since many of the crawlers parts, such as the main body, needed to be machined, part drawings were needed to communicate the details necessary for manufacture. Project Overview: The H-Canyon Ventilation Exhaust Tunnel due both to its long service history and exposure to aggressive process offgas chemistry has experienced degradation. In order to allow visual inspection of the condition of the radioactively-contaminated tunnel, a remote crawler was designed to deliver cameras as needed to return high definition video. My involvement included Vendor Searches, Cable Analysis, Thermal Analysis, and Engineering Drawings. Thermal Analysis: In order to see if internal active cooling is needed for the crawler, simplified thermal models were designed to approximate the internal temperatures: Conduction (assumes all heat sources are thermally-coupled to the crawler body); Convection (assumes no heat sources are thermally-bonded to crawler). Going Forward: Continue refining the cable analysis as the crawler model is updated and refined. Use my knowledge gained here to further my skills in engineering.

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DOE OSTI2025

Exploiting Trap Type and Color for Monitoring Macadamia Felted Coccid Acanthococcus ironsidei (Williams) and Associated Parasitic Wasps in Macadamia Orchards in Hawai’i

Acanthococcus ironsidei (Williams) (Hemiptera: Eriococcidae) is an invasive pest of macadamia, Macadamia integrifolia, in Hawai’i, causing death to macadamia trees and decreased nut productivity. Monitoring relies on wrapping double-sided sticky tapes over tree branches to trap dispersing crawlers (i.e., mobile immature stage), but this is tedious for growers, especially in large orchards. From September to November 2022 and December 2022 to February 2023, at two commercial macadamia orchards on Hawai’i Island, the use of colored sticky cards was assessed for improving the monitoring of A. ironsidei and to investigate the Hymenopteran parasitoid complex that inhabits macadamia canopies. At each study site, four different colored sticky cards (yellow, lime green, dark green, and white) were placed on the lower canopy of five trees, and on each tree, a transparent double-sided sticky tape was deployed. At bi-weekly intervals, the sticky cards were replaced and re-randomized on each tree, and the double-sided sticky tapes were replaced. The results showed that the sticky cards captured both A. ironsidei crawlers and (winged) male adults, while the double-sided sticky tapes captured only crawlers. The trap color did not have significant effects on the captures of A. ironsidei male adults at the sites, while the captures of crawlers on sticky cards were lowest on the dark green sticky traps at one site. The captures of A. ironsidei adult males on white sticky traps were generally correlated with the number of crawlers captured on the double-sided sticky tapes. The parasitoid complex captured had disparities in the attraction to color; however, the yellow, lime green and dark green colors were seemingly more effective for monitoring Encarsia lounsburyi (Berlese & Paoli), a reported parasitoid of A. ironsidei. These results have useful practical implications for improved monitoring of A. ironsidei crawlers, male adults and associated natural enemies.

Entomology↗
DOE OSTI2020

Inspection Tools for Hanford Tanks and Waste Transport Systems - 20444

Recent integrity issues in the double-shell tanks (DST) at Hanford have motivated the need for developing innovative tools that can provide information regarding the health of the tanks. These issues include the primary linear failure of AY-102 and recent concerns of thinning in the DST secondary liners. Other concerns include erosion or corrosion on transfer lines and processing pipes. In recent years, Florida International University (FIU) has supported DOE-EM by developing tools that can assist in understanding the health of tanks and waste transport system at Hanford. More specifically, FIU has developed a miniature rover that can be deployed through small risers and gain access to refractory slots in the Hanford DSTs. It traverses through the slots on the primary liner upside down via magnets to avoid debris in the slots. Recent modifications include a spring loaded magnetic arm that allows the unit to traverse over large weld seams but does not reduce the overall functionality of the system. The system has also incorporated a control capsule that will sit within the annulus of the tank and improves on issues related to signal and voltage loss over long tether lines. Lastly, the unit is also being augmented with a second module that will include a means to prep the tank surface and obtain a thickness measurement using a dual element ultrasonic sensor. FIU has also developed a 6-inch peristaltic pipe crawler that operates similar to the previous pipe crawlers developed at FIU. This crawler is a marsupial type crawler that will navigate through the 6-inch drain lines, and deploy a small rover at the entrance of the drain slots. This rover will also traverse upside down on the secondary liner and provide information regarding the health of the liner. An initial prototype for the crawler unit has been developed, assembled and tested. The system is pneumatic and consists of three modules - two grippers and one extender. The validation tests are conducted in a mockup of the drain lines and demonstrate the system's ability to navigate through long pipe lengths and elbows. In this paper, a general overview of each of the aforementioned systems is presented along with results from testing and demonstrations that shows the applicability of each system. (authors)

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DOE OSTI2020

Evaluation of H-Canyon Ventilation Exhaust Tunnel Inspection at the Savannah River Site - 20052

The Department of Energy (DOE) H-Canyon Facility at the Savannah River Site (SRS) is operated by Savannah River Nuclear Solutions (SRNS). The Facility Structural Integrity Program [1] provides a process to inspect, evaluate, and document the conditions of passive safety related structural systems and components, their degradation mechanisms and their impact on the safety envelope. The Structural Integrity Program performs periodic visual inspections to confirm the systems and components can perform their safety function and recommend corrective actions before the function is compromised. The H-Canyon Exhaust Tunnel is part of the H-Canyon Ventilation System and is periodically inspected under the Structural Integrity Program. The Tunnel performs a Safety Class passive design feature function that is available 100% of the time. The underground reinforced concrete Tunnel directs Canyon process air from the Canyon to the Sand Filter System. The radiological and chemical airborne activity coupled with the physical configuration of the tunnel precludes a manned entry into the tunnel to perform the inspection. Unlike active systems that can be subjected to physical testing to confirm capability, qualification calculations, including modeling, is performed to assess passive design feature capabilities relative to operational, accident and natural phenomena hazards events. Input for these calculations come from knowledge of field conditions, design drawings and conservative assumptions. The knowledge of field conditions comes from concrete and soil testing activities as well as inspection data. The use of cameras on crawlers to obtain inspection data and how that data is used in qualification calculations is the focus of this discussion. Remote Tunnel inspections have been performed using cameras on a stick, referred to as pole cameras, prior to Calendar Year 2003 (CY2003). Since CY2003, six camera equipped crawlers have been used. Crawlers have evolved and improved by incorporating lessons learned from the previous inspections. The latest 2019 crawler successfully traveled the entire length of the tunnel between the Canyon and Sand Filter System and captured images that were previously unseen, thus providing key visual data for the Structural Integrity Program report [2]. The inspection data serves as 1) input to qualification calculations, 2) validates current conditions remain bounded by qualification calculations, and 3) documents a record of change over time. This data is vital for the effective evaluation of the tunnel structure and aids with predicting the life cycle service life safety envelope to protect the public, environment, and facility worker. The goal of the 2019 deployment was to use a more robust vehicle to ensure travel over obstacles, perform the inspection with higher resolution cameras, and have the ability to elevate the cameras to view surfaces previously obscured by abandon-in-place ducts in the tunnel. The inspection information will serve to strengthen the input basis for qualification calculations, versus using excessive conservative calculation assumptions. This 2019 inspection was compared with previous crawler visual evidence to identify change over time to project remaining service life and confirm field conditions remain bounded by qualification calculations. The results of the 2019 Exhaust Tunnel inspection continue to improve and provide a firm basis to make sound engineering judgements regarding tunnel capability and approaches in projecting remaining service life with an aging system and component. (authors)

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DOE OSTI2021

Development of an Innovative Inspection Tool for Superheater Tubes in Fossil Fuel Power Plants

Fossil fuel power plants are complex systems containing multiple components that require periodic health monitoring. Failures in these systems can lead to increased downtime for the plant, reduction of power, and significant cost for repairs. Inspections of the plant’s superheater tubes are typically manual, laborious, and extremely time-consuming. This is due to their small diameter size (between 1.3 and 7.6 cm) and the coiled structure of the tubing. In addition, the tubes are often stacked close to each other, limiting access for external inspection. This paper presents the development and testing of an electrically powered pipe crawler that can navigate inside 5 cm diameter tubes and provide an assessment of their health. The crawler utilizes peristaltic motion within the tubes via interconnected modules for gripping and extending. The modular nature of the system allows it to traverse through straight sections and multiple 90° and 180° bends. Additional modules in the system include an ultrasonic sensor for tube thickness measurements, as well as environmental sensors, a light detecting and ranging (LiDAR) sensor, and camera. Furthermore, these modules utilize a gear system that allows for 360° rotation and provides a means to inspect the entire internal circumference of the tubes.

36 MATERIALS SCIENCE↗
NASA NTRSDate not supplied

Multidisciplinary Dynamic Testing Challenges in Validating the NASA Artemis Architecture

NASA is in the midst of bold and exciting next steps in human exploration and spaceflight. The designs of the new Space Launch System (SLS), the Orion spacecraft and the Exploration Ground Systems (EGS) for vehicle processing and launch are essentially complete and there has been significant progress in manufacturing and assembly of specific hardware for the Artemis I and Artemis II missions. Equally as important, the program level and integrated system level testing and analyses are also well underway to support integrated verification, validation, and certificate of flight readiness (CoFR) for the first Artemis mission. Testing and analysis are key to addressing technical challenges that the Artemis missions offer. Building block approaches are required that provide the right balance between component, system, and/or element level testing that satisfies verification and validation objectives and where, uncertainties are quantified and minimized. Artemis I is a system of systems that requires a fusion of test and analysis that adeptly characterizes critical interfaces between major program elements. NASA is implementing new in-situ testing that fuse traditional aerospace structures with civil structures, such as the Integrated Modal Test for the Artemis I vehicle where the Mobile Launcher and Crawler Transporter serve as a support structure whose dynamics couple with that of the Artemis I vehicle. This new paradigm requires a closer inspection of structural behavior of the Crawler Transporter and the Mobile Launcher as they now serve multiple purposes. This requires a paradigm shift to look beyond experimental modal techniques and incorporates operational modal analysis techniques to validate dynamic models from data collected during rollout to the launch pad. A further complicating factor is the Crawler Transporter generated ground forces have numerous harmonics making extracting dynamic responses of the Artemis I, Mobile Launcher, and Crawler Transporter coupled system challenging. This discussion explores all these challenges with and attempts to understand how we best build confidence in systems and system-of-systems performance capabilities and margins and understand uncertainties.

Joel W Sills↗
DOE OSTI2017

Development and Testing of Robotic Inspection Tools for the High-Level Waste Double Shell Tanks at Hanford - 17292

Florida International University (FIU) has been developing inspection tools that are capable of accessing the tank floors of double shell tanks through air supply lines and air refractory channels. This effort has led to the development of a pneumatic pipe crawler and a miniature rover. The miniature rover is a remote controlled vehicle with four wheels directly driven by independent micro DC motors.. The rover will have to navigate through channels as small as 3.81 cm by 3.81 cm, and includes turns with angles up to 90 deg.. To avoid debris, the device travels upside down, magnetically attached to the bottom of the primary tank. The pneumatic pipe crawler is a snake type robot with a modular design. The design is an evolution of previous peristaltic crawlers developed at FIU, and uses pneumatic actuators to emulate the contractions of the peristaltic movements. The inspection path consists of approximately 30 m of pipe (7.62 and 10.16 cm in diameter), reducers and several elbows. In this paper, engineering scale testing of the both systems is presented. Slight modifications have also been made to the designs, based on the testing, and are also explained. The engineering scale testing of the crawler includes approximately 30 m of piping that has the same lengths, dimensions and fittings as the air supply line of AY-102. The primary difference is that that actual line has a number of sections that are vertical. Testing of the miniature rover has included a test-bed manufactured with brick pavers, providing more realistic coefficients of friction between the tether and the channel. Efforts to reduce the load induced when the tether is in contact with a corner in the refractory channel will also be provided. (authors)

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DOE OSTI2018

Hanford Double Shell Tank Integrity Inspection - Integration of Customized Robotics - 18400

28 steel, double-shell, million gallon waste storage tanks located at the Hanford site in Washington State store both radioactive and hazardous waste. To monitor their condition and ensure continued viability, these tanks are inspected periodically through a comprehensive integrity program. In 2012, the first leak in a double-shell tank at Hanford was discovered in the 241-AY tank farm (Tank AY-102) and the failure was observed to be from the primary tank bottom. However, the exact failure location and damage mechanism have not been determined. A decision was made to pursue the capability to inspect the primary tank bottom region in order to provide additional tank integrity information. This work is particularly challenging due to the confined space in the double-shell tank annulus region (i.e. the 30 inch space between the primary and secondary tank shells), the limited dimensions of the tank risers that provide access to the annulus space (risers as small as 10 inches in diameter), and also the very small dimensions of the air channels in the concrete refractory pad that the primary waste storage tank rests on (channels are approximately two inches in diameter). Veolia Nuclear Solutions, along with Key Subcontractor Inuktun, were contracted to provide the capability to conduct these tank inspections in support of Hanford's double-shell tank integrity program. The Veolia Nuclear Solutions /Inuktun team designed, built, tested and delivered a tethered miniature robotic crawler system that utilizes the marsupial approach - a larger deployment crawler positions a smaller inspection crawler. The deployment crawler is installed via the tank riser, is magnetically coupled to the side of the tank shell, and drives to the selected deployment location at the end of one of the refractory channels where the small inspection robot is subsequently deployed. Operation of the equipment is controlled from a trailer outside the tank farm (a distance of several hundred feet). The system design includes a custom mechanism that provides for positioning and cable handling as well as the controls interface (laptop connected via control cables). The solution leveraged the Veolia Nuclear Solutions/Inuktun team's experience with delivering similar modular systems for other US and international sites. This simple but innovative solution delivered on an accelerated project schedule underlines the ability to provide effective robotic solutions to the nuclear industry. (authors)

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