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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
DOE OSTI2023

Physically-based control-oriented modeling for turbocharged stoichiometric spark-ignited engine with cooled EGR and flexible VVT systems

Accurate estimation and prediction of engine gas exchange system and in-cylinder conditions are critical for spark-ignited engine control and diagnostic algorithm development. In this paper, a physically-based, control-oriented model for a 2.8 l turbocharged, variable valve timing (VVT) and low pressure (LP) exhaust gas recirculation (EGR)-utilizing SI engine was developed. The model includes the impact of modulation to any combination of 10 actuators, including the throttle valve, compressor bypass valve, fueling rate, waste-gate, LP EGR valve, number of deactivated cylinders, intake valve open (IVO) timing, intake valve close (IVC) timing, exhaust valve open (EVO) timing and exhaust valve close (EVC) timing. The accuracy of the model in capturing engine dynamics was demonstrated by validating it against high-fidelity engine GT-Power simulation results for various drive cycles, particularly emphasizing elevated loads. In comparison to the open literature, novel contributions of the effort described in this paper includes in-cylinder gas composition modeling and turbine-out pressure estimation.

Zhang, Xu↗
NASA NTRS2012

Active Combustion Control for Aircraft Gas-Turbine Engines-Experimental Results for an Advanced, Low-Emissions Combustor Prototype

Lean combustion concepts for aircraft engine combustors are prone to combustion instabilities. Mitigation of instabilities is an enabling technology for these low-emissions combustors. NASA Glenn Research Center s prior activity has demonstrated active control to suppress a high-frequency combustion instability in a combustor rig designed to emulate an actual aircraft engine instability experience with a conventional, rich-front-end combustor. The current effort is developing further understanding of the problem specifically as applied to future lean-burning, very low-emissions combustors. A prototype advanced, low-emissions aircraft engine combustor with a combustion instability has been identified and previous work has characterized the dynamic behavior of that combustor prototype. The combustor exhibits thermoacoustic instabilities that are related to increasing fuel flow and that potentially prevent full-power operation. A simplified, non-linear oscillator model and a more physics-based sectored 1-D dynamic model have been developed to capture the combustor prototype s instability behavior. Utilizing these models, the NASA Adaptive Sliding Phasor Average Control (ASPAC) instability control method has been updated for the low-emissions combustor prototype. Active combustion instability suppression using the ASPAC control method has been demonstrated experimentally with this combustor prototype in a NASA combustion test cell operating at engine pressures, temperatures, and flows. A high-frequency fuel valve was utilized to perturb the combustor fuel flow. Successful instability suppression was shown using a dynamic pressure sensor in the combustor for controller feedback. Instability control was also shown with a pressure feedback sensor in the lower temperature region upstream of the combustor. It was also demonstrated that the controller can prevent the instability from occurring while combustor operation was transitioning from a stable, low-power condition to a normally unstable high-power condition, thus enabling the high-power condition.

DeLaat, John C.↗
NASA NTRS1980

Off-design analysis of a gas turbine powerplant augmented by steam injection using various fuels

Results are compared using coal derived low and intermediate heating valve fuel gases and a conventional distillate. The results indicate that steam injection provides substantial increases in both power and efficiency within the available compressor surge margin. The results also indicate that these performance gains are relatively insensitive as to the type of fuel. Also, in a cogeneration application, steam injection could provide some degree of flexibility by varying the split between power and process steam.

Stochl, R. J.↗
NASA NTRS1950

Preliminary Performance Data on Westinghouse Electronic Power Regulator Operating on J34-WE-32 Turbojet Engine in Altitude Wind Tunnel

The behavior of the Westinghouse electronic power regulator operating on a J34-WE-32 turbojet engine was investigated in the NACA Lewis altitude wind tunnel at the request of the Bureau of Aeronautics, Department of the Navy. The object of the program was to determine the, steady-state stability and transient characteristics of the engine under control at various altitudes and ram pressure ratios, without afterburning. Recordings of the response of the following parameters to step changes in power lever position throughout the available operating range of the engine were obtained; ram pressure ratio, compressor-discharge pressure, exhaust-nozzle area, engine speed, turbine-outlet temperature, fuel-valve position, jet thrust, air flow, turbine-discharge pressure, fuel flow, throttle position, and boost-pump pressure. Representative preliminary data showing the actual time response of these variables are presented. These data are presented in the form of reproductions of oscillographic traces.

Ketchum, James R.↗
NASA NTRS1966

Fuel and oxidizer valve assembly employs single solenoid actuator

Valve assembly simultaneously starts or stops the flow of oxidizer and fuel from separate inlet channels to reaction control motors. The assembly combines an oxidizer shutoff valve and a fuel shutoff valve which are mechanically linked and operated by a single high-speed solenoid actuator.

Source record↗
DOE OSTI2020

Dispenser Reliability: Materials R&D. A Hydrogen Fueling Infrastructure Research and Station Technology (H2FIRST) Report

Dispensers are the top cause of maintenance events and down-time at hydrogen fueling stations. In an effort to help characterize and enable improvements in dispenser reliability, an extensive accelerated lifetime testing set-up was designed and built at NREL involving components typically part of dispensing operations at fueling stations. Device Under Test (DUTs) included different components such as normally open valves, normally closed valves, fueling nozzles, breakaways devices and filters. Conditions of testing included pressures, and flow rates similar to light duty fuel cell electric vehicles fueling at -40°C, and -20°C for thousands of cycles in hydrogen. Tested components (failed and non-failed) were disassembled at SNL and polymeric O-rings were carefully retrieved and cataloged for chemical and physical characterization. Data collected was compared to similar O-rings from unexposed or non-tested components for hydrogen effects, and failure modes. Degradation analyses, based on select polymer chemistries common across all component types, their location within components, visual assessment of damage coupled with strong hydrogen effects from chemical characterization, was completed and presented to NREL and DOE. Overall, the failure rate amongst the components was not as high as expected for the test conditions. Among the component types tested, breakaways were the most susceptible to damage under these test conditions, with fueling nozzles a close second. The proper combination of selection of the right polymer and optimum component design was found to make a strong difference in component reliability under severe dispenser operating conditions. Physical degradation of polymers, rather than chemical changes due to low temperature hydrogen exposure, is more prevalent as failure mode for these test conditions. The nature and the extent of the degradation was much less at -20°C as compared to -40°C. The damage and failure rates were higher at lower temperatures than at higher test temperatures. As expected, increasing the number of cycles at the lowest test temperature (-40°C) increased damage. This indicates that cycling at the low temperature of -40°C required by SAE J2601 can reduce component life in fuel dispensing operations

08 HYDROGEN↗
NASA NTRS1989

SSME structural dynamic model development

The high pressure fuel turbopump (HPFTP) is a major component of the Space Shuttle Main Engine (SSME) powerhead. The device is a three stage centrifugal pump that is directly driven by a two stage hot gas turbine. The purpose of the pump is to deliver fuel (liquid hydrogen) from the low pressure fuel turbopump (LPFTP) through the main fuel valve (MFV) to the thrust chamber coolant circuits. In doing so, the pump pressurizes the fuel from an inlet pressure of approximately 178 psi to a discharge pressure of over 6000 psi. At full power level (FPL), the pump rotates at a speed of over 37,000 rpm while generating approximately 77,000 horsepower. Obviously, a pump failure at these speeds and power levels could jeopardize the mission. Results are summarized for work in which the solutions obtained from analytical models of the fuel turbopump impellers are compared with the results obtained from dynamic tests.

Foley, Michael J.↗
NASA NTRS1927

High-speed Oil Engines for Vehicles. Part II

Further progress toward the satisfactory solution of the difficult problem of the distribution and atomization of the injected fuel was made by extensive experimentation with various fuel valves, nozzles, and atomizing devices. Valuable information was also obtained through numerous experimental researches on the combustion of oils and the manner of introducing the combustion air into the cylinder, as well as on the physical processes of atomization, the determination of the size of drops, etc. These researches led to the conclusion that it is possible, even without producing great turbulence in the combustion chamber and at moderate pump pressure, if the degree of atomization and the penetrative power of the fuel jet are adapted to the shape of the combustion chamber and to the dimensions of the cylinder.

ENGINES, OIL↗
NASA NTRS1982

A method for determining the flight readiness of the integrated Space Shuttle system

The Space Shuttle Dynamic Integrated Test (DIT) system is described. The DIT is an open-loop system which makes no attempt to simulate Shuttle sensors, and by which the Shuttle redundancy management system is left unmodified. Open-loop operation is shown to inherently require less computing capacity during a test than the closed-loop alternative. DIT tests have generated a high degree of confidence in the Shuttle hardware, allowing the identification of such problems as a sluggish main fuel valve, which caused a countdown hold seconds before the simulated T-zero, and Main Engine Controller software malfunctions. Attention is given to the combination and substitution of sensor data, the modification of nominal flight software, and the preparation of simulation data. It is noted that greater performance would have been achieved if the interface with DIT had been a design requirement from the outset of Space Shuttle development.

Bacon, I.↗
NASA NTRS1983

Hydrazine gas generator performance on Space Shuttle

The design, functions, performance, and applications of the hydrazine gas generators (GG) on the STS are detailed. The GGs provide gas horse power for the APUs that drive the hydraulic pumps on the SRBs, which have two cross-linked systems. The Orbiter has three-cross-linked APU systems, used for gimballing the main engine and booster nozzles, actuating the main engine fuel valves and the ET umbilical disconnect, actuation of the control surfaces, and powering the landing gear, brakes, and nose wheel steering. The major design components of the Orbiter GGs are an injector, a catalyst bed, a decomposition chamber, an exhaust nozzle, and an interface structure, with the main structural material being Hasteloy B. Hydrazine injected and dispersed into the catalyst bed decomposes into gas and exits for expansion in an APU turbine. Twenty-six GGs have flown on missions STS-1 through STS-6 with over three tons of hydrazine having been expended over 44 hr of operations, as no refurbishment to that point was necessary.

Patterson, I. J.↗
NASA NTRS1923

The time lag and interval of discharge with a spring actuated fuel injection pump

Discussed here is research on a spring activated fuel pump for solid or airless injection with small, high speed internal combustion engines. The pump characteristics under investigation were the interval of fuel injection in terms of degrees of crank travel and in absolute time, the lag between the time the injection pump plunger begins its stroke and the appearance of the jet at the orifice, and the manner in which the fuel spray builds up to a maximum when the fuel valve is opened, and then diminishes.

Matthews, Robertson↗
NASA NTRS1993

Finite element based electric motor design optimization

The purpose of this effort was to develop a finite element code for the analysis and design of permanent magnet electric motors. These motors would drive electromechanical actuators in advanced rocket engines. The actuators would control fuel valves and thrust vector control systems. Refurbishing the hydraulic systems of the Space Shuttle after each flight is costly and time consuming. Electromechanical actuators could replace hydraulics, improve system reliability, and reduce down time.

Campbell, C. Warren↗
NASA NTRS2002

Test Platform for Advanced Digital Control of Brushless DC Motors (MSFC Center Director's Discretionary Fund)

A FY 2001 Center Director's Discretionary Fund task to develop a test platform for the development, implementation. and evaluation of adaptive and other advanced control techniques for brushless DC (BLDC) motor-driven mechanisms is described. Important applications for BLDC motor-driven mechanisms are the translation of specimens in microgravity experiments and electromechanical actuation of nozzle and fuel valves in propulsion systems. Motor-driven aerocontrol surfaces are also being utilized in developmental X vehicles. The experimental test platform employs a linear translation stage that is mounted vertically and driven by a BLDC motor. Control approaches are implemented on a digital signal processor-based controller for real-time, closed-loop control of the stage carriage position. The goal of the effort is to explore the application of advanced control approaches that can enhance the performance of a motor-driven actuator over the performance obtained using linear control approaches with fixed gains. Adaptive controllers utilizing an exact model knowledge controller and a self-tuning controller are implemented and the control system performance is illustrated through the presentation of experimental results.

Gwaltney, D. A.↗
NASA NTRS2004

Adaptive Controls Method Demonstrated for the Active Suppression of Instabilities in Engine Combustors

An adaptive feedback control method was demonstrated that suppresses thermoacoustic instabilities in a liquid-fueled combustor of a type used in aircraft engines. Extensive research has been done to develop lean-burning (low fuel-to-air ratio) combustors that can reduce emissions throughout the mission cycle to reduce the environmental impact of aerospace propulsion systems. However, these lean-burning combustors are susceptible to thermoacoustic instabilities (high-frequency pressure waves), which can fatigue combustor components and even the downstream turbine blades. This can significantly decrease the safe operating lives of the combustor and turbine. Thus, suppressing the thermoacoustic combustor instabilities is an enabling technology for lean, low-emissions combustors under NASA's Propulsion and Power Program. This control methodology has been developed and tested in a partnership of the NASA Glenn Research Center, Pratt & Whitney, United Technologies Research Center, and the Georgia Institute of Technology. Initial combustor rig testing of the controls algorithm was completed during 2002. Subsequently, the test results were analyzed and improvements to the method were incorporated in 2003, which culminated in the final status of this controls algorithm. This control methodology is based on adaptive phase shifting. The combustor pressure oscillations are sensed and phase shifted, and a high-frequency fuel valve is actuated to put pressure oscillations into the combustor to cancel pressure oscillations produced by the instability.

Kopasakis, George↗
NASA NTRS2005

Artificial Neural Network Test Support Development for the Space Shuttle PRCS Thrusters

A significant anomaly, Fuel Valve Pilot Seal Extrusion, is affecting the Shuttle Primary Reaction Control System (PRCS) Thrusters, and has caused 79 to fail. To help address this problem, a Shuttle PRCS Thruster Process Evaluation Team (TPET) was formed. The White Sands Test Facility (WSTF) and Boeing members of the TPET have identified many discrete valve current trace characteristics that are predictive of the problem. However, these are difficult and time consuming to identify and trend by manual analysis. Based on this exhaustive analysis over months, 22 thrusters previously delivered by the Depot were identified as high risk for flight failures. Although these had only recently been installed, they had to be removed from Shuttles OV103 and OV104 for reprocessing, by directive of the Shuttle Project Office. The resulting impact of the thruster removal, replacement, and valve replacement was significant (months of work and hundreds of thousands of dollars). Much of this could have been saved had the proposed Neural Network (NN) tool described in this paper been in place. In addition to the significant benefits to the Shuttle indicated above, the development and implementation of this type of testing will be the genesis for potential Quality improvements across many areas of WSTF test data analysis and will be shared with other NASA centers. Future tests can be designed to incorporate engineering experience via Artificial Neural Nets (ANN) into depot level acceptance of hardware. Additionally, results were shared with a NASA Engineering and Safety Center (NESC) Super Problem Response Team (SPRT). There was extensive interest voiced among many different personnel from several centers. There are potential spin-offs of this effort that can be directly applied to other data acquisition systems as well as vehicle health management for current and future flight vehicles.

Lehr, Mark E.↗
NASA NTRS2006

Model-Based Self-Tuning Multiscale Method for Combustion Control

A multi-scale representation of the combustor dynamics was used to create a self-tuning, scalable controller to suppress multiple instability modes in a liquid-fueled aero engine-derived combustor operating at engine-like conditions. Its self-tuning features designed to handle the uncertainties in the combustor dynamics and time-delays are essential for control performance and robustness. The controller was implemented to modulate a high-frequency fuel valve with feedback from dynamic pressure sensors. This scalable algorithm suppressed pressure oscillations of different instability modes by as much as 90 percent without the peak-splitting effect. The self-tuning logic guided the adjustment of controller parameters and converged quickly toward phase-lock for optimal suppression of the instabilities. The forced-response characteristics of the control model compare well with those of the test rig on both the frequency-domain and the time-domain.

Le, Dzu, K.↗
NASA NTRS2010

Advanced Vacuum Plasma Spray (VPS) for a Robust, Longlife and Safe Space Shuttle Main Engine (SSME)

In 1984, the Vacuum Plasma Spray Lab was built at NASA/Marshall Space Flight Center for applying durable, protective coatings to turbine blades for the space shuttle main engine (SSME) high pressure fuel turbopump. Existing turbine blades were cracking and breaking off after five hot fire tests while VPS coated turbine blades showed no wear or cracking after 40 hot fire tests. Following that, a major manufacturing problem of copper coatings peeling off the SSME Titanium Main Fuel Valve Housing was corrected with a tenacious VPS copper coating. A patented VPS process utilizing Functional Gradient Material (FGM) application was developed to build ceramic lined metallic cartridges for space furnace experiments, safely containing gallium arsenide at 1260 degrees centigrade. The VPS/FGM process was then translated to build robust, long life, liquid rocket combustion chambers for the space shuttle main engine. A 5K (5,000 Lb. thrust) thruster with the VPS/FGM protective coating experienced 220 hot firing tests in pristine condition with no wear compared to the SSME which showed blanching (surface pulverization) and cooling channel cracks in less than 30 of the same hot firing tests. After 35 of the hot firing tests, the injector face plates disintegrated. The VPS/FGM process was then applied to spraying protective thermal barrier coatings on the face plates which showed 50% cooler operating temperature, with no wear after 50 hot fire tests. Cooling channels were closed out in two weeks, compared to one year for the SSME. Working up the TRL (Technology Readiness Level) to establish the VPS/FGM process as viable technology, a 40K thruster was built and is currently being tested. Proposed is to build a J-2X size liquid rocket engine as the final step in establishing the VPS/FGM process TRL for space flight.

Holmes, Richard R.↗