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DOE OSTI2023

Oscillatory Power Control and Consensus in Unbalanced Networks Using Grid Forming Inverters

In this paper, a state-space nonlinear control previously designed for balanced operation of grid-forming (GFM) inverters is extended to unbalanced operations. Unbalanced voltages and currents are analyzed, and their time-varying direct, quadrature, and zero components are parameterized in terms of six constant parameters. These parameters provide primary control design choices for not only an inverter’s terminal voltage but also its injections of both real and oscillatory power. It is shown that the proposed GFM control can precisely achieve a desired balanced terminal voltage under unbalanced loads. It is also shown that, by allowing the terminal voltage to be slightly unbalanced, oscillatory power can be adaptively minimized. Lastly, it is illustrated that oscillatory power can also be shared among multiple GFM inverters. Case studies and their simulations demonstrate that the proposed GFM control is effective in meeting the aforementioned objectives.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2022

Editors’ Choice—Methods—Pressure Control Apparatus for Lithium Metal Batteries

Lithium (Li) metal anodes are essential for developing next-generation high-energy-density batteries. However, Li dendrite/whisker formation caused short-circuiting issue and short cycle life have prevented lithium metal from being viably used in rechargeable batteries. Numerous works have been done to study how to regulate the Li growth in electrochemical cycling by using external stacking forces. While it is widely agreed that stack pressure positively affects the lithium plating/stripping process, the optimized pressure range provided by different works varies greatly because of the difference in the pressure control setup. In this work, a pressure control apparatus is designed for Li metal batteries with liquid and solid-state electrolytes (SSE). With considerations of minimizing cell to cell variation, a reusable split cell and pressure load cell are made for testing electrochemical cells with high precision pressure control. The capability of the designed setup is demonstrated by studying the pressure effect on the Li plating/stripping process.

25 ENERGY STORAGE↗

NASA NTRS2012

Instrument Package Manipulation Through the Generation and Use of an Attenuated-Fluent Gas Fold

This document discusses a technique that provides a means for suspending large, awkward loads, instrument packages, components, and machinery in a stable, controlled, and precise manner. In the baseplate of the test machine, a pattern of grooves and ports is installed that when pressurized generates an attenuated- fluent gas fold providing a low-cost, near-zero-coefficient-of-friction lubrication boundary layer that supports the object evenly, and in a predictable manner. Package movement control requires minimal force. Aids to repeatable travel and positional accuracy can be added via the addition of simple guide bars and stops to the floor or object being moved. This allows easily regulated three-axis motions. Loads of extreme weight and size can be moved and guided by a single person, or by automated means, using minimal force. Upon removal of the attenuated fluent gas fold, the object returns to a stable resting position without impact forces affecting the object.

Breen, Daniel P.↗

NASA NTRS1988

Analysis of the performance of the space ultravacuum research facility in attached and free-flyer mode

The old concept of using the wake of a spacecraft to obtain an ultrahigh vacuum is revisited with a somewhat different emphasis. Since it is possible to configure a wake shield so that a surface of interest does not subtend any walls that could become contaminated, it appears that it should be possible to achieve a contamination-free, ultrahigh vacuum capability with infinite pumping speed even in the presence of high heat loads and moderate gas loads. With the new interest in developing thin films with precision controlled synthetic microstructures such as superlattices, mixed metal oxide high temperature superconductors, rare-earth magneto-optical devices, and nano-crystalline alloys, the ability to work with a variety of different materials without cross contamination should be of significance. This paper analyzes the performance of the conceptual design for a Space Ultravacuum Research Facility (SURF), both in a Shuttle-attached mode and as a free-flyer. It is shown that even in the Shuttle-attached mode, it should be possible to obtain vacuum levels equivalent to 10 to the -10 Torr with O and N2 as the primary constituents. This should be sufficient to demonstrate the feasibility of the concept, particularly the infinite pumping speed and virtual elimination of contamination aspects. As a free-flyer the SURF will be limited primarily by the gas load associated with the process being performed. For chemical beam epitaxy (CBE) it is shown that equivalent vacuum levels of 10 to the -14 Torr should be possible at 300 km.

Naumann, Robert J.↗

DOE OSTI2021

A Cooperative Game Theory-based Approach to Under-frequency Load Shedding Control

This paper proposes a cooperative game theory-based under-frequency load shedding (UFLS) approach for frequency stability and control in power systems. UFLS is a crucial factor for frequency stability and control especially in power grids with high penetration of renewable energy sources and restructured power systems. Conventional UFLS methods, most of which are off-line, usually shed fixed amounts of predetermined loads based on a predetermined schedule which can lead to over or under curtailment of load. This paper presents a co-operative game theory-based two-stage strategy to effectively and precisely determine locations and amounts of loads to be shed for UFLS control. In the first stage, the total amount of loads to be shed, also referred to as deficit in generation or the disturbance power, is computed using the initial rate of change of frequency (ROCOF) referred to the equivalent inertial center. In the second stage, the Shapley value, one of the solution concepts of cooperative game theory, is used to determine load shedding amounts and locations. The proposed method is implemented on the reduced 9-bus 3-machine Western Electricity Coordinating Council (WECC) system and simulated on Real-time Digital Simulators (RTDS). The results show that the proposed UFLS approach can effectively return the system to normal state after disturbances.

42 ENGINEERING↗

NASA NTRS1988

Miniature Remote Deadweight Calibrator

Miniature, computer-controlled deadweight calibrator developed to calibrate remotely force transducer located in cryogenic chamber. Used with microcomputer, calibration system automatically applies deadweight loads to skin-friction balance, records and reduces data, and prints out results. Actuator controller and interlocking-weight system key elements in precise, automatic transducer calibrator. Designed for full-scale load of 1,000 mg. Concept extended to accommodate other full-scale load ranges.

Supplee, Frank H., Jr.↗

DOE OSTI2022

Experimental studies of a high-gradient X-band welded hard-copper split accelerating structure

We report on recent research on high-gradient radio frequency (RF) accelerating structures indicates that the use of hard copper alloys provides improvement in high gradient performance over annealed copper. Such structures are made by bonding individually manufactured parts. However, there are no well-established bonding techniques that preserve the hardness, surface finish and cleanliness required for high gradient operation. To preserve the copper hardness, RadiaBeam has developed a novel high-gradient split accelerating structure, based on electron beam welding joining technique. This technique provides efficient bonding with strong, clean welds and minimal thermal loading, while maintaining a clean inner RF environment. Our RF design and fabrication methodology limits the small heat affected zone to the outer cavity envelop, with virtually no distortions or thermal loading of critical RF surfaces. It also incorporates provisions to precisely control the gap despite conventional issues with weld joint shrinkage. To date we have manufactured and validated an RF accelerating structure joined by electron-beam welding that incorporates a novel open split design to significantly reduce the assembly complexity and cost. In this paper, we will present the electromagnetic design of this structure, discuss bonding, and present the results of high-power tests, where the accelerating gradients of 140 MV m -1 with surface peak fields of 400 MV m -1 were achieved for flat-top pulse length of 600 ns with an RF breakdown rate of 10 -4 1/(pulsecm).

43 PARTICLE ACCELERATORS↗

NASA NTRS1981

Cleaving machine for hard crystals

Hard crystalline materials such as lithium fluoride (LiF) are cleaved in thin sections by semiautomatic machine. Yield of undistorted LiF crystals is almost 100 percent, even when cleaved section is only 1/32 inch thick. Machine contains spring-activated hammer that limits penetration of blade and controls shock that cleaves crystal. Fixture with spring-loaded clamps precisely locates and holds crystal, restraining it in ideal position for cleaving. Crystal then splays apart.

Benedicto, J. S. J.↗

NASA NTRS1986

Switching System for Redundant Power Supplies

Load-transfer unit connects airborne computer to standby power supply in case primary supply fails. Concept adaptable to systems in which power interruptions cannot be tolerated; for example, computers with volatile memories, safety equipment, and precise timers. Load-transfer unit monitors voltages and load current. Microprocessor controls transistor switches that connect load to whichever power supply has highest priority and correct voltage.

Bradford, M.↗

NASA NTRS2003

Investigation of Pressurized Wave Bearings

The wave bearing has been pioneered and developed by Dr. Dimofte over the past several years. This bearing will be the main focus of this research. It is believed that the wave bearing offers a number of advantages over the foil bearing, which is the bearing that NASA is currently pursuing for turbomachinery applications. The wave bearing is basically a journal bearing whose film thickness varies around the circumference approximately sinusoidally, with usually 3 or 4 waves. Being a rigid geometry bearing, it provides precise control of shaft centerlines. The wave profile also provides good load capacity and makes the bearing very stable. Manufacturing techniques have been devised that should allow the production of wave bearings almost as cheaply as conventional full-circular bearings.

Keith, Theo G., Jr.↗

NASA NTRS2011

Ultra-Low-Dropout Linear Regulator

A radiation-tolerant, ultra-low-dropout linear regulator can operate between -150 and 150 C. Prototype components were demonstrated to be performing well after a total ionizing dose of 1 Mrad (Si). Unlike existing components, the linear regulator developed during this activity is unconditionally stable over all operating regimes without the need for an external compensation capacitor. The absence of an external capacitor reduces overall system mass/volume, increases reliability, and lowers cost. Linear regulators generate a precisely controlled voltage for electronic circuits regardless of fluctuations in the load current that the circuit draws from the regulator.

Thornton, Trevor↗

NASA NTRSDate not supplied

Tailored Arrival Manager Plan for ecoD 2020

TAM is an automated approach to ensuring safe separation while maximizing throughput and efficiency; as currently conceived, it would serve as an ATC tool. TAM relies on NASA’s Autoresolver technology to compute trajectory-based arrival solutions that provide separation assurance while maximizing airspace and airport capacity utilization. In addition, TAM enables optimized profile descents that minimize altitude level offs and speed interruptions. Importantly, TAM trajectory clearances are intended for delivery to the flight deck through datacomm rather than voice-based communications. Once received on the flight deck, TAM solutions can be auto-loaded into a Flight Management System (FMS) for precision guidance and control along the intended arrival trajectory.

Richard A Coppenbarger↗

DOE OSTI2024

Catalyst Layer Design, Manufacturing and In-line Quality Control

In this project we successfully demonstrated the capabilities of the Reactive Spray Deposition Technology (RSDT) to fabricate large-scale CCMs for advanced PEMWEs that have one-order of magnitude lower PGM loading in their catalyst layers, and performance comparable with the commercial state-of-the-art CCMs. The RSDT is a unique methodology that combines the catalyst synthesis and CCM fabrication in one step and reduces dramatically the time for CCM manufacturing. As fabricated large-scale CCMs with geometric area of 680 cm2 demonstrated excellent activity and durability performance, and the novel duo-recombination layer design paves the way for solving the safety concerns related to PEMWEs. In addition, excellent activity and durability performance has been demonstrated with RSDT fabricated CCMs with thinner membranes and duo RL design. This is a novel approach for further performance improvement of the MEAs for PEMWEs that has been successfully demonstrated for the first time in this project. The integration of the in-situ laser diagnostics system along with the in-line optical quality control system within the RSDT that has been achieved and demonstrated in this project, is an example for possibility of designing and building advanced manufacturing technologies that can meet the requirements of the future manufacturing. Therefore, the RSDT offers a precise real-time monitoring and control of the particles size, composition, loading, porosity, thickness, and defects in the catalysts’ layers, which render this technology as the best candidate for manufacturing of cost effective CCMs for PEMWEs. By using RSDT we successfully met all project’s milestones, Go/No-Go decision, objectives, goals, and deliverables.

08 HYDROGEN↗

NASA NTRS1978

Step motor damping for high-inertia loads

Brushless tachometer generates signals for moving large and varying loads precisely. Stepper waveform generator sends short sequence of pulses to instruct control logic circuit to perform its function-that is, to select proper windings and directions of excitation to drive and damp motor. Control logic circuit bases decisions on following logic signals, derived from tachometer: rate direction, rate threshold, and position.

Veillette, L. J.↗

NASA NTRS2005

Apparatus for Precise Indium-Bump Bonding of Microchips

An improved apparatus has been designed and built for use in precise positioning and pressing of a microchip onto a substrate (which could, optionally, be another microchip) for the purpose of indium-bump bonding. The apparatus (see figure) includes the following: A stereomicroscope, A stage for precise positioning of the microchip in rotation angle (theta) about the nominally vertical pressing axis and in translation along two nominally horizontal coordinate axes (x and y), and An actuator system that causes a bonding tip to press the microchip against the substrate with a precisely controlled force. In operation, the microscope and the stage are used to position the microchip under the bonding tip and to align the indium bumps on the chip and the substrate, then the actuator system is used to apply a prescribed bonding force for a prescribed time. The improved apparatus supplants a partly similar prior apparatus that operated with less precision and repeatability, producing inconsistent and unreliable bonds. Results of the use of the prior apparatus included broken microchips, uneven bonds, and bonds characterized, variously, by overcompression or undercompression. In that apparatus, the bonding force was generated and controlled by use of a micrometer head positioned over the center of a spring-loaded scale, and the force was applied to the microchip via the scale, which was equipped for digital readout of the force. The inconsistency of results was attributed to the following causes: It was not possible to control the bonding force with sufficient precision or repeatability. Particularly troublesome was the inability to control the force at levels less than the weight of 150 g. Excessive compliance in the spring-loaded scale, combined with deviations from parallelarity of the substrate and bonding-tip surfaces, gave rise to nonuniformity in the pressure applied to the microchip, thereby generating excessive stresses and deformations in the microchip. In the improved apparatus, the bonding tip and the components that hold the substrate and the microchip are more rigid and precise than in the prior apparatus, so as to ensure less deviation from parallelarity of the bonding-tip and substrate surfaces, thereby ensuring more nearly uniform distribution of bonding force over the area of the microchip. The bonding force is now applied through, and measured by, a load cell that makes it possible to exert finer control over the force. The force can be set at any value between 0 and the weight of 800 g in increments of 0.2 g.

Wild, Larry↗

NASA NTRS2001

Reducing Bolt Preload Variation with Angle-of-Twist Bolt Loading

Critical high-pressure sealing joints on the Space Shuttle reusable solid rocket motor require precise control of bolt preload to ensure proper joint function. As the reusable solid rocket motor experiences rapid internal pressurization, correct bolt preloads maintain the sealing capability and structural integrity of the hardware. The angle-of-twist process provides the right combination of preload accuracy, reliability, process control, and assembly-friendly design. It improves significantly over previous methods. The sophisticated angle-of-twist process controls have yielded answers to all discrepancies encountered while the simplicity of the root process has assured joint preload reliability.

Thompson, Bryce↗

NASA NTRS1997

The Kinematics of Treadmill Locomotion in Space

Locomotion on a treadmill in 0 G will probably remain a centerpiece of NASA's exercise countermeasures programme. This form of physical activity has the potential to cause large bone and muscle forces as well as loading during a period of continuous treadmill exercise. A critical concern is the provision of a treadmill which can approximate 1 G performance in space. At this point, no adequate objective measurements of in-flight treadmill kinetics or of the human response to this activity have been made. Interpretation of the results obtained in the present study is limited by the following: (1) bungee tensions were not measured; (2) ground reaction forces were not measured in parallel with the kinematic measurements; and (3) the instrumentation used to film the astronauts could itself have been affected by microgravity. Despite these shortcomings, what is apparent is that exercise during NASA missions STS 7 and STS 8 resulted in leg motions that were similar to those found during 1 G locomotion on an inclined passive treadmill and on an active treadmill at an even steeper grade. In addition, it was apparent that the majority of the loads were transmitted through the forefoot, and one can surmise that this style of running would result in physiologically significant tensions in the calf musculature and resultant ankle compressive loading. Further speculation regarding limb loading is complicated by the fact that varying amounts of force are transmitted through (1) the treadmill handle and (2) bungee cords that act as a tether. New generations of treadmills are being manufactured that could provide I important information for planners of long-duration space missions. If these types of treadmill are flown on future missions, it will be possible to control bungee tensions more precisely, control for grade and speed, and, most importantly, provide data on the rates and magnitudes of limb loading. These data could then be incorporated into biomechanical models of the lower limb to more fully understand mechanisms of load transmission from distal to proximal structures and to optimize in-flight exercise protocols in such a way that muscle and bone loss could be reduced.

Thornton, W. E.↗

NASA NTRS1993

An Application of a New Electromagnetic Sensor to Real-Time Monitoring of Fatigue Crack Growth in Thin Metal Plates

A major part of fracture mechanics is concerned with studying the initiation and propagation of fatigue cracks. This typically requires constant monitoring of crack growth during fatigue cycles which necessitates automation of the whole process. If the rate of crack growth can be determined the experimenter can vary externally controlled parameters such as load level, load cycle frequency and so on. Hence, knowledge of the precise location of the crack tip at any given time is very valuable. One technique currently available for measuring fatigue crack length is the DC potential drop method. The method, however, may be inaccurate if the direction of crack growth deviates considerably from what was assumed initially or the curvature of the crack becomes significant. Another approach is to digitize an optical image of the test specimen surface and then apply a pattern recognition technique to locate the crack tip, but this method is still under development. The present work is an initial study on applying eddy current-type probes to monitoring fatigue crack growth. The performance of two types of electromagnetic probes, a conventional eddy current probe and a newly developed self-nulling probe, was evaluated for the detection characteristics at and near the tips of fatigue cracks. The scan results show that the latter probe provides a very well defined local maximum in its output in the crack tip region suggesting the definite possibility of precisely locating the tip, while the former provides a somewhat ambiguous distribution of the sensor output in the same region. The paper is organized as follows: We start by reviewing the design and performance characteristics of the self-nulling probe and then describe the scan results which demonstrate the basic properties of the self-nulling probe. Next, we provide a brief description of the software developed for tracing a simulated crack and give a brief discussion of the main results of the test. The final section summarizes the major accomplishments of the present work and the elements of the future R&D needs.

Namkung, M.↗