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DOE OSTI2022

Modelica-based modeling and simulation of district cooling systems: A case study

While equation-based object-oriented modeling language Modelica can evaluate practical energy improvements for district cooling systems, few have adopted Modelica for this type of large-scale thermo-fluid system. Further, to our best knowledge, district cooling modeling studies have yet to include hydraulics in piping networks alongside plant models featuring realistic mechanical systems and controls. These are critical details to include when looking to make energy and control improvements in many physical system installations. To fill these gaps, this study released new open-source district cooling models at the Modelica Buildings Library and leveraged these models for a real-world case study at the University of Colorado Boulder. Here, the site includes six buildings connected to a central chiller plant featuring a waterside economizer. Several energy saving strategies are pursued based on the validated model, including control setpoint optimization, equipment modification, and pump setpoint adjustments. Results indicate that a combination of the studied measures can save the campus annually 84.6 MWh of energy, 8.9% of electricity costs, 58.0 metric tons of carbon dioxide emissions, while the waterside economizer cuts down chillers’ run times by 201 days/year, reducing maintenance costs and extending chiller life.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2025

Advancing Understanding of Deep Convective Anvil Clouds

In this project we use ground-based DOE ARM observations, satellite observations, and Weather Research and Forecasting (WRF) model simulations to arrive at a more complete understanding (or, new theory) of how atmospheric heating profiles in thunderstorm cores drives how quickly air rises in the storms. The rate at which air motion increases or decreases with altitude directly relates to how much cloud mass is ejected laterally into the adjacent atmosphere, which then influences the development and maintenance of “stratiform raining cloud anvils”. Our work has led to new equations connecting the heating in these thunderstorms to these stratiform clouds, with the connection modulated by the stability structure of the atmosphere (i.e., if more stable, then a more rapid change in thunderstorm heating with altitude results in more stratiform cloud, independent of whether over land or ocean, or how organized the thunderstorms are). Improving knowledge of stratiform clouds is important, since they contribute to substantial accumulated rainfall (important to agriculture and local hydrology) as well as radiation, given their large areal extents and lifetime. The radiation impacts likely impact simulated cloud feedback in all Earth System models (ESMs).

54 ENVIRONMENTAL SCIENCES↗

NASA NTRS2018

Dynamic Power Convertor Development for Radioisotope Power Systems at NASA Glenn Research Center

The Thermal Energy Conversion Branch at NASA Glenn Research Center is supporting the development of high-efficiency power convertors for use in radioisotope power systems (RPS). Significant progress was made toward such a system that utilized Stirling conversion during the 2001 to 2015 timeframe. Flight development of the Advanced Stirling Radioisotope Generator (ASRG) was canceled in 2013 by the U.S. Department of Energy (DOE) and NASA Headquarters primarily due to budget constraints, and the Advanced Stirling Convertor (ASC) technology contract was subsequently concluded in 2015. A new chapter of technology development has recently been initiated by the NASA RPS Program. This effort is considering all dynamic power convertor options, such as Stirling and Brayton cycles. Four convertor development contracts supporting this effort were awarded in 2017. The awarded contracts include two free-piston Stirling, one thermoacoustic Stirling, and one turbo-Brayton design. The technology development contracts each consist of up to three phases: design, fabrication, and test. As of May 2018, all contracts have completed the design phase, and each underwent a design review with an independent review board. Three of the contracts are planned to execute the phase 2 option for fabrication. Convertors manifesting from these development efforts will then undergo independent validation and verification (IV and V) at NASA facilities, which will consist of convertor performance and RPS viability demonstrations. Example tests include launch vibration simulation, performance mapping over the environmental temperature range, and static acceleration exposure. In parallel with this renewed development effort, Glenn is still demonstrating free-piston Stirling convertor technology using assets from previous projects. The Stirling Research Laboratory (SRL) is still operating several convertors from previous development projects, which have similarities and relevance to current contract designs. Four of these are flexure-bearing based and another six are gas bearing based. One of the flexure-bearing convertors has accumulated over 110,000 h of operation and holds the current record for maintenance-free heat-engine run time. Another flexure-bearing convertor was recently manually shut down after 105,620 h of operation, then disassembled and inspected. This inspection produced a wealth of information about the effects of this amount of run time on the technology's components. One of the engineering unit flexure-bearing convertors recently underwent a launch simulation vibration test, a static acceleration exposure up to 20 g, and was then placed on extended operation. Among the gas-bearing convertors, the longest running unit has accumulated over 70,000 h of operation. Four high-fidelity gas-bearing convertors from the ASRG project are still operating continuously for which the longest run time has reached 28,000 h.

Oriti, Salvatore M.↗

NASA NTRS1975

Large Space Telescope - Orbital crew EV maintenance operations

The paper shows that orbital EV maintenance by the crew has a tremendous impact on several areas of the program, including operations, Shuttle interfaces, support equipment rendezvous and berthing, checkout and verification, levels of servicing achievable, logistics and spares and scientific instruments in order to permit changeout and possible future refurbishment. To achieve on-orbit EV maintenance, such challenges as designing for suited-astronaut access to all subsystem equipment elements, minimization for contamination, handling of extremely sensitive instruments, development of translation techniques, and use of existing GFE and hardware must be faced early in the preliminary design and operations analysis phases. All studies to date indicate that on-orbit EV manned maintenance of the LST (Large Space Telescope) is not only feasible but can be designed to be readily within the capability of the EV functioning astronaut. Both 1-g and neutral buoyancy man-in-the-loop simulations further support this point.

Fisher, H. T.↗

NASA NTRS2002

Automated fault-management in a simulated spaceflight micro-world

BACKGROUND: As human spaceflight missions extend in duration and distance from Earth, a self-sufficient crew will bear far greater onboard responsibility and authority for mission success. This will increase the need for automated fault management (FM). Human factors issues in the use of such systems include maintenance of cognitive skill, situational awareness (SA), trust in automation, and workload. This study examine the human performance consequences of operator use of intelligent FM support in interaction with an autonomous, space-related, atmospheric control system. METHODS: An expert system representing a model-base reasoning agent supported operators at a low level of automation (LOA) by a computerized fault finding guide, at a medium LOA by an automated diagnosis and recovery advisory, and at a high LOA by automate diagnosis and recovery implementation, subject to operator approval or veto. Ten percent of the experimental trials involved complete failure of FM support. RESULTS: Benefits of automation were reflected in more accurate diagnoses, shorter fault identification time, and reduced subjective operator workload. Unexpectedly, fault identification times deteriorated more at the medium than at the high LOA during automation failure. Analyses of information sampling behavior showed that offloading operators from recovery implementation during reliable automation enabled operators at high LOA to engage in fault assessment activities CONCLUSIONS: The potential threat to SA imposed by high-level automation, in which decision advisories are automatically generated, need not inevitably be counteracted by choosing a lower LOA. Instead, freeing operator cognitive resources by automatic implementation of recover plans at a higher LOA can promote better fault comprehension, so long as the automation interface is designed to support efficient information sampling.

NASA Discipline Space Human Factors↗

DOE OSTI2026

Explaining System-Level Prognostics with Established Machine Learning Methods

System-level prognostics is crucial for ensuring reliability and enabling predictive maintenance in complex systems with interconnected components. This study presents a framework that integrates data-driven methods to predict the remaining useful life (RUL) of a subsystem under multiple and concurrent faults within a nuclear power plant system with explainable artificial intelligence (XAI). A nuclear power plant (NPP) operation was simulated to model the degradation behavior of NPP components, and four machine learning models—Gradient Boosting Regressor (GBR), Support Vector Regressor (SVR), Fully Connected Neural Network (FCNN), and Long Short-Term Memory (LSTM)—were evaluated for prognostics with a novel system RUL parameter. The LSTM model demonstrated potential superior repeatability, while SHAP (SHapley Additive exPlanations) for explainability provided consistent and trustworthy global explanations. In contrast, LIME (Local Interpretable Model-agnostic Explanations) offered localized interpretability but showed reduced stability for sequential data. Key findings include the interplay between component-level degradation and system-wide performance, with LSTM effectively capturing these dynamics through sequence-level predictions. The XAI techniques enhanced transparency by identifying critical features influencing model predictions and aligning with domain knowledge. Furthermore, this framework has significant implications for improving trust and understanding in predictive maintenance, particularly in safety-critical industries like nuclear energy.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

NASA NTRS2001

Development of a Space Radiation Monte-Carlo Computer Simulation Based on the FLUKE and Root Codes

The radiation environment in space is a complex problem to model. Trying to extrapolate the projections of that environment into all areas of the internal spacecraft geometry is even more daunting. With the support of our CERN colleagues, our research group in Houston is embarking on a project to develop a radiation transport tool that is tailored to the problem of taking the external radiation flux incident on any particular spacecraft and simulating the evolution of that flux through a geometrically accurate model of the spacecraft material. The output will be a prediction of the detailed nature of the resulting internal radiation environment within the spacecraft as well as its secondary albedo. Beyond doing the physics transport of the incident flux, the software tool we are developing will provide a self-contained stand-alone object-oriented analysis and visualization infrastructure. It will also include a graphical user interface and a set of input tools to facilitate the simulation of space missions in terms of nominal radiation models and mission trajectory profiles. The goal of this project is to produce a code that is considerably more accurate and user-friendly than existing Monte-Carlo-based tools for the evaluation of the space radiation environment. Furthermore, the code will be an essential complement to the currently existing analytic codes in the BRYNTRN/HZETRN family for the evaluation of radiation shielding. The code will be directly applicable to the simulation of environments in low earth orbit, on the lunar surface, on planetary surfaces (including the Earth) and in the interplanetary medium such as on a transit to Mars (and even in the interstellar medium). The software will include modules whose underlying physics base can continue to be enhanced and updated for physics content, as future data become available beyond the timeframe of the initial development now foreseen. This future maintenance will be available from the authors of FLUKA as part of their continuing efforts to support the users of the FLUKA code within the particle physics community. In keeping with the spirit of developing an evolving physics code, we are planning as part of this project, to participate in the efforts to validate the core FLUKA physics in ground-based accelerator test runs. The emphasis of these test runs will be the physics of greatest interest in the simulation of the space radiation environment. Such a tool will be of great value to planners, designers and operators of future space missions, as well as for the design of the vehicles and habitats to be used on such missions. It will also be of aid to future experiments of various kinds that may be affected at some level by the ambient radiation environment, or in the analysis of hybrid experiment designs that have been discussed for space-based astronomy and astrophysics. The tool will be of value to the Life Sciences personnel involved in the prediction and measurement of radiation doses experienced by the crewmembers on such missions. In addition, the tool will be of great use to the planners of experiments to measure and evaluate the space radiation environment itself. It can likewise be useful in the analysis of safe havens, hazard migration plans, and NASA's call for new research in composites and to NASA engineers modeling the radiation exposure of electronic circuits. This code will provide an important complimentary check on the predictions of analytic codes such as BRYNTRN/HZETRN that are presently used for many similar applications, and which have shortcomings that are more easily overcome with Monte Carlo type simulations. Finally, it is acknowledged that there are similar efforts based around the use of the GEANT4 Monte-Carlo transport code currently under development at CERN. It is our intention to make our software modular and sufficiently flexible to allow the parallel use of either FLUKA or GEANT4 as the physics transport engine.

Pinsky, L. S.↗

DOE OSTI2022

Experimental Setup for Grid Control Device Software Updates in Supply Chain Cyber-Security

Supply chain cyberattacks that exploit insecure third-party software are a growing concern for the security of the electric power grid. These attacks seek to deploy malicious software in grid control devices during the fabrication, shipment, installation, and maintenance stages, or as part of routine software updates. Malicious software on grid control devices may inject bad data or execute bad commands, which can cause blackouts and damage power equipment. This paper describes an experimental setup to simulate the software update process of a commercial power relay as part of a hardware-in-the-loop simulation for grid supply chain cyber-security assessment. The laboratory setup was successfully utilized to study three supply chain cyber-security use cases.

Keller, Joseph↗

DOE OSTI2023

MJO in Different Orbital Regimes: Role of the Mean State in the MJO’s Amplitude during Boreal Winter

Abstract The Madden–Julian oscillation (MJO) exhibits pronounced seasonality, with one of the key unanswered questions being the following: what controls the maximum in MJO precipitation variance in the Southern Hemisphere during boreal winter? In this study, we examine a set of global climate model simulations in which the eccentricity and precession of Earth’s orbit are altered to change the boreal winter mean state in an attempt to reveal the processes that are responsible for the MJO’s amplitude in the boreal winter. In response to the forced insolation changes, the north–south asymmetry in sea surface temperature is amplified in boreal fall, which intensifies the Hadley circulation in boreal winter. The stronger Hadley circulation yields higher mean precipitation and stronger mean lower-tropospheric westerlies in the southern part of the Indo-Pacific warm pool. The MJO precipitation variability increases significantly where the mean precipitation and lower-tropospheric westerlies strengthen. In the column-integrated moisture budget of the simulated MJO, only surface latent heat flux feedback shows a trend that is consistent with the MJO’s amplitude, suggesting an important role for the surface latent heat flux feedback in the MJO’s amplitude during the boreal winter. An analysis of the moisture–precipitation relationship in the simulations shows that the increase in the mean precipitation lowers the convective moisture adjustment time scale, leading to the increase in precipitation variance. Our results suggest that the mean-state precipitation plays a critical role in the maintenance mechanism of the MJO.

Meteorology & Atmospheric Sciences↗

DOE OSTI2020

On the Parameterization of Convective Downdrafts for Marine Stratocumulus Clouds

The role of nonlocal transport on the development and maintenance of marine stratocumulus (Sc) clouds in coarse-resolution models is investigated, with a special emphasis on the downdraft contribution. A new parameterization of cloud-top-triggered downdrafts is proposed and validated against large-eddy simulation (LES) for two Sc cases. The applied nonlocal mass-flux scheme is part of the stochastic multiplume eddy-diffusivity/mass-flux (EDMF) framework decomposing the turbulent transport into local and nonlocal contributions. The complementary local turbulent transport is represented with the Mellor–Yamada–Nakanishi–Niino (MYNN) scheme. This EDMF version has been implemented in the Weather Research and Forecasting (WRF) single-column model (SCM) and tested for three model versions: without mass flux, with updrafts only, and with both updrafts and downdrafts. In the LES, the downdraft and updraft contributions to the total heat and moisture transport are comparable and significant. The WRF SCM results show a good agreement between the parameterized downdraft turbulent transport and LES. While including updrafts greatly improves the modeling of Sc clouds over the simulation without mass flux, the addition of downdrafts is less significant, although it helps improve the moisture profile in the planetary boundary layer.

Wu, Elynn↗

NASA NTRS1985

FINDS: A fault inferring nonlinear detection system programmers manual, version 3.0

Detailed software documentation of the digital computer program FINDS (Fault Inferring Nonlinear Detection System) Version 3.0 is provided. FINDS is a highly modular and extensible computer program designed to monitor and detect sensor failures, while at the same time providing reliable state estimates. In this version of the program the FINDS methodology is used to detect, isolate, and compensate for failures in simulated avionics sensors used by the Advanced Transport Operating Systems (ATOPS) Transport System Research Vehicle (TSRV) in a Microwave Landing System (MLS) environment. It is intended that this report serve as a programmers guide to aid in the maintenance, modification, and revision of the FINDS software.

Lancraft, R. E.↗

NASA NTRS1989

Design of an orbital debris radar ground demonstration

A breadboard radar system is being designed and tested at NASA Johnson for dealing with the space debris problem that could present a growing threat to Space Station Freedom. The major design problems are due to the small radar cross section of such debris (below -30 dBm2), the high closing velocities of the particles with respect to the Space Station (10 km/sec and higher), and the stringent weight, power-consumption, maintenance, and reliability constraints on spaceborne systems. Consideration is given to the preliminary implementation of a ground demonstration radar for testing concepts, technologies, and performance envelopes for application to the space-borne debris detection and tracking radar. Simulation results and techniques developed for predicting system performance and for evaluating antenna parameters are given. The design process of the electronically steered phased array antenna is briefly described, and block diagrams for the implementation of the radar system are given.

Paz, I.↗

NASA NTRS2010

Configuring the Orion Guidance, Navigation, and Control Flight Software for Automated Sequencing

The Orion Crew Exploration Vehicle is being designed with greater automation capabilities than any other crewed spacecraft in NASA s history. The Guidance, Navigation, and Control (GN&C) flight software architecture is designed to provide a flexible and evolvable framework that accommodates increasing levels of automation over time. Within the GN&C flight software, a data-driven approach is used to configure software. This approach allows data reconfiguration and updates to automated sequences without requiring recompilation of the software. Because of the great dependency of the automation and the flight software on the configuration data, the data management is a vital component of the processes for software certification, mission design, and flight operations. To enable the automated sequencing and data configuration of the GN&C subsystem on Orion, a desktop database configuration tool has been developed. The database tool allows the specification of the GN&C activity sequences, the automated transitions in the software, and the corresponding parameter reconfigurations. These aspects of the GN&C automation on Orion are all coordinated via data management, and the database tool provides the ability to test the automation capabilities during the development of the GN&C software. In addition to providing the infrastructure to manage the GN&C automation, the database tool has been designed with capabilities to import and export artifacts for simulation analysis and documentation purposes. Furthermore, the database configuration tool, currently used to manage simulation data, is envisioned to evolve into a mission planning tool for generating and testing GN&C software sequences and configurations. A key enabler of the GN&C automation design, the database tool allows both the creation and maintenance of the data artifacts, as well as serving the critical role of helping to manage, visualize, and understand the data-driven parameters both during software development and throughout the life of the Orion project.

Odegard, Ryan G.↗

NASA NTRS2020

Detection and Mitigation of Transient Instabilities in Multi-Agent Systems and Swarms

We first introduce the novel concept of transient instabilities in multi-agent systems and swarms, i.e., a small disturbance leads to increasing-amplitude oscillations throughout the swarm, which results in a large number of inter-agent collisions. This instability is dominant in the transient phase of the system and it does not appear in the steady-state behavior of the system, as each agent uses Lyapunov-stable feedback control laws. We present a rigorous definition of transient instability in swarms, and discuss its key properties. We also present a sufficient condition to check if a swarm will be transient stable. We study the behaviour of different control laws under this condition. We also show how transient instability phenomenon could impact the dynamics of deployable structures. Next, we present a novel control architecture that augments the baseline formation maintenance controller to mitigate transient instabilities. At its heart, the proposed architecture consists of a projection operator based estimator disguised as a reference model that generates collision-free trajectories for the agents to follow. We present numerical simulation results to demonstrate the effectiveness of our proposed approaches.

Quadrelli, Marco B.↗

NASA NTRS1986

Automation, robotics, and inflight training for manned Mars missions

The automation, robotics, and inflight training requirements of manned Mars missions will be supported by similar capabilities developed for the space station program. Evolutionary space station onboard training facilities will allow the crewmembers to minimize the amount of training received on the ground by providing extensive onboard access to system and experiment malfunction procedures, maintenance procedures, repair procedures, and associated video sequences. Considerable on-the-job training will also be conducted for space station management, mobile remote manipulator operations, proximity operations with the Orbital Maneuvering Vehicle (and later the Orbit Transfer Vehicle), and telerobotics and mobile robots. A similar approach could be used for manned Mars mission training with significant additions such as high fidelity image generation and simulation systems such as holographic projection systems for Mars landing, ascent, and rendezvous training. In addition, a substantial increase in the use of automation and robotics for hazardous and tedious tasks would be expected for Mars mission. Mobile robots may be used to assist in the assembly, test and checkout of the Mars spacecraft, in the handling of nuclear components and hazardous chemical propellent transfer operations, in major spacecraft repair tasks which might be needed (repair of a micrometeroid penetration, for example), in the construction of a Mars base, and for routine maintenance of the base when unmanned.

Holt, Alan C.↗

NASA NTRS1994

Sensor Fault Detection and Diagnosis Simulation of a Helicopter Engine in an Intelligent Control Framework

This paper presents an application of a fault detection and diagnosis scheme for the sensor faults of a helicopter engine. The scheme utilizes a model-based approach with real time identification and hypothesis testing which can provide early detection, isolation, and diagnosis of failures. It is an integral part of a proposed intelligent control system with health monitoring capabilities. The intelligent control system will allow for accommodation of faults, reduce maintenance cost, and increase system availability. The scheme compares the measured outputs of the engine with the expected outputs of an engine whose sensor suite is functioning normally. If the differences between the real and expected outputs exceed threshold values, a fault is detected. The isolation of sensor failures is accomplished through a fault parameter isolation technique where parameters which model the faulty process are calculated on-line with a real-time multivariable parameter estimation algorithm. The fault parameters and their patterns can then be analyzed for diagnostic and accommodation purposes. The scheme is applied to the detection and diagnosis of sensor faults of a T700 turboshaft engine. Sensor failures are induced in a T700 nonlinear performance simulation and data obtained are used with the scheme to detect, isolate, and estimate the magnitude of the faults.

Litt, Jonathan↗

DOE OSTI2024

A Simulated Evaluation of Powder Flowability Through a Partially Obstructed Consumable in Blown Powder Directed Energy Deposition Systems

Abstract In the interest of continued industrialization of metal additive manufacturing in modern production environments, cost is often referenced as a primary deterrent to new adopters. Conventional economic models for additive systems, processes, and supply chains often focus on specific process applications with little generalizability, or they neglect significant costs associated with production such as machine maintenance and consumable part replacement. Compounding the latter issue are substantial knowledge gaps in consumable part wear characterization for additive and other convergent manufacturing systems. In coaxial blown powder directed energy deposition systems, gas atomized metal powder is wasted during material deposition at a rate that is partly dependent on present wear phenomena in a consumable nozzle housed in the cladding head assembly. The price and lead time required to replace the nozzle incentivizes its reuse even when visibly worn. Often this initiates a process quality decline in the form of underbuilt geometry and internal defects due to losses in powder catchment efficiency. While depositing H13 steel using a hybrid manufacturing machine tool equipped with such a deposition system, a unique partial clog with a bridge-like structure formed at the consumable nozzle exit when supporting argon gas flows failed mid-process. To further understand coaxial multi-phase powder flow in the event of support gas failure, a computational fluid dynamics simulation is tailored to relevant process parameters, H13 powder material profile, and machine operator observations collected after the incident. The resulting differences in powder flow compared to control gas flow parameters is presented and discussed. The powder flowability and performance of the clogged nozzle is then assessed by using an optical profilometer to extract the profile of the clog and recreate the clog geometry within the simulation environment. In past work this simulation has been experimentally validated for a 316L steel powder material profile and used specifically for analyzing powder stream geometry and catchment efficiency. After the initial powder flow characterization, the clog is removed, and the nozzle is reprofiled. After removing the obstructing clog, the newly unobstructed nozzle geometry, the original off the shelf nozzle geometry, and additional nozzle profiles exploring different consumable refurbishment strategies are reevaluated in the simulation. Powder catchment efficiency for all variant nozzle geometries and relevant flow variables are compared and discussed, along with potential mitigation strategies for optimizing powder flowability with worn consumables. This work expands on the known morphology of blown powder obstructions and wear defects present in consumable coaxial nozzles while discussing pragmatic simulation driven responses to unanticipated subsystem failure in hybrid manufacturing machining platforms.

DeWitte, Lisa↗

NASA NTRS1983

Launch processing for Spacelab 1

The final integration of Spacelab payloads with the Shuttle is described. Attention is given to launch processing planning, schedules, quality control, and problem reports and configuration maintenance. Also covered are the integration and checkout of individual and combined experiments, mounting the end cones, attachment of the transfer tunnel, and inclusion of an extra experiments pallet. The entire Spacelab module was subjected to a full systems simulation before deliverance to the Orbiter bay. Modular parts that were transferred from building-to-building were placed in sealed containers filled with a purged atmosphere during transport.

Mcbrayer, R. O.↗