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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 397 records · Page 22
All sourcesNASA NTRSDOE OSTI
NASA NTRS1990

Tolerating failures of continuous-valued sensors

One aspect of fault tolerance in process control programs is the ability to tolerate sensor failure. A methodology for transforming a process control program that cannot tolerate sensor failures onto one that can is presented. Issues addressed include modifying specifications in order to accommodate uncertainty in sensor values and averaging sensor values in a fault tolerant manner. In addition, a hierarchy of sensor failure models is identified, and both the attainable accuracy and the run-time complexity of sensor averaging with respect to this hierarchy is discussed.

Marzullo, Keith↗
DOE OSTI2021

Overview of the Process Automation and Control Group (E-3) [Slides]

Process Automation and Control (E-3) is a part of the Weapons Associate Laboratory Directorate (DDW) which includes Weapons Engineering Directorate (WE) and the Engineering Technology and Design (E) Division. There are three teams: Fabrication and Assembly, Process Controls, and Automation and Robotics. After an overview of the group, information is provided about an internship and how to apply.

45 MILITARY TECHNOLOGY, WEAPONRY, AND NATIONAL DEF↗
DOE OSTI2021

Cyber-Physical System Implementation for Manufacturing With Analytics in the Cloud Layer

Effective and efficient modern manufacturing operations require the acceptance and incorporation of the fourth industrial revolution, also known as Industry 4.0. Traditional shop floors are evolving their production into smart factories. To continue this trend, a specific architecture for the cyber-physical system is required, as well as a systematic approach to automate the application of algorithms and transform the acquired data into useful information. This work makes use of an approach that distinguishes three layers that are part of the existing Industry 4.0 paradigm: edge, fog, and cloud. Each of the layers performs computational operations, transforming the data produced in the smart factory into useful information. Trained or untrained methods for data analytics can be incorporated into the architecture. A case study is presented in which a real-time statistical control process algorithm based on control charts was implemented. The algorithm automatically detects changes in the material being processed in a computerized numerical control (CNC) machine. The algorithm implemented in the proposed architecture yielded short response times. The performance was effective since it automatically adapted to the machining of aluminum and then detected when the material was switched to steel. The data were backed up in a database that would allow traceability to the line of g-code that performed the machining.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2019

A geometric approach for computing tolerance bounds for elastic functional data

We design an approach for constructing tolerance bounds for functional data with random warping variability. In particular, we define a generative, probabilistic model for the amplitude and phase components of such observations, which parsimoniously characterizes variability in the baseline data. Based on the proposed model, we define two different types of tolerance bounds that are able to measure both types of variability, and as a result, identify when the data has gone beyond the bounds of amplitude and/or phase. The first functional tolerance bounds are computed via a bootstrap procedure on the geometric space of amplitude and phase functions. The second functional tolerance bounds utilize functional Principal Component Analysis to construct a tolerance factor. Our report is motivated by two main applications: process control and disease monitoring. The problem of statistical analysis and modeling of functional data in process control is important in determining when a production has moved beyond a baseline. Moreover, in biomedical applications, doctors use long, approximately periodic signals (such as the electrocardiogram) to diagnose and monitor diseases. In this context, it is desirable to identify abnormalities in these signals. We additionally consider a simulated example to assess our approach and compare it to two existing methods.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2014

SU-C-BRD-03: Analysis of Accelerator Generated Text Logs for Preemptive Maintenance

Purpose: To develop a model to analyze medical accelerator generated parameter and performance data that will provide an early warning of performance degradation and impending component failure. Methods: A robust 6 MV VMAT quality assurance treatment delivery was used to test the constancy of accelerator performance. The generated text log files were decoded and analyzed using statistical process control (SPC) methodology. The text file data is a single snapshot of energy specific and overall systems parameters. A total of 36 system parameters were monitored which include RF generation, electron gun control, energy control, beam uniformity control, DC voltage generation, and cooling systems. The parameters were analyzed using Individual and Moving Range (I/MR) charts. The chart limits were calculated using a hybrid technique that included the use of the standard 3σ limits and the parameter/system specification. Synthetic errors/changes were introduced to determine the initial effectiveness of I/MR charts in detecting relevant changes in operating parameters. The magnitude of the synthetic errors/changes was based on: the value of 1 standard deviation from the mean operating parameter of 483 TB systems, a small fraction (≤ 5%) of the operating range, or a fraction of the minor fault deviation. Results: There were 34 parameters in which synthetic errors were introduced. There were 2 parameters (radial position steering coil, and positive 24V DC) in which the errors did not exceed the limit of the I/MR chart. The I chart limit was exceeded for all of the remaining parameters (94.2%). The MR chart limit was exceeded in 29 of the 32 parameters (85.3%) in which the I chart limit was exceeded. Conclusion: Statistical process control I/MR evaluation of text log file parameters may be effective in providing an early warning of performance degradation or component failure for digital medical accelerator systems. Research is Supported by Varian Medical Systems, Inc.

07 ISOTOPE AND RADIATION SOURCES↗
NASA NTRS1989

Implementing fault-tolerant sensors

One aspect of fault tolerance in process control programs is the ability to tolerate sensor failure. A methodology is presented for transforming a process control program that cannot tolerate sensor failures to one that can. Additionally, a hierarchy of failure models is identified.

Marzullo, Keith↗
NASA NTRS2006

Importance Of Quality Control in Reducing System Risk, a Lesson Learned From The Shuttle and a Recommendation for Future Launch Vehicles

This paper presents lessons learned from the Space Shuttle return to flight experience and the importance of these lessons learned in the development of new the NASA Crew Launch Vehicle (CLV). Specifically, the paper discusses the relationship between process control and system risk, and the importance of process control in improving space vehicle flight safety. It uses the External Tank (ET) Thermal Protection System (TPS) experience and lessons learned from the redesign and process enhancement activities performed in preparation for Return to Flight after the Columbia accident. The paper also, discusses in some details, the Probabilistic engineering physics based risk assessment performed by the Shuttle program to evaluate the impact of TPS failure on system risk and the application of the methodology to the CLV.

Safie, Fayssal M.↗
DOE OSTI2017

Electrolyte chemistry control in electrodialysis processing

Methods for controlling electrolyte chemistry in electrodialysis units having an anode and a cathode each in an electrolyte of a selected concentration and a membrane stack disposed therebetween. The membrane stack includes pairs of cationic selective and anionic membranes to segregate increasingly dilute salts streams from concentrated salts stream. Electrolyte chemistry control is via use of at least one of following techniques: a single calcium exclusionary cationic selective membrane at a cathode cell boundary, an exclusionary membrane configured as a hydraulically isolated scavenger cell, a multivalent scavenger co-electrolyte and combinations thereof.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2015

Thermal Management in Friction-Stir Welding of Precipitation-Hardening Aluminum Alloys

Process design and implementation in FSW is mostly dependent on empirical information gathered through experience. Basic science of friction stir welding and processing can only be complete when fundamental interrelationships between process control parameters and response variables and resulting weld microstructure and properties are established to a reasonable extent. It is known that primary process control parameters like tool rotation and translation rate and forge axis force have complicated and interactive relationships to the process response variables such as peak temperature, time at temperature etc. Of primary influence to the other process response parameters are temperature and its gradient at the deformation and heat affected zones. Through review of pertinent works in the literature and some experimental results from boundary condition work performed in precipitation hardening aluminum alloys this paper will partially elucidate the nature and effects of temperature transients caused by variation of thermal boundaries in Friction Stir Welding.

Friction Stir Welding↗
DOE OSTI2023

Integrated Process Optimization for Biochemical Conversion

This research is motivated by the challenges faced during biomass processing in bioenergy plants. It has been observed that variations in biomass characteristics, such as moisture, ash, and carbohydrate contents cause variations in feeding of the system which led to underutilization of equipment and the reactor. The objective of this research is to ensure a continuous flow of biomass to the reactor in plants that use the biochemical conversion process to generate liquid fuels. The overall goal is to lower the cost of producing biofuels, which could lead to improving US’s energy independency and growing US’s rural economy. The research team developed analytical models, such as discrete element method (DEM) models and mathematical models. The DEM models are unit-level models that explicitly capture biomass characteristics and quantify the impacts of biomass characteristics on bulk material properties and the performance of specific equipment. The mathematical models are system-level models that capture the impacts of system infeed rate, equipment processing rate, storage location and capacity, and biomass characteristics on system throughput. The functional relations predicting the bulk material properties from DEM models are incorporated to the mathematical models. The models developed were validated and evaluated using data collected at Idaho National Laboratory’s biomass processing facility. Via these models, we identified process control strategies that ensure a continuous flow of biomass to the reactor, while meeting the requirements of biochemical conversion process. Our analysis indicates that sequencing of biomass bales based on moisture level, and carbohydrate contents could have a positive impact on reducing processing time and inventory level and increasing throughput rate. Short bale sequences that repeat frequently, seem to have the greatest impact on improving system’s performance. Based on our experiments, the total annual system operating costs reduced by 20-30%, and the maximum inventory level reduced by 3 to 4 times. The operating costs include the annual equipment amortization cost and processing cost. The implementation of the models developed requires the use of standardized bale format, Radio Frequency Identification technology, sensing and real time monitoring of material attributes, automated material handling equipment, and automated process control. The scope of the model proposed can be extended to include the whole supply chain. The supply chain models help identify how many bales of different biomass feedstock to purchase given biomass availability in the region, biomass price and quality, and the biomass processing capabilities of the biorefinery. Thus, the outcomes of supply chain models can be used to inform the design of long-term contracts among farmers and the biorefinery.

09 BIOMASS FUELS↗
DOE OSTI2017

A novel tool for improving the data collection process during control room modernization human-system interface testing and evaluation activities - 271

The U.S. Department of Energy (DOE) Light Water Reactor Sustainability (LWRS) Program is developing a scientific basis to extend the existing U.S. nuclear power plant (NPP) operating life beyond the current 60-year licensing period and to ensure NPP long-term reliability, productivity, safety, and security. Under the Advanced Instrumentation, Information, and Control (II and C) Systems Technologies pathway, the LWRS Program conducts targeted research and development to address long-term aging and obsolescence of existing instrumentation and control technologies, as well as to implement and test new digital II and C technology that enables broad innovation and business improvement in the NPP operating model. To this end, the role of human factors engineering (HFE) is important as part of ensuring that the control room modernization (CRM) activities account for the operator's cognitive and physiological characteristics. Part of the HFE process for CRM entails conducting tests and evaluations (T and Es) that will inform the design of new human-system interface (HSI) technologies. Qualitative data that captures operator feedback and important human-system interactions are an important part of T and E. However, the analyzing this qualitative data in order to provide actionable design recommendations can be time-consuming and error prone. This paper presents an early version of a tool, which uses a combination of natural language processing and supervised machine learning to support the analysis of qualitative data. The objectives of this tool is to improve the process of (1) sifting through freeform text for improved design issue identification, (2) maintaining consistency in theme coding conventions, and (3) readily providing actionable design guidance that can be traceable to state-of-the-art HFE guidelines such as NUREG-0700. (authors)

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
NASA NTRS1993

Implementation of ionizing radiation environment requirements for Space Station

Proper functioning of Space Station hardware requires that the effects of high-energy ionizing particles from the natural environment and (possibly) from man-made sources be considered during design. At the Space Station orbit of 28.5-deg inclination and 330-440 km altitude, geomagnetically trapped protons and electrons contribute almost all of the dose, while galactic cosmic rays and anomalous cosmic rays may produce Single Event Upsets (SEUs), latchups, and burnouts of microelectronic devices. Implementing ionizing radiation environment requirements for Space Station has been a two part process, including the development of a description of the environment for imposing requirements on the design and the development of a control process for assessing how well the design addresses the effects of the ionizing radiation environment. We will review both the design requirements and the control process for addressing ionizing radiation effects on Space Station.

Boeder, Paul A.↗
DOE OSTI2017

A NOVEL TOOL FOR IMPROVING THE DATA COLLECTION PROCESS DURING CONTROL ROOM MODERNIZATION HUMAN-SYSTEM INTERFACE TESTING AND EVALUATION ACTIVITIES

The U.S. Department of Energy (DOE) Light Water Reactor Sustainability (LWRS) Program is developing a scientific basis to extend the existing U.S. nuclear power plant (NPP) operating life beyond the current 60-year licensing period and to ensure NPP long-term reliability, productivity, safety, and security. Under the Advanced Instrumentation, Information, and Control (II&C) Systems Technologies pathway, the LWRS Program conducts targeted research and development to address long-term aging and obsolescence of existing instrumentation and control technologies, as well as to implement and test new digital II&C technology that enables broad innovation and business improvement in the NPP operating model. To this end, the role of human factors engineering (HFE) is important as part of ensuring that the control room modernization (CRM) activities account for the operator’s cognitive and physiological characteristics. Part of the HFE process for CRM entails conducting tests and evaluations (T&Es) that will inform the design of new human-system interface (HSI) technologies. Qualitative data that captures operator feedback and important human-system interactions are an important part of T&E. However, the analyzing this qualitative data in order to provide actionable design recommendations can be time-consuming and error prone. This paper presents an early version of a tool that can be used to analyze this qualitative data to (1) sift through freeform text for improved design issue identification, (2) maintain consistency in theme coding conventions, and (3) readily provide actionable design guidance that can be traceable to state-of-the-art HFE guidelines such as NUREG-0700. A description of this tool is discussed next.

99 GENERAL AND MISCELLANEOUS↗
DOE OSTI2014

Heterogeneous recurrence monitoring and control of nonlinear stochastic processes

Recurrence is one of the most common phenomena in natural and engineering systems. Process monitoring of dynamic transitions in nonlinear and nonstationary systems is more concerned with aperiodic recurrences and recurrence variations. However, little has been done to investigate the heterogeneous recurrence variations and link with the objectives of process monitoring and anomaly detection. Notably, nonlinear recurrence methodologies are based on homogeneous recurrences, which treat all recurrence states in the same way as black dots, and non-recurrence is white in recurrence plots. Heterogeneous recurrences are more concerned about the variations of recurrence states in terms of state properties (e.g., values and relative locations) and the evolving dynamics (e.g., sequential state transitions). This paper presents a novel approach of heterogeneous recurrence analysis that utilizes a new fractal representation to delineate heterogeneous recurrence states in multiple scales, including the recurrences of both single states and multi-state sequences. Further, we developed a new set of heterogeneous recurrence quantifiers that are extracted from fractal representation in the transformed space. To that end, we integrated multivariate statistical control charts with heterogeneous recurrence analysis to simultaneously monitor two or more related quantifiers. Experimental results on nonlinear stochastic processes show that the proposed approach not only captures heterogeneous recurrence patterns in the fractal representation but also effectively monitors the changes in the dynamics of a complex system.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
NASA NTRS1993

On identified predictive control

Self-tuning control algorithms are potential successors to manually tuned PID controllers traditionally used in process control applications. A very attractive design method for self-tuning controllers, which has been developed over recent years, is the long-range predictive control (LRPC). The success of LRPC is due to its effectiveness with plants of unknown order and dead-time which may be simultaneously nonminimum phase and unstable or have multiple lightly damped poles (as in the case of flexible structures or flexible robot arms). LRPC is a receding horizon strategy and can be, in general terms, summarized as follows. Using assumed long-range (or multi-step) cost function the optimal control law is found in terms of unknown parameters of the predictor model of the process, current input-output sequence, and future reference signal sequence. The common approach is to assume that the input-output process model is known or separately identified and then to find the parameters of the predictor model. Once these are known, the optimal control law determines control signal at the current time t which is applied at the process input and the whole procedure is repeated at the next time instant. Most of the recent research in this field is apparently centered around the LRPC formulation developed by Clarke et al., known as generalized predictive control (GPC). GPC uses ARIMAX/CARIMA model of the process in its input-output formulation. In this paper, the GPC formulation is used but the process predictor model is derived from the state space formulation of the ARIMAX model and is directly identified over the receding horizon, i.e., using current input-output sequence. The underlying technique in the design of identified predictive control (IPC) algorithm is the identification algorithm of observer/Kalman filter Markov parameters developed by Juang et al. at NASA Langley Research Center and successfully applied to identification of flexible structures.

Bialasiewicz, Jan T.↗
NASA NTRS1993

Neuromorphic Learning From Noisy Data

Two reports present numerical study of performance of feedforward neural network trained by back-propagation algorithm in learning continuous-valued mappings from data corrupted by noise. Two types of noise considered: plant noise which affects dynamics of controlled process and data-processing noise, which occurs during analog processing and digital sampling of signals. Study performed with view toward use of neural networks as neurocontrollers to substitute for, or enhance, performances of human experts in controlling mechanical devices in presence of sensor and actuator noise and to enhance performances of more-conventional digital feedback electronic process controllers in noisy environments.

Merrill, Walter C.↗
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↗
DOE OSTI2025

Advanced Manufactured Strain Sensors for Extreme Environments

Experimentation at irradiation test facilities are essential for reducing the innovation time of developmental fuels, fuel cladding, and structural materials employed in next-generation nuclear reactors. However, due to the harsh conditions generated in such reactors and limited instrumentation space, the evaluation of a material’s mechanical properties is often limited to characterization after the materials have been removed from reactor conditions, or post-irradiation examination. These experiments are costly, time-consuming, and fail to capture the critical time-evolving phenomena that occur during the irradiation experiments. Advanced manufactured digital image correlation patterns and strain sensor devices serve as two promising technologies that can be deployed in the confined and challenging orientations of these irradiation experiments while also providing key insight on salient materials phenomena (i.e., mechanical properties). To guide the development of the printed strain sensors prior to their deployment in critical experiments, the adhesion strength between the substrate and printed film interface is measured via tensile testing and a non-contact laser-induced spallation technique. The establishment of these process control steps helped guide the successful fabrication and testing of direct-write strain sensing devices discussed in this work. The fabrication process controls are necessary for enabling the sustained operation of these strain sensing device through experimentation and minimize the potential for premature failure.

36 - MATERIALS SCIENCE↗