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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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NASA NTRS2017

Tailoring a ConOps for NASA LSP Integrated Operations

An integral part of the Systems Engineering process is the creation of a Concept of Operations (ConOps) for a given system, with the ConOps initially established early in the system design process and evolved as the system definition and design matures. As Integration Engineers in NASA's Launch Services Program (LSP) at Kennedy Space Center (KSC), our job is to manage the interface requirements for all the robotic space missions that come to our Program for a Launch Service. LSP procures and manages a launch service from one of our many commercial Launch Vehicle Contractors (LVCs) and these commercial companies are then responsible for developing the Interface Control Document (ICD), the verification of the requirements in that document, and all the services pertaining to integrating the spacecraft and launching it into orbit. However, one of the systems engineering tools that have not been employed within LSP to date is a Concept of Operations. The goal of this paper is to research the format and content that goes into these various aerospace industry ConOps and tailor the format and content into template form, so the template may be used as an engineering tool for spacecraft integration with future LSP procured launch services. This tailoring effort was performed as the authors final Masters Project in the Spring of 2016 for the Stevens Institute of Technology and modified for publication with INCOSE (Owens, 2016).

Knowledge↗

NASA NTRS1997

A Web-Based System for Monitoring and Controlling Multidisciplinary Design Projects

In today's competitive environment, both industry and government agencies are under enormous pressure to reduce the time and cost of multidisciplinary design projects. A number of frameworks have been introduced to assist in this process by facilitating the integration of and communication among diverse disciplinary codes. An examination of current frameworks reveals weaknesses in various areas such as sequencing, displaying, monitoring, and controlling the design process. The objective of this research is to explore how Web technology, in conjunction with an existing framework, can improve these areas of weakness. This paper describes a system that executes a sequence of programs, monitors and controls the design process through a Web-based interface, and visualizes intermediate and final results through the use of Java(Tm) applets. A small sample problem, which includes nine processes with two analysis programs that are coupled to an optimizer, is used to demonstrate the feasibility of this approach.

Salas, Andrea O.↗

DOE OSTI2021

The IDAES process modeling framework and model library—Flexibility for process simulation and optimization

Abstract Energy systems and manufacturing processes of the 21st century are becoming increasingly dynamic and interconnected, which require new capabilities to effectively model and optimize their design and operations. Such next generation computational tools must leverage state‐of‐the‐art techniques in optimization and be able to rapidly incorporate new advances. To address these requirements, we have developed the Institute for the Design of Advanced Energy Systems (IDAES) Integrated Platform, which builds on the strengths of both process simulators (model libraries) and algebraic modeling languages (advanced solvers). This paper specifically presents the IDAES Core Modeling Framework (IDAES‐CMF), along with a case study demonstrating the application of the framework to solve process optimization problems. Capabilities provided by this framework include a flexible, modifiable, open‐source platform for optimization of process flowsheets utilizing state‐of‐the‐art solvers and solution techniques, fully open and extensible libraries of dynamic unit operations models and thermophysical property models, and integrated support for superstructure‐based conceptual design and optimization under uncertainty.

42 ENGINEERING↗

DOE OSTI2021

Operability and control in process intensification and modular design: Challenges and opportunities

Abstract In this article, the importance of considering operability and control criteria in the analysis and design of intensified and modular processes is discussed. We first analyze the impact on operability of key factors including: (i) degrees of freedom, (ii) process constraints, (iii) numbering up vs. scaling up, and (iv) dynamic/periodic operation. Comparative examples are presented to showcase the pros and cons in intensified/modular systems vs. their conventional counterparts from operability and control aspects. Then we look into metrics and tools to address these challenges such as: (i) flexibility analysis, (ii) operability‐based design, and (iii) advanced model‐based control. Considering different conceptual design stages as synthesis intensification, steady‐state design, and dynamic operational optimization, we highlight the need to incorporate different levels of operability considerations. Future research opportunities and perspectives are also identified, particularly emphasizing the importance of a holistic strategy for integrated design, operability, and control of intensified and modular process systems.

Pistikopoulos, Efstratios N.↗

NASA NTRS2020

Integrated Concurrent Engineering Teams for Increased Efficiency in Flight Projects

A highly integrated Concurrent Engineering Team (CET) within a flight project evolves in its function and has the potential to provide many benefits through the project lifecycle. The benefits include superior systems-oriented design products, as well as overall improved project efficiency and higher-performing interpersonal relationships within the project. If physically integrated, this can manifest as a Concurrent Engineering Center (CEC) centrally located within a project’s physical office space. Here we discuss the process to establish and maintain a tightly integrated engineering and design team for providing highly streamlined service to the project, including a cost/benefits analysis discussion.

Flight Project↗

NASA NTRS2020

Integrated Concurrent Engineering Teams for Increased Efficiency in Flight Projects

Flight Project↗

DOE OSTI2017

The human dimensions of energy use in buildings: A review

The “human dimensions” of energy use in buildings refer to the energy-related behaviors of key stakeholders that affect energy use over the building life cycle. Stakeholders include building designers, operators, managers, engineers, occupants, industry, vendors, and policymakers, who directly or indirectly influence the acts of designing, constructing, living, operating, managing, and regulating the built environments, from individual building up to the urban scale. Among factors driving high-performance buildings, human dimensions play a role that is as significant as that of technological advances. However, this factor is not well understood, and, as a result, human dimensions are often ignored or simplified by stakeholders. This work presents a review of the literature on human dimensions of building energy use to assess the state-of-the-art in this topic area. The paper highlights research needs for fully integrating human dimensions into the building design and operation processes with the goal of reducing energy use in buildings while enhancing occupant comfort and productivity. This research focuses on identifying key needs for each stakeholder involved in a building's life cycle and takes an interdisciplinary focus that spans the fields of architecture and engineering design, sociology, data science, energy policy, codes, and standards to provide targeted insights. Greater understanding of the human dimensions of energy use has several potential benefits including reductions in operating cost for building owners; enhanced comfort conditions and productivity for building occupants; more effective building energy management and automation systems for building operators and energy managers; and the integration of more accurate control logic into the next generation of human-in-the-loop technologies. The review concludes by summarizing recommendations for policy makers and industry stakeholders for developing codes, standards, and technologies that can leverage the human dimensions of energy use to reliably predict and achieve energy use reductions in the residential and commercial buildings sectors.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2012

Advanced Control and Protection system Design Methods for Modular HTGRs

The project supported the Nuclear Regulatory Commission (NRC) in identifying and evaluating the regulatory implications concerning the control and protection systems proposed for use in the Department of Energy's (DOE) Next-Generation Nuclear Plant (NGNP). The NGNP, using modular high-temperature gas-cooled reactor (HTGR) technology, is to provide commercial industries with electricity and high-temperature process heat for industrial processes such as hydrogen production. Process heat temperatures range from 700 to 950 C, and for the upper range of these operation temperatures, the modular HTGR is sometimes referred to as the Very High Temperature Reactor or VHTR. Initial NGNP designs are for operation in the lower temperature range. The defining safety characteristic of the modular HTGR is that its primary defense against serious accidents is to be achieved through its inherent properties of the fuel and core. Because of its strong negative temperature coefficient of reactivity and the capability of the fuel to withstand high temperatures, fast-acting active safety systems or prompt operator actions should not be required to prevent significant fuel failure and fission product release. The plant is designed such that its inherent features should provide adequate protection despite operational errors or equipment failure. Figure 1 shows an example modular HTGR layout (prismatic core version), where its inlet coolant enters the reactor vessel at the bottom, traversing up the sides to the top plenum, down-flow through an annular core, and exiting from the lower plenum (hot duct). This research provided NRC staff with (a) insights and knowledge about the control and protection systems for the NGNP and VHTR, (b) information on the technologies/approaches under consideration for use in the reactor and process heat applications, (c) guidelines for the design of highly integrated control rooms, (d) consideration for modeling of control and protection system designs for VHTR, and (e) input for developing the bases for possible new regulatory guidance to assist in the review of an NGNP license application. This NRC project also evaluated reactor and process heat application plant simulation models employed in the protection and control system designs for various plant operational modes and accidents, including providing information about the models themselves, and the appropriateness of the application of the models for control and protection system studies. A companion project for the NRC focused on the potential for new instrumentation that would be unique to modular HTGRs, as compared to light-water reactors (LWRs), due to both the higher temperature ranges and the inherent safety features.

08 HYDROGEN↗

NASA NTRS1989

Launch site integration of Liquid Rocket Boosters

The impacts of introducing Liquid Rocket Boosters (LRB) into the STS/KSC launch environment are identified and evaluated. Proposed ground systems configurations are presented along with a launch site requirements summary. Pre-launch processing scenarios are described and the required facility modifications and new facility requirements are analyzed. Flight vehicle design recommendations to enhance launch processing are discussed. Processing approaches to integrate LRB with existing STS launch operations are evaluated. The key features and significance of launch site transition to a new STS configuration in parallel with ongoing launch activities are enumerated.

Scott, Leland P.↗

NASA NTRSDate not supplied

Human Systems Intergration & Engineering: HSI & E Design Influence

The design of space systems is a long and complicated process where changes to the design increase cost and schedule as the design progresses into implementation. Human Systems Integration uses tools such as mockups, Virtual Reality, Augmented Reality and human simulations early in the design process to evaluate designs for usability, operability, and maintainability. This early design influence provides cost and schedule savings during manufacturing and operations. Examples of how MSFC EV74 Human Systems Integration Team have used these tools to evaluate hardware designs will be discussed.

Tanya Andrews↗

DOE OSTI2025

A Novel Manufacturing Process of Lightweight Automotive Seats (Integration of Additive Manufacturing and Reinforced Polymer Composite)

Lightweight automotive seats offer multiple benefits to original equipment manufacturers in terms of cost savings from various aspects, including less material usage, more integrated processes, and compliance with Corporate Average Fuel Economy Standards. Original equipment manufacturers have been focusing on innovative ways to produce light weight automotive seats. The commercially available automotive seats are currently made of multiple metal components combined through welding and fasteners. The use of additive manufacturing and composite structures is particularly useful for light weighting the automotive components. Additive manufacturing (AM) offers multiple advantages over traditional manufacturing processes such as freedom of design thereby enabling complex structural geometries, mass customization and waste minimization, and control over the fiber alignment through deposition in a predetermined pattern. Combining metal inserts with polymer composites through a novel manufacturing process allows design of lightweight and high-performance materials for automotive components. However, fabricating these metal polymer composite structures through traditional manufacturing processes limits their mechanical properties due to limited design freedom, lack of control over fiber orientation in composite parts, and poor interfacial bonding between the constituent materials. It is essential to develop a novel manufacturing process to enable high throughput production of lightweight automotive seats using metal and polymer composites. As such it is important to design the automotive seat suitable for manufacturing via this process and perform mechanical characterization on various subcomponents of the seat to ensure that the design and performance requirements provided by the auto manufacturer are met. The aim of this project is to develop a novel manufacturing technique to produce lightweight automotive seat by combining AM with conventional manufacturing processes. The car seat back panel will be designed via topology optimization and numerical simulations to minimize the overall weight while ensuring it meets all the performance requirements. The optimization of the seat back structure will be based on computational stress analysis to maximize the stiffness and minimize the weight. Materials currently used by Ford Motor Company will be adopted for a few subcomponents while the in-house composite materials will be used for the rest of the seat back. The composite and metallic materials will be tested to determine their mechanical properties as these are necessary for simulations. A novel manufacturing process will be developed to integrate AM metal inserts with discontinuous reinforced composite through large scale additive manufacturing and compression overmolding processes. The developed manufacturing technique will be used to fabricated various subcomponents suitable for the seat back design and mechanically tested to determine their properties. The manufacturing of the lightweight seat back design through this process involves integrated AM metal inserts with the composite structure for recliner connection. The manufacturing of the entire seat back which is lightweight through the novel manufacturing process will be discussed. The performance of the designed seat back will be investigated through numerical simulations and shown to meet all the requirements provided by the auto manufacturer. The final goal of developing a novel manufacturing process for lightweight automotive seats is met through design optimization of seat back, manufacturing of subcomponents, mechanical characterization, and validation through numerical simulations. The routes to achieve the final goal of the project and the depth in which they were investigated changed throughout the project due to personnel changes and the COVID-19 pandemic. The project resulted in the development of a novel manufacturing process to integrate metal inserts with tailored polymer composite preforms through overmolding. Leveraging this proven manufacturing process, a lightweight seat back was designed through topology optimization and numerical simulations. The designed seat back uses AM metal inserts and compression overmolding of tailored polymer composite preforms obtained via large scale additive manufacturing. The metal polymer composite structures fabricated through this process exhibited enhancement in stiffness and improved ductility upon testing. Overall, the project provided an alternative design and manufacturing technique for automotive seat back that enables weight saving while meeting the safety and performance requirements.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2021

Multi‐fidelity digital twin structural model for a sub‐scale downwind wind turbine rotor blade

Abstract This paper presents the development of a multi‐fidelity digital twin structural model (virtual model) of an as‐built wind turbine blade. The goal is to develop and demonstrate an approach to produce an accurate and detailed model of the as‐built blade for use in verifying the performance of the operating two‐bladed, downwind rotor. The digital twin model development methodology, presented herein, involves a novel calibration process to integrate a wide range of information including design specifications, manufacturing information, and structural testing data (modal and static) to produce a multi‐fidelity digital twin structural model: a detailed high‐fidelity model (i.e., 3D finite element analysis [FEA]) and consistent beam‐type models for aeroelastic simulation. A key element is that the multi‐fidelity structural digital twin method follows the rotor from the stages of design, to manufacturing, then to the ground testing and field operation. The result of this comprehensive approach is an accurate multi‐fidelity digital twin structural model for the geometric, structural, and structural dynamic properties of the as‐built blade within a 1% match in mass properties, 3.2% in blade frequencies, and 6% in deflection. The different stages of processing this information within the methodology are discussed. The rotor examined is the SUMR‐Demonstrator (SUMR‐D), which was installed on the Controls Advanced Research Testbed (CART‐2) wind turbine at the National Wind Technology Center. The digital twin model developed here was utilized to design controllers to safely operate SUMR‐D in field tests, which are providing additional data for further evaluation and development of the multi‐fidelity digital twin structural model.

Chetan, Mayank↗

NASA NTRS1988

BLITZEN - A highly integrated massively parallel machine

The architecture and VLSI design of a new massively parallel processing array chip are described. The BLITZEN processing element array chip, which contains 1.1 million transistors, serves as the basis for a highly integrated, miniaturized, high-performance, massively parallel machine that is currently under development. Each processing element has 1K bits of static RAM and performs bit-serial processing with functional elements for arithmetic, logic, and shifting.

Blevins, D. W.↗

NASA NTRS1988

BLITZEN: A highly integrated massively parallel machine

Blevins, D. W.↗

DOE OSTI2013

Freeform Fluidics

This work explores the integration of miniaturized fluid power and additive manufacturing. Oak Ridge National Laboratory (ORNL) has been developing an approach to miniaturized fluidic actuation and control that enables high dexterity, low cost and a pathway towards energy efficiency. Previous work focused on mesoscale digital control valves (high pressure, low flow) and the integration of actuation and fluid passages directly with the structure, the primary application being fluid powered robotics. The fundamental challenge was part complexity. ORNL s new additive manufacturing technologies (e-beam, laser and ultrasonic deposition) enables freeform manufacturing using conventional metal alloys with excellent mechanical properties. The combination of these two technologies, miniaturized fluid power and additive manufacturing, can enable a paradigm shift in fluid power, increasing efficiency while simultaneously reducing weight, size, complexity and cost. This paper focuses on the impact additive manufacturing can have on new forms of fluid power components and systems. We begin with a description of additive manufacturing processes, highlighting the strengths and weaknesses of each technology. Next we describe fundamental results of material characterization to understand the design and mechanical limits of parts made with the e-beam process. A novel design approach is introduced that enables integration of fluid powered actuation with mechanical structure. Finally, we describe a proof-of-principle demonstration: an anthropomorphic (human-like) hydraulically powered hand with integrated power supply and actuation.

additive manufacturing↗

NASA NTRSDate not supplied

Using Systems Engineering to Develop an Integrated Crew Health and Performance System to Mitigate Risk for Human Exploration Missions

New space exploration missions are currently being designed to take humanity beyond low Earth orbit (LEO) to cis-lunar space, the lunar surface, and eventually to Mars. These missions carry increased risks due to a number of factors, including distance from Earth, exposure to deep space hazards, reduced capacity and ability to resupply and evacuate, and increased communication delays. As distance from Earth grows and mission length increases, a growing proportion of mission risk can be attributed to the “human system.” Almost twenty years ago, the Institute of Medicine in the United States recommended the early and complete integration of the human system into the spacecraft and mission design process to mitigate this increased risk inherent in exploration missions. Exploration missions will require increasing levels of crew self-sufficiency that will challenge the current operational paradigms established in LEO. Enabling progressive Earth independence requires management of the increasingly complex interactions among spacecraft systems and integration of all the data and functions that affect human health and performance into one coordinated system –the Crew Health and Performance (CHP) system. This system is a critical spacecraft system that is analogous to other systems such as propulsion, guidance and navigation, or avionics. Design and integration of the CHP system requires the evidence-based merger of typically disparate disciplines such as medicine, human factors, and life support system design, using systems engineering (SE) practices. SE provides traceability of spacecraft requirements and enables reliable and repeatable trade space analysis of the many competing options for hardware and software to be included in the mission architecture. The approach described here enables spacecraft and mission designers to align the scope of a CHP system with mission specific requirements, decrease risk to the crew, and increase the probability of mission success.

Kerry McGuire↗

DOE OSTI2021

Fabrication of Six Degrees-of-Freedom Hexflex Positioner With Integrated Strain Sensing Using Nonlithographically Based Microfabrication

In this study, a process flow is described for the low cost, flexible fabrication of metal micro-electromechanical systems (MEMS) with high performance integrated sensing. The process is capable of producing new designs in ≈1 week at an average unit cost of <$1 k/device even at batch sizes of ≈1–10, with expected sensing performance limits of about 135 dB over a 10 kHz sensor bandwidth. This is a ≈20× reduction in cost, ≈25× reduction in time, and potentially >30× increase in sensing dynamic range over comparable state-of-the-art compliant nanopositioners. The nonlithographically based microfabrication (NLBM) process is uniquely suited to create high performance nanopositioning architectures which are customizable to the positioning requirements of a range of nanoscale applications. These can significantly reduce the cost of nanomanufacturing research and development, as well as accelerate the development of new processes and the testing of fabrication process chains without excess capital investment. A six degrees-of-freedom (6DOF) flexural nanopositioner with integrated sensing for all 6DOF was fabricated using the newly developed process chain. The fabrication process was measured to have ≈30 μ m alignment. Sensor arm, flexure, and trace widths of 150 μ m, 150 μ m, and 800 μ m, respectively, were demonstrated. Process capabilities suggest lower bounds of 25 μ m, 50 μ m, and 100 μ m, respectively. Dynamic range sensing of 52 dB was demonstrated for the nanopositioner over a 10 kHz sensor bandwidth. Improvements are proposed to approach sensor performance of about 135 dB over a 10 kHz sensor bandwidth.

42 ENGINEERING↗

NASA NTRS1995

Integrated design and manufacturing for the high speed civil transport (a combined aerodynamics/propulsion optimization study)

This report documents the efforts of a Georgia Tech High Speed Civil Transport (HSCT) aerospace student design team in completing a design methodology demonstration under NASA's Advanced Design Program (ADP). Aerodynamic and propulsion analyses are integrated into the synthesis code FLOPS in order to improve its prediction accuracy. Executing the integrated product and process development (IPPD) methodology proposed at the Aerospace Systems Design Laboratory (ASDL), an improved sizing process is described followed by a combined aero-propulsion optimization, where the objective function, average yield per revenue passenger mile ($/RPM), is constrained by flight stability, noise, approach speed, and field length restrictions. Primary goals include successful demonstration of the application of the response surface methodolgy (RSM) to parameter design, introduction to higher fidelity disciplinary analysis than normally feasible at the conceptual and early preliminary level, and investigations of relationships between aerodynamic and propulsion design parameters and their effect on the objective function, $/RPM. A unique approach to aircraft synthesis is developed in which statistical methods, specifically design of experiments and the RSM, are used to more efficiently search the design space for optimum configurations. In particular, two uses of these techniques are demonstrated. First, response model equations are formed which represent complex analysis in the form of a regression polynomial. Next, a second regression equation is constructed, not for modeling purposes, but instead for the purpose of optimization at the system level. Such an optimization problem with the given tools normally would be difficult due to the need for hard connections between the various complex codes involved. The statistical methodology presents an alternative and is demonstrated via an example of aerodynamic modeling and planform optimization for a HSCT.

Baecher, Juergen↗