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The technology was originally designed to assist workers using gloveboxes to document nuclear materials handling issues. The application defined in the DisrupTech process was the use of the technology to improve tracking and handling of materials in pharmacies or in pharmaceutical manufacturing. This report focuses on the use of the technology in pharmacy applications to reduce drug errors.
A significant emphasis upon automation within the Space Biology Initiative hardware appears justified in order to conserve crew labor and crew training effort. Two generic forms of automation were identified: automation of data and information handling and decision making, and the automation of material handling, transfer, and processing. The use of automatic data acquisition, expert systems, robots, and machine vision will increase the volume of experiments and quality of results. The automation described may also influence efforts to miniaturize and modularize the large array of SBI hardware identified to date. The cost and benefit model developed appears to be a useful guideline for SBI equipment specifiers and designers. Additional refinements would enhance the validity of the model. Two NASA automation pilot programs, 'The Principal Investigator in a Box' and 'Rack Mounted Robots' were investigated and found to be quite appropriate for adaptation to the SBI program. There are other in-house NASA efforts that provide technology that may be appropriate for the SBI program. Important data is believed to exist in advanced medical labs throughout the U.S., Japan, and Europe. The information and data processing in medical analysis equipment is highly automated and future trends reveal continued progress in this area. However, automation of material handling and processing has progressed in a limited manner because the medical labs are not affected by the power and space constraints that Space Station medical equipment is faced with. Therefore, NASA's major emphasis in automation will require a lead effort in the automation of material handling to achieve optimal crew utilization.
Air-cooled stack technology offers the potential for a simpler system architecture (versus liquid-cooled) for applications below 4 kilowatts. The combined cooling and cathode air allows for a reduction in part count and hence a lower cost solution. However, efficient heat rejection challenges escalate as power and ambient temperature increase. For applications in ambient temperatures below freezing, the air-cooled approach has additional challenges associated with not overcooling the fuel cell stack. The focus of this project was freeze tolerance while maintaining all other stack and system requirements. Through this project, Plug Power advanced the state of the art in technology for air-cooled PEM fuel cell stacks and related GenDrive material handling application fuel cell systems. This was accomplished through a collaborative work plan to improve freeze tolerance and mitigate freeze-thaw effect failure modes within innovative material handling equipment fuel cell systems designed for use in freezer forklift applications. Freeze tolerance remains an area where additional research and understanding can help fuel cells to become commercially viable. This project evaluated both stack level and system level solutions to improve fuel cell stack freeze tolerance. At this time, the most cost effective solutions are at the system level. The freeze mitigation strategies developed over the course of this project could be used to drive fuel cell commercialization. The fuel cell system studied in this project was Plug Power's commercially available GenDrive platform providing battery replacement for equipment in the material handling industry. The fuel cell stacks were Ballard's commercially available FCvelocity 9SSL (9SSL) liquid-cooled PEM fuel cell stack and FCvelocity 1020ACS (Mk1020) air-cooled PEM fuel cell stack.
Controlled, Ecological Life Support Systems (CELSS) that utilize plants to provide food, water and oxygen could consume considerable amounts of labor unless crop production, recovery and processing are automated. Robotic manipulators equipped with special end-effectors and programmed to perform the sensing and materials handling tasks would minimize the amount of astronaut labor required. The Human Rated Test Facility (HRTF) planned for Johnson Space Center could discover and demonstrate techniques of crop production which can be reliably integrated with machinery to minimize labor requirements. Before the physical components (shelves, lighting fixtures, etc.) can be selected, a systems analysis must be performed to determine which alternative processes should be followed and how the materials handling tasks should be automated. Given that the current procedures used to grow crops in a CELSS may not be the best methods to automate, then what are the alternatives? How may plants be grown, harvested, processed for food, and the inedible components recycled? What commercial technologies current exist? What research efforts are underway to develop new technologies which might satisfy the need for automation in a CELSS? The answers to these questions should prove enlightening and provide some of the information necessary to perform the systems analysis. The planting, culturing, gathering, threshing and separation, food processing, and recovery of inedible portions of wheat were studied. The basic biological and materials handling processes of each task are defined and discussed. Current practices at Johnson Space Center and other NASA centers are described and compared to common production practices in the plant production industry. Technologies currently being researched which might be applicable are identified and illustrated. Finally, based on this knowledge, several scenarios are proposed for automating the tasks for wheat.
This report proposes a method that will allow lunar vertical-shaft mining. Lunar mining allows the exploitation of mineral resources imbedded within the surface. The proposed lunar vertical-shaft mining system is comprised of five subsystems: structure, materials handling, drilling, mining, and planning. The structure provides support for the exploration and mining equipment in the lunar environment. The materials handling subsystem moves mined material outside the structure and mining and drilling equipment inside the structure. The drilling process bores into the surface for the purpose of collecting soil samples, inserting transducer probes, or locating ore deposits. Once the ore deposits are discovered and pinpointed, mining operations bring the ore to the surface. The final subsystem is planning, which involves the construction of the mining structure.
The Spacelab D-1 (Deutchland Eins) Mission is discussed from the points of view of safety, materials handling, and toxic materials; the laboratory and equipment used; and some of the different philosophies utilized on this flight. How to enhance scientific return at the same time as being safe was examined.
Electrolytic reduction processes as a means to provide pure elements for lunar resource utilization have many advantages. Such processes have. the potential of removing all the oxygen from the lunar soil for use in life support and for propellant. Electrochemical reduction also provides a direct path for the. production of pure metals and silicon which can be utilized for in situ manufacturing and power production. Some of the challenges encountered in the electrolytic reduction processes include the feeding of the electrolytic cell (the transfer of electrolyte containing lunar soil), the withdrawal of reactants and refined products such as the liquidiron~siliconalloy with a number of impurities, and the spent regolith slag, produced in the hot electrolytic cell for the reduction of lunar regolith. The paper will discuss some of the possible solutions to the challenges of handling molten materials on the lunar surface, as well as the path toward the construction and testing of a proof-of-concept facility.
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Radioactive decay of naturally occurring Radon-222 present in just-produced natural gas can lead to deposition of its radiogenic daughter, Lead-210, and subsequent radiogenic progeny within natural gas handling, treatment, and distribution facilities. Worker safety issues and disposal challenges arise when these accumulate to radiologically problematic activity levels. This is due to the 22.3-year half-life of Lead-210, allowing for multi-decade period of accumulation to occur and to persist, even after facility operations have ceased. Due to the far shorter half-lives of Lead-210 radiogenic progeny, especially that of Polonium-210, secular equilibrium within the Lead-210-Bismuth-210-Polonium-210 decay chain is quickly approached during facility operations and achieved after facility operations end. Lead-210 that accumulates in pipe scale can complicate any subsequent intrusive facility modifications, such as disassembly and dismantlement, potentially exposing workers to adverse radioactivity and impeding recycling and/or disposal of radiologically impacted equipment or other material. Experience has shown it is not strictly the presence of Lead-210 that is problematic but rather its 'unexpected' presence when this Technologically Enhanced Naturally Occurring Radioactive Material (TENORM) is discovered during intrusive work not incorporating radiological health and safety and material handling plans. Conversely, when implementing a program that proactively considers the potential for Lead-210, this form of TENORM simply becomes another 'special waste' that can be safely, efficiently, and effectively addressed during a decommissioning effort, without associated adverse worker exposures, project cost over-runs, and schedule delays. This paper will discuss how proactive radioactive scanning quickly and safely identified Lead-210 and its radiogenic progeny within a natural gas sweetening and compressor station located in northern Montana, a portion of which was undergoing decommissioning, aiding in safe and compliant material handling and recycling. The location of this operation necessitated that the decommissioning program be completed on schedule to prevent weather-related impacts due to the onset of adverse winter conditions. Further, the radioactive data acquired during this project will be shown to provide important insight into historic behavior of Lead-210 in terms of its disposition and its more recent decay. From these data, it became possible to back-model the average activity of Radon-222 within the natural gas being processed during the life of the operation, how the estimated Radon-222 activity within the processed natural gas conformed to measured Radon-222 at various other natural gas fields, and how this information can be leveraged in developing safe and successful plans for future intrusive work at this and companion site operations. This presentation will also note the apparent preferential accumulation of Lead-210 within both rubber-based materials, such as gaskets and seals, and grease-based products found within natural gas flow lines. Thoughts regarding processes that may lead to this finding will be explored. (authors)
This paper will discuss the feasibility, application, and economy of applying collaborative robots (co-bots) in lieu of traditional through-the-wall tele-operated manipulator systems, traditionally used within hazardous (radioactive) environments. Both fixed facility and mobile applications will be discussed. Both single- and dual-armed co-bot systems will be employed. The six-axis, plus gripper, single-armed co-bots will provide for machine vision enhanced pick-n-place applications within shielded rooms and also include force-reflecting (haptic) teleoperations controls for non-routine materials-handling operations. The dual-armed system will be mounted to a motorized stand with motorized adjustment both vertically and rotationally (around its base). To complement these co-bots, both two-dimensional and three-dimensional vision technologies will be implemented. The vision technologies, in these applications, are used in lieu of traditional radiation shielding windows. two-dimensional video systems will provide for large area viewing, incorporating pan, tilt, and zoom capabilities. Three-dimensional video systems will be mounted to the dual-armed robot stand and provide viewing, including depth-of-perception, to the operator, performing material handling and other tasks, from an operator workstation located outside the hazardous environment. The unique workstation used with the dual-armed systems will also be described. (authors)
The global nuclear power industry, and to a lesser extent, the decommissioning and demolition of old nuclear weapons plants, obviously present challenges to those in the radioactive waste management field. Some if not many of these challenges have already been dealt with, and resolved, in the steel industry, including its recycling component. This paper presents proven state-of-the-art radiation detection systems used in steel and related recycling facilities, emphasizing current, reliable and flexible technologies for characterization, volume reduction, and remote handling of recyclable solid wastes contaminated and, just as important, not contaminated, with a wide range of radioactive isotopes. It will also cover features of remotely operated waste handling equipment effective in reducing or eliminating exposure of workers engaged in decontamination and demolition work on active and/or inactive nuclear installations. The industry group identified above has a long-standing policy regarding any radioactivity in potentially recyclable as well as waste materials it receives: if it is detected, it is rejected. The US Steel Manufacturers Association (SMA) put it this way in one of their Public Policy Statements: 'SMA members have not, and will not, accept scrap that is known to be radioactively contaminated' (emphasis included in the original) (1). This policy, adopted around the globe, obviously has major implications for decommissioning and demolition projects. To put it bluntly, if rad-contaminated metal, concrete, or other materials are sent to a facility for possible recycling, reuse or even disposal, they may well be rejected. If so, the materials will be returned to the generator--at the generator's cost-and a new solution will have to be found. This also results in additional costs for the generator. Facilities in the steel making and metal recycling industries have access to, and routinely count on, a wide range of proven detection technologies and techniques for monitoring incoming shipments and sorting the materials in them. The approaches range from using sensitive handheld instruments for pinpointing and isolating small devices such as isotope-containing gauges and radium dials all the way up to technologies effective for large volumes and weights of contaminated construction and demolition material. In this latter realm, the most suitable, robust, and field-proven system for decommissioning and demolition work is a radiation detection system fitted to a grappling and/or magnetic device, known as the Crickets{sup TM} technology, which automatically scans bulk material with no added effort or time in material handling operations. Highly versatile, a Crickets{sup TM} system can be put to work on any material-handling system, including grapples handling volumes ranging from 1 up to 18 cubic yards, while detecting radioactivity in real-time over a very wide dose range, from nSv to Sv levels. Other field-proven real-time measuring radiation detection devices can be fixed to conveyor belts with traverse speeds up 3 meters/second, also measuring in real time and over the same dose range, allowing both recyclable and waste materials with a pre-set level of radioactivity to be diverted off the belt. Finally, there are highly sensitive radiation portal installations for detecting radiation from materials being transported by vehicles, including those with roll-offs, dump trailers, and other containers, again in real-time and for the same dose ranges. For vehicles, the speed must be carefully controlled-the vehicles need to travel from 5 to 10 km/h through the scanning zone to ensure that maximum detection capability is maintained. When radiation detection systems at recycling and steel making facilities detect radioactive material in an incoming shipment, these facilities have a zero tolerance for accepting the cargo. Therefore, it is imperative that material from a demolition operation that is slated to be sent for recycling or other reuse be checked at the point of demolition at similar detection levels to avoid possible rejection later of a shipment because of its radioactivity. In addition to measuring overall radiation levels (for example, total gamma), when necessary, combinations of different radiation detection media can be used to detect the presence and intensities of specific isotopes such as U-235, Cs-137, Co-60, Am-241, etc., again in real-time and over a similar dose range. These detection technologies can be fixed or transportable. More important for the rad-waste management profession, this overall systems approach can be tailored and adapted during use on-site in any dismantling, demolition or remediation project, to allow materials to be thoroughly scanned before being released to the recycling stream for reuse, or to appropriate long-term storage and disposal facilities. Potentially recyclable materials with contamination such as steel beams and rebar will set off alarms at recycling facilities, resulting in unnecessary added expenses to the generator, primarily due to increased transportation costs, time delays and additional rad-waste handling and disposal charges. Additionally, there are situations where relatively lightly contaminated materials, once identified and appropriately characterized, can be reused in new construction applications, such as concrete from demolition being used in the base layer for roads or recycled steel used for repair or construction of bridges. In other cases, specific smaller volumes can be sent to specialized rad-waste disposal sites. These radiation detection systems can also be custom tailored to ensure proper handling and disposition of contaminated materials destined for reuse in specific applications where, for example, acceptable levels of radioactivity in NORM or TENORM can be reused or safely disposed of. (authors)
Knowing a detailed operating cycle is critical for developing and testing equipment. Operating cycles can be separated by two clear distinctions: (1) regulatory or non-regulatory and (2) application at the engine-only or full machine level. The Environmental Protection Agency’s (EPA) Nonroad Transient Cycle (NRTC) may be a good representation of engine use in many types of equipment, but there is a gap in standardized and validated drive cycles specifically for nonroad material handlers. Lacking a standardized drive cycle makes it difficult to accurately benchmark machine performance and validate new powertrain technologies. The objective of this investigation is to illustrate the development of a custom drive cycle augmented with real-world customer use data that serves multiple purposes: (1) understand the range of operation and utilization that formulated inputs for electrified architecture analysis and (2) develop a repetitive and consistent maneuver to establish baseline energy consumption enabling equivalent comparison to future electrified prototype builds. This article presents a solution specifically for a 23-ton nonroad material handler in which material handling, machine transport, and extended idle were homologated to form representative short cycles defined by machine velocity and hydraulic cylinder position. The most intensive material handling short cycles had a load factor of 40% and an average fuel rate of 16 L/h. Combined with a visual aid, the short cycles exhibited low variability, having less than 5% root mean square (RMS) error in lift and reach position with respect to the average. The machine’s performance on these short cycles at the Advanced Power Systems Research Center (APSRC) was compared to results from two real-world customer locations operating the instrumented test machine in a cyclical manner, and for similar ground conditions were found to be comparable in fuel consumption.
This project, entitled “Recovery Act: Fuel Cell-Powered Lift Truck Sysco (Houston) Fleet Deployment”, was in response to DOE funding opportunity announcement DE-PS36-08GO98009, Topic 7B, which promotes the deployment of fuel cell powered material handling equipment in large, multi-shift distribution centers. This project promoted large-volume commercialdeployments and helped to create a market pull for material handling equipment (MHE) powered fuel cell systems. Specific outcomes and benefits involved the proliferation of fuel cell systems in 5-to 20-kW lift trucks at a high-profile, real-world site that demonstrated the benefits of fuel cell technology and served as a focal point for other nascent customers. The project allowed for the creation of expertise in providing service and support for MHE fuel cell powered systems, growth of existing product manufacturing expertise, and promoted existing fuel cell system and component companies. The project also stimulated other MHE fleet conversions helping to speed the adoption of fuel cell systems and hydrogen fueling technology. This document also contains the lessons learned during the project in order to communicate the successes and difficulties experienced, which could potentially assist others planning similar projects.
The efficient utilization of lignocellulosic biomass for biofuel and biochemical production is hindered by material handling issues such as clogging and segregation among other challenges. Preprocessing methods such as drying, screening, and milling have improved conversion yield but have not sufficiently enhanced flowability, especially herbaceous biomass. The poor flowability of herbaceous biomass is rooted in some particle attributes that remain less altered by those methods, e.g., irregular particle shape, high roughness, and high compressibility, making it hard to scale up throughput to a key benchmark for a biorefinery – 2000 ton per day. Applying additional preprocessing methods like pelletization and torrefaction to drastically change those particle attributes can improve flow and handling but has not been comprehensively verified through test. The flowability of herbaceous biomass feedstock formats generated by three different preprocessing methods was recently assessed at Idaho National Laboratory’s Biomass Feedstock National User Facility: first, loose particles size reduced from as-received materials; second, pellets produced from an efficient densification process; and third, powders milled from torrefied pellets. Benchmarking tests including static angle of repose, basic flow energy measured in a powder rheometer, and discharge flow in an adjustable hopper, were conducted to evaluate those feedstock formats. Beyond the capacity of existing experimental apparatuses, a digital engineering approach involving flow simulations and AI models were used to identity the material attributes and processing parameters that have dominant influences on flow throughput. Techno-economic analysis focusing on hopper flow as a typical material handling operation was conducted for those feedstock formats. Perspectives will be discussed on whether the 2000-ton daily throughput for a biorefinery is achievable at an acceptable cost by using any of the tested preprocessing methods.
Though there is a plethora of ergonomic guidelines for manual material handling, including maximum weight limits, there is not much guidance for the largest size of an object that a person can carry. Moreover, given the new Artemis space program’s intent to reestablish and maintain human presence on the Moon, there is a need to set manual material handling requirements for the partial gravity environment. Lunar surface carry limits while wearing a pressurized spacesuit is chief among them. Specifically, volumetric limits are required to determine the maximum dimensions of an item that a crewmember will be able to carry on the lunar surface. This study will assess spacesuit motion data to determine acceptable locations where the hand can be positioned for carrying an object, as hand position will vary with the crewmember anthropometry, spacesuits constraints and mechanism. Maximum volume limits will be derived from clearances between the suit and the gloved hand. The mobility of the suit and task contexts (e.g., terrain types, ground clearance) will also be taken into consideration to ensure that the volume being carried does not interfere with suit hardware or impart any mobility restrictions. The specific analysis methods and outcomes will be detailed in the final proceeding. The outcome of this study is expected to provide guidelines for maximum volumes that can be carried both two-handed and one-handed while wearing a spacesuit.
The project objective was to further assist in the commercialization of fuel cell and H2 technology by building further upon the successful fuel cell lift truck deployments that were executed by LiftOne in 2007, with longer deployments of this technology in real-world applications. We involved facilities management, operators, maintenance personnel, safety groups, and Authorities Having Jurisdiction. LiftOne strived to educate a broad group from many areas of industry and the community as to the benefits of this technology. Included were First Responders from the local areas. We conducted month long deployments with end-users to validate the value proposition and the market requirements for fuel cell powered lift trucks. Management, lift truck operators, Authorities Having Jurisdiction and the general public experienced 'hands on' fuel cell experience in the material handling applications. We partnered with Hydrogenics in the execution of the deployment segment of the program. Air Products supplied the compressed H2 gas and the mobile fueler. Data from the Fuel Cell Power Packs and the mobile fueler was sent to the DOE and NREL as required. Also, LiftOne conducted the H2 Education Seminars on a rotating basis at their locations for lift trucks users and for other selected segments of the community over the project's 36 month duration. Executive Summary The technology employed during the deployments program was not new, as the equipment had been used in several previous demos and early adoptions within the material handling industry. This was the case with the new HyPx Series PEM - Fuel Cell Power Packs used, which had been demo'd before during the 2007 Greater Columbia Fuel Cell Challenge. The Air Products HF-150 Fueler was used outdoors during the deployments and had similarly been used for many previous demo programs. The methods used centered on providing this technology as the power for electric sit-down lift trucks at high profile companies operating large fleets. As a long-standing lift truck dealership, LiftOne was able to introduce the fuel cells to such companies in the demanding applications. Accomplishments vs Objectives: We were successful in respect to the stated objectives. The Education Segment's H2 Education Sessions were able to introduce fuel cell technology to many companies and reached the intended broad audience. Also, demos of the lift truck at the sessions as well as the conferences; expos and area events provided great additional exposure. The Deployments were successful in allowing the 6 participating companies to test the 2 fuel cell powered lift trucks in their demanding applications. One of the 6 sites (BMW) eventually adopted over 80 fuel cells from Plug Power. LiftOne was one of the 3 fuel cell demonstrators at BMW for this trial and played a major role in helping to prove the viability and efficiency of this alternative form of energy for BMW. The other 5 companies that participated in the project's deployments were encouraged by the trials and while not converting over to fuel cell power at this time, expressed the desire to revisit acquisition scenarios in the near future as the cost of fuel cells and infrastructure continue to improve. The Education sessions began in March of 2009 at the 7 LiftOne Branches and continued throughout the duration of the project. Attendees came from a large base of lift truck users in North Carolina, South Carolina and Virginia. The sessions were free and invitations were sent out to potential users and companies with intrigue. In addition to the Education content at the sessions (which was offered in a 'H2 101' format), LiftOne was able to demonstrate a working fuel cell powered lift truck, which proved to be a big draw with the 'hands on' experience. LiftOne also demo'd the fuel cell lift trucks at many conferences, expos, professional association meetings, trade shows and 'Green' events in major cities region including Charlotte, Greenville, and Columbia. Such events allowed for H2 Education Material to be presented, and recruit attendees for future sessions. The Deployments began in May '09 and continued through August'10. While the overall results were good, there were some technical problems with the fuel cells at times during the trials. These items are detailed in the attachment provided with this submission. There were never any safety issues during the trials as design features and diagnostic capabilities allowed for quick analysis and field repairs. There were no products developed during this award, as we demo'd existing products. During the project, Tom Dever was able to speak at several panel type discussions and presentations at the NHA/ Fuel Cell & H2 Energy Annual Conference, as well as at the Promat Show in Chicago. Expertise and deployment/ education experiences were imparted during these events. The presentations are included as attachments.
Gaseous mixtures of diatomic hydrogen isotopologues and helium are often encountered in the nuclear energy industry and in analytical chemistry. Compositions of stored mixtures can vary due to interactions with storage and handling materials. When tritium is present, it decays to form ions and helium-3, both of which can lead to further compositional variation. Monitoring of composition is typically achieved by mass spectrometry, a method that is bulky and energy-intensive. Mass spectrometers disperse sample material through vacuum pumps, which is especially troublesome if tritium is present. Moreover, our ultimate goal is to create a compact, fast, low-power sensor that can determine composition with minimal gas consumption and waste generation, as a complement to mass spectrometry that can be instantiated more widely. We propose calorimetry of metal hydrides as an approach to this, due to the strong isotope effect on gas absorption, and demonstrate the sensitivity of measured heat flow to atomic composition of the gas. Peak shifts are discernible when mole fractions change by at least 1%. A mass flow restriction results in a unique dependence of the measurement on helium concentration. We present a mathematical model as a first step toward prediction of the peak shapes and positions. The model includes a useful method to compute estimates of phase diagrams for palladium in the presence of arbitrary mixtures of hydrogen isotopologues. As a result, we expect that this approach can be used to deduce unknown atomic compositions from measured calorimetric data over a useful range of partial pressures of each component.
Kerith Stender and Kimberly Monroe conducted an ergonomic assessment of the drum handling tasks performed at several sites at LANL. Drum handling tasks at TA-50 Building 69 were reviewed on May 26th, 2011 with Fred Moya. A meeting was held with Joe Abeyta, Jose Chavez, and Don Thorp on July 13th, 2011 to discuss drum handling issues and manual material handling equipment specifications. A second meeting was held on August 9th, 2011 with Stephanie Jacquez, Juan Garcia and Alfred Vallo to review issues associated with drum handling at TA-54. Alfred Vallo toured the domes at TA-54 with Kimberly Monroe on August 11th, 2011. At that time, employee feedback was solicited from multiple employees handling drums throughout the area. A final review meeting was held on September 28th with Kimberly Monroe, Kerith Stender, and Juan Garcia to finalize this report.