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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 NTRS2019

Development of a Maxwell X-57 High Lift Motor Reference Design

NASA's all-electric X-57 airplane will utilize 14 electric motors, of which 12 are exclusively for lift augmentation during takeoff and landing. This report covers the design and development process taken to create an open reference model representative of the 12 lift augmenting motors. A combined worst case scenario was used as the design point, which represents the simultaneously occurring worst case aspects of thermal, static stress, electromagnetic, and rotor dynamic conditions. This work also highlights the tightly coupled nature of aerospace electric motor design, requiring constant iteration between all disciplines involved. Further adding to the uniqueness is the cooling method, which is limited to nacelle skin forced convection cooling only, no internal air flow is permitted. The stator outer diameter limit of 156.45 mm greatly impacts the degree of coupling between the electromagnetic design with the thermal analysis. The permanent magnet synchronous motor developed here operates between 385 V and 538 V, at a peak current of 50 A. Detailed electromagnetic, thermal, static load, and rotordynamic analysis was completed for this electric motor; all of which are required for a full design. The rotordynamic analysis took into consideration the motor housing which is designed specifically for this motor. The final electric motor has a mass of 2.34 kg, produces 24.1 Nm of torque with a specific power of 5.56 kW/kg, and has an efficiency of 96.61% at the combined worst case design point.

Electric Aircraft↗
NASA NTRS1990

Space Transportation Avionics Technology Symposium. Volume 1: Executive summary

The focus of the symposium was to examine existing and planned avionics technology processes and products and to recommend necessary changes for strengthening priorities and program emphases. Innovative changes in avionics technology development and design processes, identified during the symposium, are needed to support the increasingly complex, multi-vehicle, integrated, autonomous space-based systems. Key technology advances make such a major initiative viable at this time: digital processing capabilities, integrated on-board test/checkout methods, easily reconfigurable laboratories, and software design and production techniques.

Source record↗
NASA NTRS1990

Space Transportation Avionics Technology Symposium. Volume 2: Conference Proceedings

The focus of the symposium was to examine existing and planned avionics technology processes and products and to recommend necessary changes for strengthening priorities and program emphases. Innovative changes in avionics technology development and design processes are needed to support the increasingly complex, multi-vehicle, integrated, autonomous space-based systems. Key technology advances make such a major initiative viable at this time: digital processing capabilities, integrated on-board test/checkout methods, easily reconfigurable laboratories, and software design and production techniques.

Source record↗
NASA NTRS2013

Towards a Decision Support System for Space Flight Operations

The Mission Operations Directorate (MOD) at the Johnson Space Center (JSC) has put in place a Model Based Systems Engineering (MBSE) technological framework for the development and execution of the Flight Production Process (FPP). This framework has provided much added value and return on investment to date. This paper describes a vision for a model based Decision Support System (DSS) for the development and execution of the FPP and its design and development process. The envisioned system extends the existing MBSE methodology and technological framework which is currently in use. The MBSE technological framework currently in place enables the systematic collection and integration of data required for building an FPP model for a diverse set of missions. This framework includes the technology, people and processes required for rapid development of architectural artifacts. It is used to build a feasible FPP model for the first flight of spacecraft and for recurrent flights throughout the life of the program. This model greatly enhances our ability to effectively engage with a new customer. It provides a preliminary work breakdown structure, data flow information and a master schedule based on its existing knowledge base. These artifacts are then refined and iterated upon with the customer for the development of a robust end-to-end, high-level integrated master schedule and its associated dependencies. The vision is to enhance this framework to enable its application for uncertainty management, decision support and optimization of the design and execution of the FPP by the program. Furthermore, this enhanced framework will enable the agile response and redesign of the FPP based on observed system behavior. The discrepancy of the anticipated system behavior and the observed behavior may be due to the processing of tasks internally, or due to external factors such as changes in program requirements or conditions associated with other organizations that are outside of MOD. The paper provides a roadmap for the three increments of this vision. These increments include (1) hardware and software system components and interfaces with the NASA ground system, (2) uncertainty management and (3) re-planning and automated execution. Each of these increments provide value independently; but some may also enable building of a subsequent increment.

Meshkat, Leila↗
NASA NTRS2013

Towards a decision support system for space flight operations

The Mission Operations Directorate (MOD) at the Johnson Space Center (JSC) has put in place a Model Based Systems Engineering (MBSE) technological framework for the development and execution of the Flight Production Process (FPP). This framework has provided much added value and return on investment to date. This paper describes a vision for a model based Decision Support System (DSS) for the development and execution of the FPP and its design and development process. The envisioned system extends the existing MBSE methodology and technological framework which is currently in use. The MBSE technological framework currently in place enables the systematic collection and integration of data required for building an FPP model for a diverse set of missions. This framework includes the technology, people and processes required for rapid development of architectural artifacts. It is used to build a feasible FPP model for the first flight of spacecraft and for recurrent flights throughout the life of the program. This model greatly enhances our ability to effectively engage with a new customer. It provides a preliminary work breakdown structure, data flow information and a master schedule based on its existing knowledge base. These artifacts are then refined and iterated upon with the customer for the development of a robust end-to-end, high-level integrated master schedule and its associated dependencies. The vision is to enhance this framework to enable its application for uncertainty management, decision support and optimization of the design and execution of the FPP by the program. Furthermore, this enhanced framework will enable the agile response and redesign of the FPP based on observed system behavior. The differences between the anticipated system behavior and the observed behavior may be due to the processing of tasks internally, or due to external factors such as changes in program requirements or conditions associated with other organizations that are outside of MOD. The paper provides a roadmap for the four increments of this vision. These increments include (1) the existing capabilities (2) hardware and software system components and interfaces with the NASA ground system, (3) uncertainty management and (4) re-planning and automated execution. Each of these increments provides value independently; but some may also enable building of a subsequent increment.

Ruszkowski, James↗
NASA NTRS1995

Formal development of a clock synchronization circuit

This talk presents the latest stage in formal development of a fault-tolerant clock synchronization circuit. The development spans from a high level specification of the required properties to a circuit realizing the core function of the system. An abstract description of an algorithm has been verified to satisfy the high-level properties using the mechanical verification system EHDM. This abstract description is recast as a behavioral specification input to the Digital Design Derivation system (DDD) developed at Indiana University. DDD provides a formal design algebra for developing correct digital hardware. Using DDD as the principle design environment, a core circuit implementing the clock synchronization algorithm was developed. The design process consisted of standard DDD transformations augmented with an ad hoc refinement justified using the Prototype Verification System (PVS) from SRI International. Subsequent to the above development, Wilfredo Torres-Pomales discovered an area-efficient realization of the same function. Establishing correctness of this optimization requires reasoning in arithmetic, so a general verification is outside the domain of both DDD transformations and model-checking techniques. DDD represents digital hardware by systems of mutually recursive stream equations. A collection of PVS theories was developed to aid in reasoning about DDD-style streams. These theories include a combinator for defining streams that satisfy stream equations, and a means for proving stream equivalence by exhibiting a stream bisimulation. DDD was used to isolate the sub-system involved in Torres-Pomales' optimization. The equivalence between the original design and the optimized verified was verified in PVS by exhibiting a suitable bisimulation. The verification depended upon type constraints on the input streams and made extensive use of the PVS type system. The dependent types in PVS provided a useful mechanism for defining an appropriate bisimulation.

Miner, Paul S.↗
NASA NTRS2015

Design Process of Flight Vehicle Structures for a Common Bulkhead and an MPCV Spacecraft Adapter

Design and manufacturing space flight vehicle structures is a skillset that has grown considerably at NASA during that last several years. Beginning with the Ares program and followed by the Space Launch System (SLS); in‐house designs were produced for both the Upper Stage and the SLS Multipurpose crew vehicle (MPCV) spacecraft adapter. Specifically, critical design review (CDR) level analysis and flight production drawing were produced for the above mentioned hardware. In particular, the experience of this in‐house design work led to increased manufacturing infrastructure for both Marshal Space Flight Center (MSFC) and Michoud Assembly Facility (MAF), improved skillsets in both analysis and design, and hands on experience in building and testing (MSA) full scale hardware. The hardware design and development processes from initiation to CDR and finally flight; resulted in many challenges and experiences that produced valuable lessons. This paper builds on these experiences of NASA in recent years on designing and fabricating flight hardware and examines the design/development processes used, as well as the challenges and lessons learned, i.e. from the initial design, loads estimation and mass constraints to structural optimization/affordability to release of production drawing to hardware manufacturing. While there are many documented design processes which a design engineer can follow, these unique experiences can offer insight into designing hardware in current program environments and present solutions to many of the challenges experienced by the engineering team.

Aggarwal, Pravin↗
NASA NTRS2005

Heart Pump Design for Cleveland Clinic Foundation

Through a Lewis CommTech Program project with the Cleveland Clinic Foundation, the NASA Lewis Research Center is playing a key role in the design and development of a permanently implantable, artificial heart pump assist device. Known as the Innovative Ventricular Assist System (IVAS), this device will take on the pumping role of the damaged left ventricle of the heart. The key part of the IVAS is a nonpulsatile (continuous flow) artificial heart pump with centrifugal impeller blades, driven by an electric motor. Lewis is part of an industry and academia team, led by the Ohio Aerospace Institute (OAI), that is working with the Cleveland Clinic Foundation to make IVAS a reality. This device has the potential to save tens of thousands of lives each year, since 80 percent of heart attack victims suffer irreversible damage to the left ventricle, the part of the heart that does most of the pumping. Impeller blade design codes and flow-modeling analytical codes will be used in the project. These codes were developed at Lewis for the aerospace industry but will be applicable to the IVAS design project. The analytical codes, which currently simulate the flow through the compressor and pump systems, will be used to simulate the flow within the blood pump in the artificial heart assist device. The Interdisciplinary Technology Office heads up Lewis' efforts in the IVAS project. With the aid of numerical modeling, the blood pump will address many design issues, including some fluid-dynamic design considerations that are unique to the properties of blood. Some of the issues that will be addressed in the design process include hemolysis, deposition, recirculation, pump efficiency, rotor thrust balance, and bearing lubrication. Optimum pumping system performance will be achieved by modeling all the interactions between the pump components. The interactions can be multidisciplinary and, therefore, are influenced not only by the fluid dynamics of adjacent components but also by thermal and structural effects. Lewis-developed flow-modeling codes to be used in the pump simulations will include a one-dimensional code and an incompressible three-dimensional Navier-Stokes flow code. These codes will analyze the prototype pump designed by the Cleveland Clinic Foundation. With an improved understanding of the flow phenomena within the prototype pump, design changes to improve the performance of the pump system can be verified by computer prior to fabrication in order to reduce risks. The use of Lewis flow modeling codes during the design and development process will improve pump system performance and reduce the number of prototypes built in the development phase. The first phase of the IVAS project is to fully develop the prototype in a laboratory environment that uses a water/glycerin mixture as the surrogate fluid to simulate blood. A later phase of the project will include testing in animals for final validation. Lewis will be involved in the IVAS project for 3 to 5 years.

Source record↗
NASA NTRS1993

The automated ground network system

The primary goal of the Automated Ground Network System (AGNS) project is to reduce Ground Network (GN) station life-cycle costs. To accomplish this goal, the AGNS project will employ an object-oriented approach to develop a new infrastructure that will permit continuous application of new technologies and methodologies to the Ground Network's class of problems. The AGNS project is a Total Quality (TQ) project. Through use of an open collaborative development environment, developers and users will have equal input into the end-to-end design and development process. This will permit direct user input and feedback and will enable rapid prototyping for requirements clarification. This paper describes the AGNS objectives, operations concept, and proposed design.

Smith, Miles T.↗
NASA NTRS2006

Accuracy Quantification of the Loci-CHEM Code for Chamber Wall Heat Transfer in a GO2/GH2 Single Element Injector Model Problem

A robust rocket engine combustor design and development process must include tools which can accurately predict the multi-dimensional thermal environments imposed on solid surfaces by the hot combustion products. Currently, empirical methods used in the design process are typically one dimensional and do not adequately account for the heat flux rise rate in the near-injector region of the chamber. Computational Fluid Dynamics holds promise to meet the design tool requirement, but requires accuracy quantification, or validation, before it can be confidently applied in the design process. This effort presents the beginning of such a validation process for the Loci-CHEM CFD code. The model problem examined here is a gaseous oxygen (GO2)/gaseous hydrogen (GH2) shear coaxial single element injector operating at a chamber pressure of 5.42 MPa. The GO2/GH2 propellant combination in this geometry represents one the simplest rocket model problems and is thus foundational to subsequent validation efforts for more complex injectors. Multiple steady state solutions have been produced with Loci-CHEM employing different hybrid grids and two-equation turbulence models. Iterative convergence for each solution is demonstrated via mass conservation, flow variable monitoring at discrete flow field locations as a function of solution iteration and overall residual performance. A baseline hybrid was used and then locally refined to demonstrate grid convergence. Solutions were obtained with three variations of the k-omega turbulence model.

West, Jeff↗
NASA NTRS2006

Accuracy Quantification of the Loci-CHEM Code for Chamber Wall Heat Fluxes in a G02/GH2 Single Element Injector Model Problem

A robust rocket engine combustor design and development process must include tools which can accurately predict the multi-dimensional thermal environments imposed on solid surfaces by the hot combustion products. Currently, empirical methods used in the design process are typically one dimensional and do not adequately account for the heat flux rise rate in the near-injector region of the chamber. Computational Fluid Dynamics holds promise to meet the design tool requirement, but requires accuracy quantification, or validation, before it can be confidently applied in the design process. This effort presents the beginning of such a validation process for the Loci- CHEM CPD code. The model problem examined here is a gaseous oxygen (GO2)/gaseous hydrogen (GH2) shear coaxial single element injector operating at a chamber pressure of 5.42 MPa. The GO2/GH2 propellant combination in this geometry represents one the simplest rocket model problems and is thus foundational to subsequent validation efforts for more complex injectors. Multiple steady state solutions have been produced with Loci-CHEM employing different hybrid grids and two-equation turbulence models. Iterative convergence for each solution is demonstrated via mass conservation, flow variable monitoring at discrete flow field locations as a function of solution iteration and overall residual performance. A baseline hybrid grid was used and then locally refined to demonstrate grid convergence. Solutions were also obtained with three variations of the k-omega turbulence model.

West, Jeff↗
NASA NTRS2011

NASA's Habitat Demonstration Unit (HDU) Pressurized Excursion Module (PEM) In-Field Demonstration at Desert RATS 2010

This paper describes the construction, assembly, subsystem integration, transportation, and field testing operations associated with the Habitat Demonstration Unit (HDU) Pressurized Excursion Module (PEM) and discusses lessons learned. In a one-year period beginning summer 2009, a tightly scheduled design-develop-build process was utilized by a small NASA "tiger team" to produce the functional HDU-PEM prototype in time to participate in the 2010 Desert Research and Technology Studies (Desert RATS) field campaign. The process required the coordination of multiple teams, subcontractors, facility management and safety staff. It also required a well-choreographed material handling and transportation process to deliver the finished product from the NASA-Johnson Space Center facilities to the remote Arizona desert locations of the field test. Significant findings of this paper include the team s greater understanding of the HDU-PEM s many integration issues and the in-field training the team acquired which will enable the implementation of the next-generation of improvements and development of high-fidelity field operations in a harsh environment. The Desert RATS analog environment is being promoted by NASA as an efficient means to design, build, and integrate multiple technologies in a mission architecture context, with the eventual goal of evolving the technologies into robust flight hardware systems. The HDU-PEM in-field demonstration at Desert RATS 2010 provided a validation process for the integration team, which has already begun to retool for the 2011 field tests that require an adapted architecture.

Tri, Terry O.↗
NASA NTRS2010

Evaluating the Medical Kit System for the International Space Station(ISS) - A Paradigm Revisited

Medical capabilities aboard the International Space Station (ISS) have been packaged to help astronaut crew medical officers (CMO) mitigate both urgent and non-urgent medical issues during their 6-month expeditions. Two ISS crewmembers are designated as CMOs for each 3-crewmember mission and are typically not physicians. In addition, the ISS may have communication gaps of up to 45 minutes during each orbit, necessitating medical equipment that can be reliably operated autonomously during flight. The retirement of the space shuttle combined with ten years of manned ISS expeditions led the Space Medicine Division at the NASA Johnson Space Center to reassess the current ISS Medical Kit System. This reassessment led to the system being streamlined to meet future logistical considerations with current Russian space vehicles and future NASA/commercial space vehicle systems. Methods The JSC Space Medicine Division coordinated the development of requirements, fabrication of prototypes, and conducted usability testing for the new ISS Medical Kit System in concert with implementing updated versions of the ISS Medical Check List and associated in-flight software applications. The teams constructed a medical kit system with the flexibility for use on the ISS, and resupply on the Russian Progress space vehicle and future NASA/commercial space vehicles. Results Prototype systems were developed, reviewed, and tested for implementation. Completion of Preliminary and Critical Design Reviews resulted in a streamlined ISS Medical Kit System that is being used for training by ISS crews starting with Expedition 27 (June 2011). Conclusions The team will present the process for designing, developing, , implementing, and training with this new ISS Medical Kit System.

Hailey, Melinda J.↗
NASA NTRS1999

Advanced Technology Inlet Design, NRA 8-21 Cycle II: DRACO Flowpath Hypersonic Inlet Design

The report outlines work performed in support of the flowpath development for the DRACO engine program. The design process initiated to develop a hypersonic axisymmetric inlet for a Mach 6 rocket-based combined cycle (RBCC) engine is discussed. Various design parametrics were investigated, including design shock-on-lip Mach number, cone angle, throat Mach number, throat angle. length of distributed compression, and subsonic diffuser contours. Conceptual mechanical designs consistent with installation into the D-21 vehicle were developed. Additionally, program planning for an intensive inlet development program to support a Critical Design Review in three years was performed. This development program included both analytical and experimental elements and support for a flight-capable inlet mechanical design.

Sanders, Bobby W.↗
NASA NTRS2019

Load Flow Analysis with Analytic Derivatives for Electric Aircraft Design Optimization

Many of the aircraft concepts of the future are exploring the use of hybrid-, turbo- or all-electric propulsion systems to improve performance and decrease environmental impacts. These aircraft concepts range from small rotorcraft for urban air mobility to conventional commercial transports to large blended wing body designs. Developing the conceptual design for these vehicles presents a challenge, however, as traditional aircraft design tools often were not developed to handle these unique propulsion system architectures. Previous studies on these vehicles have therefore relied on relatively simple models of the electrical transmission and distribution system. This paper presents the development of a hybrid AC-DC load flow (or power flow) analysis capability to enhance the conceptual design of these concept vehicles. Specifically, the desire was to create a load flow analysis capability within the OpenMDAO framework that is also being used to develop a set of compatible tools for rapid optimization of conceptual designs. This load flow analysis capability is unique in its flexible object-oriented structure and implementation of analytic derivatives to facilitate the use of solvers and gradient based optimization in the design process. The developed hybrid load flow analysis capability is first verified against a published 13-bus example then used to model the electrical distribution system for a turbo-electric tiltwing aircraft.

Load flow↗
NASA NTRSDate not supplied

NASA’s Human Landing System: Enabling the Next Generation of Lunar Science

The Human Landing System (HLS) is the mode of transportation that will take astronauts to the lunar surface as part of NASA's Artemis exploration program. HLS also serves as a research platform both on the surface and in lunar orbit, enabling critical scientific investigations on and of the Moon. With support at NASA centers around the country, the HLS program, based at Marshall Space Flight Center in Huntsville, Alabama, is working closely with its commercial partners throughout the development process to design and build innovative and technically advanced lunar landers – new vehicles designed for the modern era of space travel – leveraging decades of human spaceflight experience and the speed of the commercial sector. In 2019, NASA asked U.S. industry for proposals to design and develop a human lander for the first human mission to the lunar surface under Artemis. Initial contracts were awarded to Blue Origin Federation, Dynetics, and SpaceX to advance their designs. Following the execution of the ten-month Base Period, NASA announced in April 2021 that the agency selected SpaceX to move forward with its human landing system [1] and land the first two astronauts on the lunar surface during the Artemis III mission. Following two protest periods, NASA awarded the contract, known as Option A, to SpaceX in July 2021 and resumed work in November 2021 (Fig. 1). In parallel, the HLS program has been preparing for the acquisition that will procure regular crewed transportation to the lunar surface following Artemis III. NASA released a request for information (RFI) in July 2021 asking U.S. industry for feedback to help inform the future solicitation, known as Lunar Exploration Transportation Services (LETS) [2]. Also in July 2021, NASA released the NextSTEP-2 Appendix N broad agency announcement soliciting new work from U.S. industry to mature their HLS designs and perform risk reduction activities in advance of the LETS procurement [3]. NASA selected Blue Origin Federation, Dynetics, Lockheed Martin, Northrop Grumman, and SpaceX to participate [4]. This work will also help better inform the LETS procurement and prepare industry to propose. NASA hopes to release a draft request for proposals (RFP) in Spring 2022.

R C Weber↗
NASA NTRS1982

Non-mass-analyzed ion implantation equipment for high volume solar cell production

Equipment designed for junction formation in silicon solar cells is described. The equipment, designed for a production level of approximately one megawatt per year, consists of an ion implanter and annealer. Low cost is achieved by foregoing the use of mass analysis during the implantation, and by the use of a belt furnace for annealing. Results of process development, machine design and cost analysis are presented.

Armini, A. J.↗