Role of NDE and In-Situ Process Monitoring in Managing Risk of AM Space Hardware
We will discuss NASA’s interest in qualifying in-situ monitoring and NDE methods for certification of AM space hardware.
additive manufacturing↗
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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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Instrumentation and Testing of Ground and Flight Hardware
The goal of this white paper is to highlight some of the key issues associated with the instrumentation and testing of ground and flight hardware. The information is arranged topically and follows a line of organization that begins with the development of test objectives, the development of requirements, the purchase and installation of instrumentation, and covers many considerations to ensure that measurements will provide the required data during the conduct of the test. Ideally, all of these considerations would be factored into a test program; however, due to programmatic, budgetary, and calendar restraints, only a subset of these factors will typically be considered. Although the primary emphasis of this text is on thermal measurements, all disciplines can benefit from these recommendations.
Thermocouple↗
Hardware Autonomy for Space Infrastructure
NASA prioritizes autonomous systems development with the expectation that it will continue to drive significant improvements in human and science exploration capability. Crew operations benefit from a spectrum of machine assistance to complete replacement of dangerous or highly repetitive tasks. Many science operations have a teleoperation component, and similarly benefit from a range of autonomy implementations that make long distance applications feasible. As we consider longer duration deep space missions, we also consider higher levels of autonomy in order meet emergent safety, maintenance, and logistics needs. One of the challenges within this scope is installation and maintenance of infrastructure, such as large scale instrumentation and communications equipment, crew habitats, and operational facilities. We describe how a programmable meta-material architecture may shift the paradigm of how we design, build, and operate future space infrastructure and assets. A primary objective of this strategy is to free the design space from launch vehicle constraints and fundamentally shift how a mission is designed and conducted. This integrates advances in materials (mechanical meta-materials), manufacturing (cooperative mobile robotics), and autonomy (multi-agent planning algorithms). Engineering systems that utilize a modular and reconfiguration building block approach, such as digital communication and computation systems, currently lead in terms of size and complexity scalability. NASA is extending the benefits and flexibility of digital systems to hardware systems, to optimize materials life-cycle management and expand our space exploration mission capabilities to meet long duration and deep space infrastructure needs, in accordance with long term NASA goals of "in-space reliance" and "mass-less exploration."
In space assembly↗
Ssdev-Ecat: A Configurable Motion Control Server for Mars 2020 Hardware Testbeds
We describe the design and implementation of a motion control server that proved crucial to the safe assembly and validation of Mars 2020 hardware in the absence of flight avionics.
Biesiadecki, Jeff↗
Hardware-in-the-Loop Simulation of Modular Antenna Assembly
Robots are playing an increasing role in space exploration and in-space servicing. Robotic arms are good for performing in-space tasks such as modular assembly. The SPIDER arm (SPace Infrastructure Dexterous Robot) of the OSAM-1 mission represents an example of a system that can perform modular antenna assembly tasks in environmental conditions that would be dangerous for astronauts. One of the WVRTC activities is to perform independent verification and validation of the SPIDER assembly operations. Space robotic systems adopting large manipulators such as the SPIDER arm are complex to test and verify under normal 1-G conditions. Our work involves proof-of-principle testing of a hardware-inthe-loop (HIL) simulator operating in 1-g conditions, which replicates the motion of the space robot end-effector under the same geometric, kinematic and dynamic conditions, and in response to externally applied forces from its space environment. In particular, our software simulates in real-time the robot dynamics inclusive of flexibility, an important aspect in case of a long robotic arms operating in 0-G conditions. For example, the same oscillatory motions of the space manipulator’s end-effector can be mimicked on ground through our industrial manipulator, allowing us to test the feasibility of complex operation such as assembling modular components.
Robotic Assembly↗
Role of NDE and In Situ Process Monitoring in Managing Risk of AM Space Hardware
We will discuss NASA’s interest in qualifying in situ monitoring and NDE methods for certification of AM space hardware. NASA is interested in qualifying in situ monitoring for complex, critical parts that are difficult to inspect using traditional NDE.
Erin Lanigan↗
Tutorial: Electrified Aircraft Propulsion Approaches for Modeling and Electrical Hardware-in-the-Loop Testing
This tutorial session outlines capabilities made available by the National Aeronautics and Space Administration for testing electrified aircraft propulsion (EAP) hardware and software prior to using turbomachinery. Removing these components from the experimentation process until necessary significantly reduces the development and testing costs and safety risks. Three facilities, the NASA Electric Aircraft Testbed (NEAT) and the Hybrid Propulsion Emulation Rig (HyPER) are unique facilities that provide the following capabilities: (i) the verification of megawatt-scale electrical and electromechanical system components at altitude, (ii) the verification of EAP control systems on sub-scale representative electromechanical architectures. The importance, operation, and specifications of each facility is described with detail. Provided examples of past testing showcase the abilities of each facility. Simple and complex methods for replicating the steady state and dynamical mechanical loading on the electrical power system are discussed
Electrified Aircraft Propulsion↗
SUbsonic Single Aft eNgine (SUSAN) Power/Propulsion System Hardware-in-the-Loop Test Results
Electrified Aircraft Propulsion (EAP) technology offers a promising path forward for reducing greenhouse gas emissions and other negative environmental effects from the commercial aviation sector. EAP systems can reduce fuel burn and improve performance over state-of the-art designs, however the increased complexity and highly coupled nature of these systems present challenges that require new control approaches. The SUbsonic Single Aft eNgine (SUSAN) Electrofan is a concept aircraft developed by NASA as a reference design for a commercial transport aircraft with a highly integrated hybrid-electric powertrain. This paper summarizes the results of a Hardware-in-the-Loop (HIL) test of a control architecture developed for the SUSAN power/propulsion system (PPS). The test was performed in the Hybrid Propulsion Emulation Rig (HyPER) facility at the NASA Glenn Research Center (GRC) and involved a real-time reference model of the SUSAN PPS and control system running with a sub-scale electro-mechanical system replacing one of the PPS subsystems. A side-by-side comparison of the simulated and real systems in the HIL test results shows that the control architecture functions well in both the simulation and the real-time HIL environment. In both cases the controller is able to simultaneously deliver the required thrust response and balance power levels between the electrical and turbomachinery subsystems.
Jonah J Sachs-Wetstone↗
SUbsonic Single Aft eNgine (SUSAN) Power/Propulsion System Hardware-in-the-Loop Test Results
Electrified Aircraft Propulsion (EAP) technology offers a promising path forward for reducing greenhouse gas emissions and other negative environmental effects from the commercial aviation sector. EAP systems can reduce fuel burn and improve performance over state-of the-art designs, however the increased complexity and highly coupled nature of these systems present challenges that require new control approaches. The SUbsonic Single Aft eNgine (SUSAN) Electrofan is a concept aircraft developed by NASA as a reference design for a commercial transport aircraft with a highly integrated hybrid-electric powertrain. This paper summarizes the results of a Hardware-in-the-Loop (HIL) test of a control architecture developed for the SUSAN power/propulsion system (PPS). The test was performed in the Hybrid Propulsion Emulation Rig (HyPER) facility at the NASA Glenn Research Center (GRC) and involved a real-time reference model of the SUSAN PPS and control system running with a sub-scale electro-mechanical system replacing one of the PPS subsystems. A side-by-side comparison of the simulated and real systems in the HIL test results shows that the control architecture functions well in both the simulation and the real-time HIL environment. In both cases the controller is able to simultaneously deliver the required thrust response and balance power levels between the electrical and turbomachinery subsystems.
EAP↗
VIPER Rover Overview and Mobility and Hardware
Presentation of VIPER Rover Overview, Mobility and Hardware at Technology Infusion Panel at STMD Lunar Surface Innovation Consortium
viper↗
Subscale Hardware-In-The-Loop Results for Hybrid Electric Turbofan Controls Use Cases
NASA is investigating hybrid electric turbine engine systems for commercial transport aircraft due to the potentially significant improvements hybrid electric technology offers in performance, fuel consumption, and operational and design flexibility. Recently, the technology has been tested at full scale in partnership with industry and advanced to Technology Readiness Level 4. This presentation will focus on a recent subscale hardware-in-the-loop test of an open source turbofan engine model developed by NASA. The Advanced Geared Turbofan 30,000 lbf – electrified (AGTF30-e) engine is used as a reference model to demonstrate control system design and use cases for an example mild hybrid electric system with no large-scale energy storage. This model is run in real-time in NASA’s Hybrid Propulsion Emulation Rig (HyPER) and is used to drive an emulation of the turbomachinery system using subscale electric machines. This dynamic scaled shaft emulation interacts with a subscale (<100 kW) hybrid system consisting of electric machines, motor controllers, and a programmable electronic load. Specific use cases demonstrated include the use of Turbine Electrified Energy Management to improve operation during transients, megawatt-scale power extraction from the AGTF30-e, and power transfer between engine spools. Results related to the effectiveness of hybrid systems are qualitatively compared to results from industry testing.
Hybrid↗
Performance Evaluation of Multi-Vendor Grid-Forming Inverters for Grid-Connected Operation Through Hardware Experimentation
This paper presents the functional performance evaluation tests of multiple (three) commercial grid-forming (GFM) inverters when they operate in parallel with the grid through hardware experiments. The goal of these tests is to explore and benchmark the GFM inverters' functionalities and dynamic response when they are operated in parallel with power grids. Both steady-state (changing the inverter's frequency and voltage droop) and transient (adding step changes to grid's frequency/voltage) tests are performed for each GFM inverter with the same testing circuit and testing protocol. The key findings are summarized as follows: 1) The GFM inverters can be dispatched through frequency and voltage droop intercepts to output the target power; and 1) the GFM inverters automatically respond to system frequency and voltage events to output the needed power; 3) all the GFM inviters shows stability issues when absorbing reactive power from the grid.
frequency droop↗
Visualizing a Vulnerability: Its Connections to Hardware and Software
All Hazards Analysis (AHA) is a framework developed by Idaho National Laboratory that provides capabilities to collect, store, analyze, and visualize critical infrastructure information. A core function of AHA is its ability to simulate faults or outages in networks of infrastructure originating from a plethora of causes, ranging from natural disasters to cyberattacks. AHA utilizes Hardware and Software Bills of Material (HBOM and SBOM, respectively) along with Known Exploited Vulnerabilities (KEVs) to document the potential attack vectors for each piece of infrastructure. The objective of this contribution to AHA was to create a visualization tool that could capture the small details held in each individual artifact as well as preserve the large-scale connections that link them together to aid threat modeling.
58 GEOSCIENCES↗
Development of a Practical Secondary Control for Hardware Microgrids
Practical, vendor-agnostic interoperability guidelines for the secondary control architecture of microgrids (MGs) with multiple grid-forming (GFM) inverter-based resources (IBRs) have not yet been developed. Therefore, this paper proposes a generic and vendor-agnostic secondary control architecture that operates with all GFM IBRs and synchronous generators. This secondary control does not require the use of additional measurement devices in the MG and utilizes the inherent communication systems of the GFM units, such as Modbus TCP/IP. The practical challenges of Modbus registers, such as packet loss and quantization error, and their detrimental impacts on secondary control actions are investigated. The proposed three-stage modification for any secondary control architecture to mitigate these impacts includes: 1) averaging the data read, 2) situational event-triggering of the controller, and 3) finite iteration of the controlling action. The proposed method is validated using a three-phase electric power, 480 V, 60 Hz, 500 kVA laboratory hardware microgrid with commercial two GFM IBRs and one diesel generator. The experimental results corroborates the fact the proposed modification in the secondary control architecture is advantageous for practical usage under erroneous measurements.
grid-forming inverter↗
Development of a Practical Secondary Control for Hardware Microgrids: Preprint
Practical vendor-agnostic interoperability guidelines for the secondary control architecture of microgrids (MGs) with multiple grid-forming (GFM) inverter-based resources (IBRs) have not yet been developed. Therefore, this paper proposes a generic and vendor-agnostic secondary control architecture that works with all GFM IBRs and synchronous generators. This secondary control does not need to employ any additional measurement devices in the MG and uses the inherent communication systems of the GFM units, such as Modbus TCP/IP. The practical challenges of Modbus holding registers such as packet loss, quantization error, etc. and their deteriorating impacts on the secondary control action are investigated. The proposed three-stage modification of any secondary control architecture to eliminate these impacts includes 1) averaging the data read, 2) situational event-triggering of the controller, and 3) the finite iteration of the controlling action. The proposed method is validated using a laboratory hardware MG with commercial GFM units.
inverter based resources↗
Employing a Hardware-in-the-Loop Approach to Realize a Fully Homomorphic Controller for a Small Modular Advanced High Temperature Reactor
This paper addresses the cybersecurity challenges of advanced nuclear reactors by integrating fully homomorphic encryption (FHE) into their control systems, enabling encrypted processing of control signals without compromising functionality. Advanced nuclear reactors, including Small Modular Reactors (SMRs) and microreactors, aim to achieve autonomous and remote operations, reducing costs and enhancing competitiveness. However, these advancements expand the attack surface for cyberattacks, particularly in autonomous and remote operation scenarios. Cyberattacks can exploit vulnerabilities to manipulate physical processes, causing shutdowns, asset damage, or public harm. Such attacks begin with passive reconnaissance, where adversaries intercept communications or observe behaviors to gather information, which is then leveraged to execute cyber-physical attacks by injecting malicious commands. Nuclear power must adopt cybersecurity protection measures to secure the integrity and availability of their digital control systems. This paper demonstrates the application of FHE to secure operations by enabling encrypted processing of sensitive signals and parameters -- ensuring privacy without exposing data. FHE supports secure mathematical operations on encrypted data without requiring decryption. Using a hardware-in-the-loop (HIL) approach, this paper implements an FHE-integrated controller on a BeagleBone Black (BBB) controlling a simulation of the Small Modular Advanced High Temperature Reactor (SmAHTR). By doing so, the encrypted controller protects the integrity of critical set points and control signals during transmission and processing. Thus, FHE-integrated controllers enhance secure operations of advanced nuclear reactors while maintaining functionality.
control systems↗
Evaluating Thermostats’ Deadbands Using HVAC Hardware-In-the-Loop Experiment for Advanced Control Strategies
Thermostats play a crucial role in energy consumption, user control, and occupant comfort by serving as the interface between the heating, ventilation, and air conditioning (HVAC) system and the building's occupants. The deadband, also referred to as temperature differential, is defined as the temperature difference between the desired setpoint and upper threshold or lower threshold for the HVAC equipment to turn on or off. It is a key factor influencing energy efficiency and user satisfaction. This paper presents a comparative analysis of the deadbands of five different thermostats, tested with a residential heat pump, aiming to identify variations in their deadband settings and implications for energy usage and management. The experimental study was conducted using a HVAC hardware-in-the-loop (HIL) system that allows thermostats to be connected with physical HVAC equipment, driven by conditions in a simulated residential building. The study explores the trade-offs between energy efficiency and occupant comfort and highlights how different thermostats cycle differently based on their deadband settings. The findings offer valuable insights into how thermostat deadband affects comfort and energy use, as well as the cycling frequency of a heat pump.
Ramaraj, Sugirdhalakshmi [National Renewable Energ↗
hls4ml: A Flexible, Open-Source Platform for Deep Learning Acceleration on Reconfigurable Hardware
We present hls4ml, a free and open-source platform that translates machine learning (ML) models from modern deep learning frameworks into high-level synthesis (HLS) code that can be integrated into full designs for field-programmable gate arrays (FPGAs) or application-specific integrated circuits (ASICs). With its flexible and modular design, hls4ml supports a large number of deep learning frameworks and can target HLS compilers from several vendors, including Vitis HLS, Intel oneAPI and Catapult HLS. Together with a wider eco-system for software-hardware co-design, hls4ml has enabled the acceleration of ML inference in a wide range of commercial and scientific applications where low latency, resource usage, and power consumption are critical. In this paper, we describe the structure and functionality of the hls4ml platform. The overarching design considerations for the generated HLS code are discussed, together with selected performance results.
Schulte, Jan-Frederik [Purdue U.] (ORCID:000000034↗