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DOE OSTI2024

Next-Generation, High-temperature, High-frequency, High-efficiency, High-power-density Traction System

To meet performance and reliability requirements necessary for broader adoption of electric drive vehicles, the Electrical and Electronics Technical Team of the U.S. Drive partnership has established aggressive design goals for next-generation electric vehicle drivetrains. Specifically, the 2025 roadmap stipulates a 100 kW/L power density target and a $\$$2.7/kW cost target for power electronics, in addition to high-voltage operation (i.e., greater than 800 VDC). The additional targets for traction motor and the overall system performance impose further challenges on the power electronics design. For example, many high specific power machines have reduced iron content, and therefore reduced intrinsic filtering, thus requiring the inverter to supply a low-distortion drive current. These machines also typically have a high pole count, thus requiring drive current at a higher electrical frequency. Other motors, such as brush-less dc and switch reluctance machines, require a carefully-shaped, non-sinusoidal drive current (Yang, Shang, Brown, & Krishnamurthy, 2015), (Zhang, Bowman, O'Connel, & Haran, 2018), (Anderson, et al., 2018). Two- and three-level inverter topologies are the conventional framework for the power electronics design of the drivetrain, and some demonstrations have shown recent progress towards addressing cost, power density and efficiency goals (Gurpinar & Ozpineci, 2018), (Zhu, Kim, Chen, Erickson, & Maksimović, 2018), (Deshpande, Chen, Narayanasamy, Sathyanarayanan, & Luo, 2018), (Alizadeh, et al., 2019). However, an unconventional approach may be necessary to take the dramatic leap in power density necessitated by the roadmap—while simultaneously addressing the other system needs. Therefore, this project leverages the flying capacitor multilevel (FCML) topology, together with a scalable, modular approach, to address these needs. This type of hybrid converter has several advantages: lower voltage (i.e., less than 300 V) transistors can be used, energy-dense capacitors process most of the power, and the output current waveform is multilevel and exhibits a frequency multiplying effect—in other words, the output has reduced dv/dt and filtering requirements for the same high voltage dc bus. For example, in an electric vehicle with an 800 V bus, a 10-level FCML could leverage 100 V, commercially available GaN devices switching at 115 kHz to produce a ~1 MHz switching waveform (modulated according to the motor drive requirements) with one ninth of the dv/dt of a two-level converter. Prior work has already demonstrated promising performance and gravimetric power density figures for more electric aircraft applications (Pallo, Foulkes, Modeer, Coday, & Pilawa-Podgurski, 2018). This project leverages lessons learned to achieve the volumetric power density of 100 kW/L by employing advanced liquid cooling, address the 300,000 mile reliability challenge with redundant design, topology failure studies and online health monitoring, and reduce costs to $\$$2.7/kW through the use of low-cost GaN devices, modular converter assemblies, and modest modifications to traditional manufacturing methods. The project involved several hardware designs, each achieving increasing performance. At the conclusion of the project, a volumetric power density of 380 kW/L was achieved, in a 800V dc-ac converter, greatly surpassing even the aggressive target goal.

33 ADVANCED PROPULSION SYSTEMS↗

NASA NTRS2005

On-board fault-tolerant SAR processor for spaceborne imaging radar systems

A real-time high-performance and fault-tolerant FPGA-based hardware architecture for the processing of synthetic aperture radar (SAR) images has been developed for advanced spaceborne radar imaging systems. In this paper, we present the integrated design approach, from top-level algorithm specifications, system architectures, design methodology, functional verification, performance validation, down to hardware design and implementation.

imaging Radar↗

NASA NTRS2017

Relating a Jet-Surface Interaction Experiment to a Commercial Supersonic Transport Aircraft Using Numerical Simulations

Reynolds-Averaged Navier-Stokes (RANS) simulations were performed for a commercial supersonic transport aircraft concept and experimental hardware models designed to represent the installed propulsion system of the conceptual aircraft in an upcoming test campaign. The purpose of the experiment is to determine the effects of jet-surface interactions from supersonic aircraft on airport community noise. RANS simulations of the commercial supersonic transport aircraft concept were performed to relate the representative experimental hardware to the actual aircraft. RANS screening simulations were performed on the proposed test hardware to verify that it would be free from potential rig noise and to predict the aerodynamic forces on the model hardware to assist with structural design. The simulations showed a large region of separated flow formed in a junction region of one of the experimental configurations. This was dissimilar with simulations of the aircraft and could invalidate the noise measurements. This configuration was modified and a subsequent RANS simulation showed that the size of the flow separation was greatly reduced. The aerodynamic forces found on the experimental models were found to be relatively small when compared to the expected loads from the model’s own weight.Reynolds-Averaged Navier-Stokes (RANS) simulations were completed for two configurations of a three-stream inverted velocity profile (IVP) nozzle and a baseline single-stream round nozzle (mixed-flow equivalent conditions). For the Sideline and Cutback flow conditions, while the IVP nozzles did not reduce the peak turbulent kinetic energy on the lower side of the jet plume, the IVP nozzles did significantly reduce the size of the region of peak turbulent kinetic energy when compared to the jet plume of the baseline nozzle cases. The IVP nozzle at Sideline conditions did suffer a region of separated flow from the inner stream nozzle splitter that did produce an intense, but small, region of turbulent kinetic energy in the vicinity of the nozzle exit. When viewed with the understanding that jet noise is directly related to turbulent kinetic energy, these IVP nozzle simulations show the potential to reduce noise to observers located below the nozzle. However, these RANS simulations also show that some modifications may be needed to prevent the small region of separated flow-induced turbulent kinetic energy from the inner stream nozzle splitter at Sideline conditions.

Reynolds-Averaged Navier Stokes↗

DOE OSTI2021

Determining quantum phase diagrams of topological Kitaev-inspired models on NISQ quantum hardware

Topological protection is employed in fault-tolerant error correction and in developing quantum algorithms with topological qubits. But, topological protection intrinsic to models being simulated , also robustly protects calculations, even on NISQ hardware. We leverage it by simulating Kitaev-inspired models on IBM quantum computers and accurately determining their phase diagrams. This requires constructing conventional quantum circuits for Majorana braiding to prepare the ground states of Kitaev-inspired models. The entanglement entropy is then measured to calculate the quantum phase boundaries. We show how maintaining particle-hole symmetry when sampling through the Brillouin zone is critical to obtaining high accuracy. This work illustrates how topological protection intrinsic to a quantum model can be employed to perform robust calculations on NISQ hardware, when one measures the appropriate protected quantum properties. It opens the door for further simulation of topological quantum models on quantum hardware available today.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

NASA NTRSDate not supplied

Design and Analysis of Convolutional Neural Network for RF Signal Modulation Classification for In-Orbit Deployment

To effectively transmit data to and from satellites requires a complex and robust RF communication system. Commonly, several different types of signal modulations may be required to maximize satellite efficiency depending on a variety of unexpected channel impairments. We propose a neural network algorithm capable of learning these RF signal modulations using a supervised learning technique designed for low power, high-efficiency in-orbit deployment. The work presented demonstrates a convolutional neural network (CNN) capable of learning and recognizing a set of modulation schemes commonly used to transmit RF information. We are capable of recognizing the modulation scheme from the I and Q data channels directly, with no preprocessing or data conversion required other than breaking the incoming signal into a set of uniform normalized samples. We perform a network design and size analysis, showing that reasonably high accuracy can be obtained using networks with a relatively low number of trainable parameters. Given that a user of a system such as this may wish to receive a signal using a modulation scheme that the network has not previously learned, we demonstrate that transfer learning can learn new modulation schemes by retraining only the fully connected layers in the CNN. Thus, this type of network would excel in outer space deployment using high-efficiency transfer learning hardware. Modulation recognition can be performed through rapid feedforward computation, and the CNN training process is significantly simplified when learning new modulations is required.

CNN↗

NASA NTRS1994

Flight test of takeoff performance monitoring system

The Takeoff Performance Monitoring System (TOPMS) is a computer software and hardware graphics system that visually displays current runway position, acceleration performance, engine status, and other situation advisory information to aid pilots in their decision to continue or to abort a takeoff. The system was developed at the Langley Research Center using the fixed-base Transport Systems Research Vehicle (TSRV) simulator. (The TSRV is a highly modified Boeing 737-100 research airplane.) Several versions of the TOPMS displays were evaluated on the TSRV B-737 simulator by more than 40 research, United States Air Force, airline and industry and pilots who rated the system satisfactory and recommended further development and testing. In this study, the TOPMS was flight tested on the TSRV. A total of 55 takeoff and 30 abort situations were investigated at 5 airfields. TOPMS displays were observed on the navigation display screen in the TSRV research flight deck during various nominal and off-nominal situations, including normal takeoffs; reduced-throttle takeoffs; induced-acceleration deficiencies; simulated-engine failures; and several gross-weight, runway-geometry, runway-surface, and ambient conditions. All tests were performed on dry runways. The TOPMS software executed accurately during the flight tests and the displays correctly depicted the various test conditions. Evaluation pilots found the displays easy to monitor and understand. The algorithm provides pretakeoff predictions of the nominal distances that are needed to accelerate the airplane to takeoff speed and to brake it to a stop; these predictions agreed reasonably well with corresponding values measured during several fully executed and aborted takeoffs. The TOPMS is operational and has been retained on the TSRV for general use and demonstration.

Middleton, David B.↗

DOE OSTI2015

Power Hardware-in-the-Loop-Based Anti-Islanding Evaluation and Demonstration

The National Renewable Energy Laboratory (NREL) teamed with Southern California Edison (SCE), Clean Power Research (CPR), Quanta Technology (QT), and Electrical Distribution Design (EDD) to conduct a U.S. Department of Energy (DOE) and California Public Utility Commission (CPUC) California Solar Initiative (CSI)-funded research project investigating the impacts of integrating high-penetration levels of photovoltaics (PV) onto the California distribution grid. One topic researched in the context of high-penetration PV integration onto the distribution system is the ability of PV inverters to (1) detect islanding conditions (i.e., when the distribution system to which the PV inverter is connected becomes disconnected from the utility power connection) and (2) disconnect from the islanded system within the time specified in the performance specifications outlined in IEEE Standard 1547. This condition may cause damage to other connected equipment due to insufficient power quality (e.g., over-and under-voltages) and may also be a safety hazard to personnel that may be working on feeder sections to restore service. NREL teamed with the Florida State University (FSU) Center for Advanced Power Systems (CAPS) to investigate a new way of testing PV inverters for IEEE Standard 1547 unintentional islanding performance specifications using power hardware-in-loop (PHIL) laboratory testing techniques.

14 SOLAR ENERGY↗

NASA NTRS1988

Telescope protection algorithm for the Space Infrared Telescope Facility

This paper presents a proposed on-board Telescope Protection Algorithm (TPA) for the Space Infrared Telescope Facility (SIRTF). This TPA consists of hardware and software capable of performing both fail-operational and fail-safe modes of operation. In the fail-operational mode, each ephemeris load and slew/dwell command sequence is checked on-board before use. The slew command monitor detects unallowable slew/dwell commands and transfers control to an algorithm which slews to and maintains a safe telescope orientation while preserving precise attitude determination and control. This fail-operational mode is also given the authority to autonomously restart the slew/dwell sequence at a point beyond the faulty command. The fail-safe system consists of software and hardware which detects impending earth, moon, or sun avoidance zone violations and activates a backup hardware safe hold mode. The subject TPA and relevant sensor complement were designed for the SIRTF mission; however, this system can easily be used as a basis for failure detection and correction in a wide range of other missions.

Class, B. F.↗

DOE OSTI2018

Fast Grid Frequency Support from Distributed Inverter-Based Resources

This presentation summarizes power hardware-in-the-loop testing performed to evaluate the ability of distributed inverter-coupled generation to support grid frequency on the fastest time scales. The research found that distributed PV inverters and other DERs can effectively support the grid on sub-second time scales.

14 SOLAR ENERGY↗

DOE OSTI2026

ORCHA: A performance portability system for extreme heterogeneity

Heterogeneity is the prevalent trend in the rapidly evolving high-performance computing (HPC) landscape in both hardware and application software. The diversity in hardware platforms, currently comprising various accelerators and a future possibility of specializable chiplets, poses a significant challenge for scientific software developers aiming to harness optimal performance across different computing platforms while maintaining the quality of solutions when their applications are simultaneously growing more complex. Code synthesis and code generation can provide mechanisms to mitigate this challenge. We have developed a divide and conquer approach where different aspects of performance are handled by different stand-alone tools that are interfaced with the application through generated code. This portability system, ORCHA, enables users to configure and orchestrate their computations among available resources on a platform by specifying a high-level recipe, thereby permitting a many-to-many paradigm where each recipe results in a different variant of the application. The core design goal is to let users decide the application’s hardware mapping and orchestration by editing only the high-level recipe—without modifying the maintained source code or binding the application to a particular runtime system. Tools in ORCHA distribution are: CG-Kit for translating the recipe into an execution graph; Milhoja to execute the graph by orchestrating data and task movement among hardware resources; and Macroprocessor that enables users to define their own code-shorthand for higher composability and easier management of code variants. Additionally, the design of ORCHA permits tools to work in a plug-and-play mode where the application can build and run without CG-Kit and Milhoja, and either tool can be swapped out for other tools with similar capabilities by modifying the code generation portion of ORCHA. In this paper, we describe the design of ORCHA and the role that code-generation plays in isolating applications from tools. We demonstrate the breadth of configurations ORCHA enables with a case study in which an application configuration is realized on three distinct hardware mappings—a GPU-centric, a CPU/GPU balanced, and a CPU/GPU concurrent layouts by using different recipes.

Lee, Youngjun↗

NASA NTRS1996

Laparoscopic surgery in weightlessness

BACKGROUND: Performing a surgical procedure in weightlessness has been shown not to be any more difficult than in a 1g environment if the requirements for the restraint of the patient, operator, and surgical hardware are observed. The feasibility of performing a laparoscopic surgical procedure in weightlessness, however, has been questionable. Concerns have included the impaired visualization from the lack of gravitational retraction of the bowel and from floating debris such as blood. METHODS: In this project, laparoscopic surgery was performed on a porcine animal model in the weightlessness of parabolic flight. RESULTS: Visualization was unaffected due to the tethering of the bowel by the elastic mesentery and the strong tendency for debris and blood to adhere to the abdominal wall due to surface tension forces. CONCLUSIONS: There are advantages to performing a laparoscopic instead of an open surgical procedure in a weightless environment. These will become important as the laparoscopic support hardware is miniaturized from its present form, as laparoscopic technology becomes more advanced, and as more surgically capable crew medical officers are present in future long-duration space-exploration missions.

manned↗

NASA NTRS1979

Space shuttle solid rocket booster cost-per-flight analysis technique

A cost per flight computer model is described which considers: traffic model, component attrition, hardware useful life, turnaround time for refurbishment, manufacturing rates, learning curves on the time to perform tasks, cost improvement curves on quantity hardware buys, inflation, spares philosophy, long lead, hardware funding requirements, and other logistics and scheduling constraints. Additional uses of the model include assessing the cost per flight impact of changing major space shuttle program parameters and searching for opportunities to make cost effective management decisions.

Forney, J. A.↗

NASA NTRS2003

Evaluation of Advanced Computing Techniques and Technologies: Reconfigurable Computing

The focus of this project was to survey the technology of reconfigurable computing determine its level of maturity and suitability for NASA applications. To better understand and assess the effectiveness of the reconfigurable design paradigm that is utilized within the HAL-15 reconfigurable computer system. This system was made available to NASA MSFC for this purpose, from Star Bridge Systems, Inc. To implement on at least one application that would benefit from the performance levels that are possible with reconfigurable hardware. It was originally proposed that experiments in fault tolerance and dynamically reconfigurability would be perform but time constraints mandated that these be pursued as future research.

Wells, B. Earl↗

NASA NTRS2016

NASA ERA Integrated CFD for Wind Tunnel Testing of Hybrid Wing-Body Configuration

The NASA Environmentally Responsible Aviation (ERA) Project explored enabling technologies to reduce impact of aviation on the environment. One project research challenge area was the study of advanced airframe and engine integration concepts to reduce community noise and fuel burn. To address this challenge, complex wind tunnel experiments at both the NASA Langley Research Center's (LaRC) 14'x22' and the Ames Research Center's 40'x80' low-speed wind tunnel facilities were conducted on a BOEING Hybrid Wing Body (HWB) configuration. These wind tunnel tests entailed various entries to evaluate the propulsion-airframe interference effects, including aerodynamic performance and aeroacoustics. In order to assist these tests in producing high quality data with minimal hardware interference, extensive Computational Fluid Dynamic (CFD) simulations were performed for everything from sting design and placement for both the wing body and powered ejector nacelle systems to the placement of aeroacoustic arrays to minimize its impact on vehicle aerodynamics. This paper presents a high-level summary of the CFD simulations that NASA performed in support of the model integration hardware design as well as the development of some CFD simulation guidelines based on post-test aerodynamic data. In addition, the paper includes details on how multiple CFD codes (OVERFLOW, STAR-CCM+, USM3D, and FUN3D) were efficiently used to provide timely insight into the wind tunnel experimental setup and execution.

Computational Fluid Dynamics↗

NASA NTRS2016

NASA ERA Integrated CFD for Wind Tunnel Testing of Hybrid Wing-Body Configuration

NASAs Environmentally Responsible Aviation (ERA) Project explores enabling technologies to reduce aviations impact on the environment. One research challenge area for the project has been to study advanced airframe and engine integration concepts to reduce community noise and fuel burn. In order to achieve this, complex wind tunnel experiments at both the NASA Langley Research Centers (LaRC) 14x22 and the Ames Research Centers 40x80 low-speed wind tunnel facilities were conducted on a Boeing Hybrid Wing Body (HWB) configuration. These wind tunnel tests entailed various entries to evaluate the propulsion airframe interference effects including aerodynamic performance and aeroacoustics. In order to assist these tests in producing high quality data with minimal hardware interference, extensive Computational Fluid Dynamic (CFD) simulations were performed for everything from sting design and placement for both the wing body and powered ejector nacelle systems to the placement of aeroacoustic arrays to minimize its impact on the vehicles aerodynamics. This paper will provide a high level summary of the CFD simulations that NASA performed in support of the model integration hardware design as well as some simulation guideline development based on post-test aerodynamic data. In addition, the paper includes details on how multiple CFD codes (OVERFLOW, STAR-CCM+, USM3D, and FUN3D) were efficiently used to provide timely insight into the wind tunnel experimental setup and execution.

Computational Fluid Dynamics↗

NASA NTRS1990

The NASA, Marshall Space Flight Center drop tube user's manual

A comprehensive description of the structural and instrumentation hardware and the experimental capabilities of the 105-meter Marshall Space Flight Center Drop Tube Facility is given. This document is to serve as a guide to the investigator who wishes to perform materials processing experiments in the Drop Tube. Particular attention is given to the Tube's hardware to which an investigator must interface to perform experiments. This hardware consists of the permanent structural hardware (with such items as vacuum flanges), and the experimental hardware (with the furnaces and the sample insertion devices). Two furnaces, an electron-beam and an electromagnetic levitator, are currently used to melt metallic samples in a process environment that can range from 10(exp -6) Torr to 1 atmosphere. Details of these furnaces, the processing environment gases/vacuum, the electrical power, and data acquisition capabilities are specified to allow an investigator to design his/her experiment to maximize successful results and to reduce experimental setup time on the Tube. Various devices used to catch samples while inflicting minimum damage and to enhance turnaround time between experiments are described. Enough information is provided to allow an investigator who wishes to build his/her own furnace or sample catch devices to easily interface it to the Tube. The experimental instrumentation and data acquisition systems used to perform pre-drop and in-flight measurements of the melting and solidification process are also detailed. Typical experimental results are presented as an indicator of the type of data that is provided by the Drop Tube Facility. A summary bibliography of past Drop Tube experiments is provided, and an appendix explaining the noncontact temperature determination of free-falling drops is provided. This document is to be revised occasionally as improvements to the Facility are made and as the summary bibliography grows.

Rathz, Thomas J.↗

NASA NTRSDate not supplied

Integral Channel Nozzles and Heat Exchangers using Additive Manufacturing Directed Energy Deposition NASA HR-1 Alloy

Heat exchangers for use in propulsion applications are very critical components because they must be efficient, compact and light and often operate with working fluids at extreme temperatures or pressures or both. Various components and systems use heat exchangers such as combustion chambers of gas turbines and internal combustion engines, fuel cells (air supply and thermal management), electric batteries (thermal management), evaporators and recuperators of waste-heat-to-power systems, and rocket engines. Even if the results are more generally applicable, the heat exchangers applications to which this study is more closely related are regeneratively cooled rocket nozzles and chambers, and repressurization systems for the launch vehicles. These components are often thin-walled and contain pressurized fluids, like propellants at cryogenic or elevated temperatures. Given that the environments that these propulsion components must endure are challenging, the manufacturing to meet these specifications often require long lead times due to specialty processes and unique tooling associated with the combined thin-wall integral channel and large-scale structures. Additive manufacturing (AM) offers programmatic advantages for reduction in processing time and cost in addition to various technical advantages, including the possibility to achieve enhanced hardware complexity targeted to superior performance, part consolidation, and the capability of processing of novel alloys. While AM is already being utilized for heat exchanger components in propulsion applications, almost all these AM components are made by means of Laser Powder Bed Fusion (L-PBF). L-PBF allows for fine features but is rather limited with respect to the overall size of the components that can be manufactured. Recent developments are maturing the Laser Powder Directed Energy Deposition (LP-DED) process which may be used, for example, to make integral channel thin-wall regeneratively-cooled rocket nozzles with diameters greater than 1 m. This paper highlights some integral channel heat exchanger demonstrator hardware applications of LP-DED, as well as the characterization of this process in combination with the use of the NASA HR-1 alloy. To properly utilize LP-DED for heat exchanger manufacturing, various aspects are being characterized such as geometry limitations, measurement of surface texture and geometric angled surfaces, surface enhancements for internal channels, and material evaluation. NASA HR-1 (FeNi-Cr) is a high strength hydrogen resistant superalloy developed for use in aerospace applications, such as heat exchangers. Some aspects and considerations about the design of heat exchangers are summarized together with data relevant to LP-DED manufacturing in combination with the NASA HR-1 alloy. Microchannels were successful deposited down to 2.54 mm and 1 mm wall thickness, wall angles of 30°, both with high reproducibility. It was also found that the areal surface roughness is highly dependent on the size of the powder feedstock used for deposition. The characterization of these LP-DED features is critical for fluid flow and heat transfer predictions as it can be exploited to enhance heat transfer at the cost of increased pressure drop.

Additive Manufacturing↗

NASA NTRSDate not supplied

Integral Channel Nozzles and Heat Exchangers using Additive Manufacturing Directed Energy Deposition NASA HR-1 Alloy

additive manufacturing↗