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DOE OSTI2025

Evaluating Thermostats' Deadbands Using HVAC Hardware-In-the-Loop Experiment for Advanced Control Strategies

Smart thermostats have gained significant popularity due to their potential for optimizing energy consumption and enhanced user control while ensuring occupants' comfort. 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. It is a key factor influencing energy efficiency and user satisfaction. This paper presents a comparative analysis of the deadbands of five different smart thermostats, tested with a heat pump, aiming to identify variations in their deadband settings and implications for energy management. The experimental study was conducted using a HVAC hardware-in-theloop (HIL) system that integrates smart thermostats with physical HVAC equipment in a simulated house environment. The study explores the trade-offs between energy efficiency and occupant comfort and highlights how different thermostats participating in demand response event cycle differently based on their deadband settings. The findings offer valuable insights into how selecting the right thermostat or configuring smart thermostat with appropriate deadband settings can be leveraged to enhance demand response capabilities, shift loads effectively and improve operational flexibility in HVAC systems.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2025

Closed-Loop Control of Active Nematic Flows

Stabilizing and shaping autonomous flows of active fluids is a fundamental challenge and a prerequisite for applications. We embed a light-responsive microtubule-based nematic in a proportional-integral control loop that adjusts the applied light intensity in response to real-time measurements of the spatially averaged flow speed. The self-regulating hardware-software-wetware system maintains a target flow speed against external or internal perturbations, including protein aging and aggregation, sample-to-sample variability, and temperature variation. Varying the controller’s gains reveals antagonistic roles between feedback and intrinsic processes, leading to nontrivial dynamics observed in fluctuation spectra. In particular, oscillations emerge from the interplay between the controller, motor binding kinetics, and active hydrodynamic relaxation. Accounting for the underlying binding timescale, our coarse-grained model and nematohydrodynamics simulations corroborate these observations. This work provides insight into the coupled dynamics of controlled active matter, laying the foundation for spatiotemporal patterning of active stress to generate and stabilize new dynamical configurations.

Active nematics↗

NASA NTRS1988

Development of experimental systems for material sciences under microgravity

As part of the Space Experiment Program of the Society of Japanese Aerospace Companies, three experimental systems (G452, G453, G454) have been developed for materials science studies under microgravity by the NEC Corporation. These systems are to be flown as Get Away Special payloads for studying the feasibility of producing new materials. Together with the experimental modules carrying the hardware specific to the experiment, the three systems all comprise standard subsystems consisting of a power supply, sequence controller, temperature controller, data recorder, and video recorder.

Tanii, Jun↗

DOE OSTI2025

Evaluating Thermostats' Deadbands Using HVAC Hardware-In-the-Loop Experiment for Advanced Control Strategies: Preprint

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

NASA NTRS2022

Precious Cargo: Transporting Contamination-Sensitive Instruments & Optics

The James Webb Space Telescope (JWST) is a multi-national program with instruments and hardware supplied by companies all over the world and numerous states in the United States. In order to transport larger assemblies, like the Optical Telescope Element / Integrated Science Instrument Module (OTIS), and ultimately JWST, the Space Telescope Transporter for Air, Road and Sea (STTARS) was designed and constructed. STTARS is a massive mobile cleanroom (longer than 2 semi-trailers) that provides an ISO class 7 payload environment while being transported by road, airborne and marine vehicles. Temperature, humidity, and particle counts are controlled and continuously tracked, with fallout and NVR witness samples placed in strategic locations for confirmation. Instruments or sensitive hardware were purged continuously during transport. STTARS has 5 main components: the upper tent frame, lower tent frame, pallet, strong back and lid. After transporting OTIS to Northrup Grumman (NG), STTARS was modified to increase its height to house the JWST Observatory on its voyage to French Guiana. This new configuration was designated Observatory STTARS (OSTTARS). OSTTARS was too tall to travel by C5 aircraft, so the trip to the launch site was made by ship. Through JWST’s land, air, and sea transports, STTARS and OSTTARS kept JWST hardware exceptionally clean and safe.

James Webb Space Telescope↗

NASA NTRSDate not supplied

Precious Cargo: Transporting contamination-sensitive instruments & optics

James Webb Space Telescope↗

NASA NTRS2003

High-Temperature Switched-Reluctance Electric Motor

An eight-pole radial magnetic bearing has been modified into a switched-reluctance electric motor capable of operating at a speed as high as 8,000 rpm at a temperature as high as 1,000 F (=540 C). The motor (see figure) is an experimental prototype of starter-motor/generator units that have been proposed to be incorporated into advanced gas turbine engines and that could operate without need for lubrication or active cooling. The unique features of this motor are its electromagnet coils and, to some extent, its control software. Heretofore, there has been no commercial-off-the-shelf wire capable of satisfying all of the requirements for fabrication of electromagnet coils capable of operation at temperatures up to 1,000 F (=540 C). The issues addressed in the development of these electromagnet coils included thermal expansion, oxidation, pliability to small bend radii, micro-fretting, dielectric breakdown, tensile strength, potting compound, thermal conduction, and packing factor. For a test, the motor was supported, along with a rotor of 18 lb (.8-kg) mass, 3-in. (.7.6-cm) diameter, 21-in. (.53-cm) length, on bearings packed with high-temperature grease. The motor was located at the mid span of the rotor and wrapped with heaters. The motor stator was instrumented with thermocouples. At the time of reporting the information for this article, the motor had undergone 14 thermal cycles between room temperature and 1,000 F (.540 C) and had accumulated operating time >27.5 hours at 1,000 F (=540 C). The motor-controller hardware includes a personal computer equipped with analog-to-digital input and digital-to-analog output cards. The controller software is a C-language code that implements a switched-reluctance motor-control principle: that is, it causes the coils to be energized in a sequence timed to generate a rotating magnetic flux that creates a torque on a scalloped rotor. The controller can operate in an open- or closed-loop mode. In addition, the software has been modified to enable the simultaneous operation of the prototype motor or another, similar apparatus as both a motor and a magnetic bearing. Combined bearing/motor operation has been demonstrated at room temperature but had not yet been demonstrated at high temperature at the time of reporting the information for this article.

Montague, Gerald↗

NASA NTRS1991

Test equipment data package for the KC-135 fiber pulling apparatus

The Fiber Pulling Apparatus (FPA) is a device designed to produce continuous glass fibers from simulated lunar soil, and to determine the effects of reduced gravity, specifically 1/6 g on fiber formation and resultant properties. Briefly, pre-melt simulated lunar soil will be placed in a pint crucible and heated to 1200 C or higher, up to a maximum temperature of 1400 C. At a given temperature, a quartz fiber will be immersed into the melt and then pulled through a chill block and wound onto a cylindrical bobbin using a servo motor control. A high resolution video camera will record the fiber as it is being pulled. This assembly wil be enclosed in Plexiglas. Before fiber pulling commences, the apparatus will be backfilled with dry nitrogen. A separate data acquisition system will support this apparatus. This system will contain a personal computer, video recorder, and monitor. Temperature, acceleration, winding speed, and video images will be controlled and recorded using the data acquisition system. Thus, the FPA will consist of two hardware packages, the fiber production assembly and the data acquisition rack. The primary objective of this test is to determine the effects of 1/6 g on the formation of continuous glass fiber made from simulated lunar soil. Baseline studies using the FPA on the ground will provide a reference for the 1/6 g studies. Of particular interest will be the effect of 1/6 g on the free fluid zone where the fiber exits the crucible. In the fiber spinning parlance this zone is known as the upper jet region, where the boundary slope is greater than one tenth. The properties of the resulting glass fiber will depend on the jet shape as well as distributions of velocity, temperature and tension within the jet. It is unknown at this time how 1/6 g will effect these parameters.

Kosten, Sue↗

NASA NTRS1994

Temperature prediction of space flight experiments by computer thermal analysis

Life sciences experiments are especially sensitive to temperature. A small temperature difference between otherwise identical samples can cause various differences in biological reaction rates. Knowledge of experimental temperatures and temperature histories help to distinguish the effects of microgravity and temperature on spaceflight experiments compared to ground based studies, and allow appropriate controls and sensitivity tests. Up to the present time, the Orbiter (Space Shuttle) has not generally provided temperature measurement instrumentation inside ambient lockers located in the Mid-deck of the Orbiter, or inside similar facilities such as Spacehab and Spacelab, but many pieces of hardware do have temperature recording capability. Most of these temperatures, however, have only been roughly measured or estimated. Such reported experimental temperatures, while accurate within a range of several degrees Celsius, are of limited utility to biological researchers. The temperature controlled lockers used in spaceflight, such as Commerical-Refrigeration Incubation Modules (C-R/IMs), severely reduce the mass and volume available for test samples and do not necessarily provide uniform thermal environments. While these test carriers avoid some of the experimental temperature variations of the ambient lockers, the number of samples which can be accommodated in these temperature controlled units is limited. In the present work, improved models of thermal prediction and control were sought. Temperatures are predicted by thermal analysis software using empirical temperatures recorded during STS-57. These temperatures are compared to data recorded throughout the mission using Ambient Temperature Recorders (ATRs) located within several payload lockers. Additional test cases are undertaken using controlled ground experiments to more precisely determine the reliability of the thermal model. The approach presented should increase the utility of various spaceflight carriers in the support of biological and material science research and ground control studies done in preparation for flight.

Birdsong, M. B.↗

DOE OSTI2025

Development of a Flow Stabilization Algorithm Enabling Measurement of Low Oxygen Concentrations in Liquid Sodium

To enhance the automated control of the plugging meter (PM) and thereby enhance detection fidelity in ultralow oxygen environments [≤1 parts per million by weight (wppm)], a novel proportional derivative controller has been implemented with conventional PM hardware. This ramp sign stabilized flow (RSSF) controller manipulates the sign (heating or cooling direction) at a fixed rate, enabling precise temperature adjustment around the saturation temperature of the bulk sodium. This adjustment helps maintain flow stability in a partially formed sodium oxide plug, thus greatly reducing the temperature amplitude in the plugging cycle and promoting simple and accurate oxygen determinations in addition to an increased sampling rate. Rather than relying on the subjective nature of indexing the time when the flow rate changes due to the plugging or unplugging onset to the PM temperature, a running average of the correlated oxygen concentration with time over multiple plugging events can provide oxygen readings ranging from an absolute uncertainty of 500 wppb in real time to less than 50 wppb for a 24-h sampling window. Finally, the RSSF controller was tested at 508 ± 7 wppb with measured oxygen of 542 ± 179 wppb, further reducing the variance between the saturation temperature and the plugging temperature.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

NASA NTRS2004

Imaging System For Measuring Macromolecule Crystal Growth Rates in Microgravity

In order to determine how macromolecule crystal quality improvement in microgravity is related to crystal growth characteristics, a team of scientists and engineers at NASA's Marshal Space Flight Center (MSFC) developed flight hardware capable of measuring the crystal growth rates of a population of crystals growing under the same conditions. As crystal growth rate is defined as the change or delta in a defined dimension or length (L) of crystal over time, the hardware was named Delta-L. Delta-L consists of three sub assemblies: a fluid unit including a temperature-controlled growth cell, an imaging unit, and a control unit (consisting of a Data Acquisition and Control Unit (DACU), and a thermal control unit). Delta-L will be used in connection with the Glovebox Integrated Microgravity Isolation Technology (g-LIMIT) inside the Microgravity Science Glovebox (MSG), onboard the International Space Station. This paper will describe the Delta-L imaging system. The Delta-L imaging system was designed to locate, resolve, and capture images of up to 10 individual crystals ranging in size from 10 to 500 microns with a point-to-point accuracy of +/- 2.0 microns within a quartz growth cell observation area of 20 mm x 10 mm x 1 mm. The optical imaging system is comprised of a video microscope camera mounted on computer controlled translation stages. The 3-axis translation stages and control units provide crewmembers the ability to search throughout the growth cell observation area for crystals forming in size of approximately 10 microns. Once the crewmember has selected ten crystals of interest, the growth of these crystals is tracked until the size reaches approximately 500 microns. In order to resolve these crystals an optical system with a magnification of 10X was designed. A black and white NTSC camera was utilized with a 20X microscope objective and a 0.5X custom designed relay lens with an inline light to meet the magnification requirement. The design allows a 500 pm crystal to be viewed in the vertical dimension on a standard NTSC monitor (4:3 aspect ratio). Images of the 10 crystals are collected periodically and stored in sets by the DACU.

Corder, Eric L.↗

NASA NTRS2015

Design and Demonstration of the Mars Organic Molecule Analyzer (MOMA) on the ExoMars 2018 Rover

The Mars Organic Molecule Analyzer (MOMA) investigation is a key astrobiology experiment scheduled to launch on the joint ESA-Roscosmos ExoMars 2018 rover mission. MOMA will examine the chemical composition of geological samples acquired from depths of up to two meters below the martian surface, where fragile organic molecules may be protected from destructive cosmic radiation and/or oxidative chemical reactions. The heart of the MOMA mass spectrometer subsystem (i.e., MOMA-MS) is a miniaturized linear ion trap (LIT) that supports two distinct modes of operation to detect: i) volatile and semi-volatile, low-to-moderate mass organics (less than or equal to 500 Da) via pyrolysis coupled with gas chromatography mass spectrometry (pyr/GCMS); and, ii) more refractory, moderate-to-high mass compounds (up to 1000 Da) via laser desorption (LDMS) at ambient Mars pressures. Additionally, the LIT mass analyzer enables selective ion trapping via multi-frequency waveform ion excitation (e.g., stored waveform inverse Fourier transform, or SWIFT), and structural characterization of complex molecules using tandem mass spectrometry (MSIMS). A high-fidelity Engineering Test Unit (ETU) of MOMAMS, including the LIT subassembly, dual-gun electron ionization source, micropirani pressure gauge, solenoid-driven aperture valve, redundant detection chains, and control electronics, has been built and tested at NASA GSFC under relevant operational conditions (pressure, temperature, etc.). Spaceflight qualifications of individual hardware components and integrated subassemblies have been validated through vibration, shock, thermal, lifetime, and performance evaluations. The ETU serves as a pathfinder for the flight model buildup, integration and test, as the ETU meets the form, fit and function of the flight unit that will be delivered to MPS in late 2015. To date, the ETU of MOMA-MS has been shown to meet or exceed all functional requirements, including mass range, resolution, accuracy, instrumental drift, and Iimit-of-detection specifications, thereby enabling the primary science objectives of the MOMA investigation and ExoMars 2018 mission.

Mars Organic Molecule Analyzer↗

NASA NTRS2006

Extreme Temperature Electronics Using a Reconfigurable Analog Array

Temperature and radiation tolerant electronics, as well as long life survivability are key capabilities required for future NASA missions. Current approaches to electronics for extreme environments focus on component level robustness and hardening. Compensation techniques such as bias cancellation circuitry have also been employed. However, current technology can only ensure very limited lifetime in extreme environments. Previous work presented a novel approach, based on evolvable hardware technology, which allows adaptive in-situ circuit redesign/reconfiguration during operation in extreme environments. This technology would complement material/device advancements and increase the mission capability to survive harsh environments. This work describes a new reconfigurable analog chip developed by JPL and SPAWAR that is targeted for extreme temperature and evolutionary hardware experiments. Being based on Gm-C technology, this chip can have its functionality tuned and adapted to extreme temperatures through voltage bias adjustment. This tuning process will be controlled by Evolutionary Algorithms. This paper presents details of the reconfigurable analog chip as well as a system level overview. Some early experiments are also described.

evolvable hardware↗

NASA NTRS1989

Quantitative computer simulations of extraterrestrial processing operations

The automation of a small, solid propellant mixer was studied. Temperature control is under investigation. A numerical simulation of the system is under development and will be tested using different control options. Control system hardware is currently being put into place. The construction of mathematical models and simulation techniques for understanding various engineering processes is also studied. Computer graphics packages were utilized for better visualization of the simulation results. The mechanical mixing of propellants is examined. Simulation of the mixing process is being done to study how one can control for chaotic behavior to meet specified mixing requirements. An experimental mixing chamber is also being built. It will allow visual tracking of particles under mixing. The experimental unit will be used to test ideas from chaos theory, as well as to verify simulation results. This project has applications to extraterrestrial propellant quality and reliability.

Vincent, T. L.↗

NASA NTRS2008

A Flexible Evolvable Architecture for Constellation Mission Systems User Applications

While simulating a complex set of repair tasks to be performed by EVA crewmembers on an upcoming mission, flight controllers and astronauts determine that the repair will take much longer than originally anticipated. All equipment in the vicinity of the worksite must be powered off to maintain a safe environment for the astronauts. Because heater power will be unavailable, several critical components will now be at risk of freezing and permanent damage. If an impending thermal violation is detected, Mission Control will have very limited time to react. Therefore, flight controllers must not only modify their procedures to account for these risks, they must also incorporate into their displays outputs from thermal models, alternate temperature measurements, new alarm limits, and emergency power-on commands to enable the detection and response to freezing conditions. Current software for mission control systems makes scenarios like this difficult to address. Given the time frame for modifying software, operations teams are left with labor-intensive operational workarounds as their only options. NASA Ames Research Center (ARC) and NASA Johnson Space Center (JSC) are collaborating on the development of a flexible software system for mission operations that will enable greater user flexibility than has been available to date. Using composable software, end users in the scenario described above could recompose procedures and command and control displays to allow flight controllers to monitor temperature measurements, identify time-critical conditions, and execute the procedures required to respond to these conditions before flight hardware is permanently damaged.

Trimble, Jay P.↗

NASA NTRS1980

A study of universal modulation techniques applied to satellite data collection

A universal modulation and frequency control system for use with data collection platform (DCP) transmitters is examined. The final design discussed can, under software/firmwave control, generate all of the specific digital data modulation formats currently used in the NASA satellite data collection service and can simultaneously synthesize the proper RF carrier frequencies employed. A novel technique for DCP time and frequency control is presented. The emissions of NBS radio station WWV/WWVH are received, detected, and finally decoded in microcomputer software to generate a highly accurate time base for the platform; with the assistance of external hardware, the microcomputer also directs the recalibration of all DCP oscillators to achieve very high frequency accuracies and low drift rates versus temperature, supply voltage, and time. The final programmable DCP design also employs direct microcomputer control of data reduction, formatting, transmitter switching, and system power management.

Source record↗

NASA NTRS1989

Technical Evaluation Motor 3 (TEM-3)

A primary objective of the technical evaluation motor program is to recover the case, igniter and nozzle hardware for use on the redesigned solid rocket motor flight program. Two qualification objectives were addressed and met on TEM-3. The Nylok thread locking device of the 1U100269-03 leak check port plug and the 1U52295-04 safe and arm utilizing Krytox grease on the barrier-booster shaft O-rings were both certified. All inspection and instrumentation data indicate that the TEM-3 static test firing conducted 23 May 1989 was successful. The test was conducted at ambient conditions with the exception of the field joints (set point of 121 F, with a minimum of 87 F at the sensors), igniter joint (set point at 122 F with a minimum of 87 F at sensors) and case-to-nozzle joint (set point at 114 F with a minimum of 87 F at sensors). Ballistics performance values were within specification requirements. Nozzle performance was nominal with typical erosion. The nozzle and the case joint temperatures were maintained at the heaters controlling set points while electrical power was supplied. The water and the CO2 quench systems prevented damage to the metal hardware. All other test equipment performed as planned, contributing to a successful motor firing. All indications are that the test was a success, and all expected hardware will be refurbished for the RSRM program.

Garecht, Diane↗

NASA NTRS2004

A Selected Operational History of the Internal Thermal Control System (ITCS) for International Space Station (ISS)

The Internal Thermal Control System (ITCS) has been developed jointly by Boeing Corporation, Huntsville, Alabama and Honeywell Engines & Systems, Torrance, California to meet the internal thermal control needs for the International Space Station (ISS). The ITCS provides heat removal for the critical life support systems and thermal conditioning for numerous experiment racks. The ITCS will be fitted on a number of modules on the ISS. The first US Element containing the ITCS, Node 1, was launched in December 1998. Since Node 1 does not contain a pump to circulate the fluid it was not filled with ITCS fluid until after the US Laboratory Module was installed. The second US Element module, US Laboratory Module, which contains the pumps and all the major ITCS control hardware, was launched in February 2001. The third US Element containing the ITCS, the US Airlock, was launched in July 2001. The dual loop system of the ITCS is comprised of a lowtemperature loop (LTL) and a moderate-temperature loop (MTL). Each loop has a pump package assembly (PPA), a system flow control assembly (SFCA), a threeway mixing valve (TWMV), several rack flow control assemblies (RFCA), cold plates, pressure sensors, temperature sensors, pump bypass assembly (PBA) and a heat exchanger. In addition, the MTL has an additional TWMV, a payload regeneration heat exchanger (P/RHE) and a manual flow control valve (MFCV). The LTL has a service performance and checkout unit (SPCU) heat exchanger. The two loops are linked via one loop crossover assembly (LCA) providing cross loop capabilities and a single PPA, two-loop functionality. One important parameter monitored by the ground stations and on-orbit is the amount of fluid leakage from the ITCS. ISS fluid leakage is of importance since ITCS fluid is costly to re-supply, may be difficult to clean up in zero-g, and if uncontained could lead to equipment failures and potential hazards. This paper examines the nominal leakage observed over period of a year of on-orbit operation and compares this with analysis predictions. This paper also addresses the off-nominal leakage and a fluid transfer event causing significant changes in accumulator quantity.

Patel, Vipul P.↗