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Aerosol Inlets for a Mid-Sized Uncrewed Aerial System (UAS)
The purpose of this technical report is to document the efforts to design and test two inlet systems for aerosol sampling suitable for deployment on a medium-sized fixed-wing Uncrewed Aerial System (UAS). This work, which was supported by the U.S. Department of Energy’s Atmospheric Radiation Measurement (ARM) user facility, was conducted at the Pacific Northwest National Laboratory (PNNL) for the ARM Aircraft Facility (AAF) starting in November 2017. The current work is a part of AAF efforts to instrument the ArcticShark (a mid-sized UAS owned and operated by the AAF) for atmospheric research and develop a scientific payload for deployment on a similar-sized UAS with minimal adaptation and integration. An aerosol inlet system is necessary to sample and transport ambient air sample to the scientific instrumentation with minimal distortions to the aerosols. Two isokinetic aerosol inlets were designed: the first is a simple passive system for a single instrument suitable to be installed in a wing pylon; the second is a system with active control designed to sample and distribute air among several heterogeneous instruments and to provide basic humidity control of the air sample so that the measured aerosol parameters should correspond to “dry” conditions (a common requirement). Both systems could be easily adapted for deployment on another platform and/or with a different set of instrumentation. Several conducted flight tests showed that the inlets’ performance met our design goals.
Report on Lightning Simulation Standards and Facilities
Lightning strikes pose a significant threat to various forms of infrastructure and electrical equipment. Aircraft and high explosives are of particular interest due to the massive ramifications of the device being compromised due to exposure to lightning damage. However, due to lightning being a varying weather phenomenon, testing a device’s vulnerability to lightning is generally not as simple as simply exposing it to real world lightning. To consistently test a device’s ability to survive the worst-case scenario of lightning exposure, the effects of the most severe lightning strikes must be able to be reproduced consistently and measurably. One such facility for this purpose is the Sandia Lightning Simulator (SLS), which is designed to simulate the current waveform of a severe lightning flash. However, the SLS’s design and age lead to difficulties in its operation and inconsistencies in its output. The methodology used in other lightning simulation facilities may offer information on how to improve the SLS’s operation, or at the very least, expose the SLS’s hidden strengths. This report explores lightning simulation, lightning testing standards, and lightning simulation facilities.
Laser Additive Manufacturing Process Development for Bismuth Telluride Thermoelectric Material
Thermoelectric generators have strong potential for aerospace and aircraft applications. However, traditional manufacturing methods for thermoelectric devices severely limit device adaptability and consequently marketability. Laser powder bed fusion is an additive manufacturing method which shows promising potential for producing thermoelectric devices. Thermoelectric materials pose unique challenges compared to metals because of low thermal conductivity, brittle fracture characteristics, and irregular powder particle morphologies. Herein, we communicate processing procedures to fabricate thermoelectric parts of Bi 2 Te 3 through laser powder bed fusion. In this study, we identify the successful combination of key process parameters—laser power, scan speed, hatch distance, and powder layer thickness—to achieve high-quality parts in terms of density and physical properties, and we demonstrate the impact of process parameter variation on built part quality. While it cannot exclusively determine part quality, the volumetric energy density is a useful guide in deciding process parameters for thermoelectric materials, and the optimal value is between 9 and 11 J/mm 3 for Bi 2 Te 3 . We demonstrate successful fabrication of different freeform geometries of Bi 2 Te 3 powders. The results suggest it is possible to extend this method more broadly to other semiconductor materials, including thermoelectric power generation materials applicable for space applications.
Static Strain Modelling, Calibration, and Measurements for High-Temperature Wireless SAW Resonator Operation
Static strain measurements are relevant for Integrated System Health Monitoring of civil structures, aircrafts, power plants and advanced manufacturing equipment, with implications for safety, process efficiency, and maintenance costs. Wireless strain sensing is highly desirable where the presence of wires poses significant safety concerns, increases maintenance, and thus overall costs, or where they are not feasible, such as in applications which contain moving parts. This paper presents wireless interrogation of surface acoustic wave resonators (SAWRs) fabricated on langasite (LGS) along Euler angles (0°, 138.5°, 32.9°) and aimed at the detection of static strain at hightemperature (HT, above 100°C). Both commercial HT strain gauges and finite element analysis (FEA Abaqus software) were used and compared for SAWR strain calibration from room temperature (RT) to HT. In addition, this work investigated a compromise between high temperature operation vs. sensitivity based on the thickness of ceramic adhesive used. For instance, a reduction in the adhesive thickness from about 150 μm to 135 μm, resulted in a 39% increase in sensitivity at RT. It was also observed that the sensitivity dropped up to 34% from RT to 200°C. Furthermore, wireless operation, calibration, and increase in sensitivity constitute important advances in the use of LGS SAW devices to monitor static stress in high-temperature harsh environments.
Classification of Cloud Particle Imagery from Aircraft Platforms Using Convolutional Neural Networks
Abstract A vast amount of ice crystal imagery exists from a variety of field campaign initiatives that can be utilized for cloud microphysical research. Here, nine convolutional neural networks are used to classify particles into nine regimes on over 10 million images from the Cloud Particle Imager probe, including liquid and frozen states and particles with evidence of riming. A transfer learning approach proves that the Visual Geometry Group (VGG-16) network best classifies imagery with respect to multiple performance metrics. Classification accuracies on a validation dataset reach 97% and surpass traditional automated classification. Furthermore, after initial model training and preprocessing, 10 000 images can be classified in approximately 35 s using 20 central processing unit cores and two graphics processing units, which reaches real-time classification capabilities. Statistical analysis of the classified images indicates that a large portion (57%) of the dataset is unusable, meaning the images are too blurry or represent indistinguishable small fragments. In addition, 19% of the dataset is classified as liquid drops. After removal of fragments, blurry images, and cloud drops, 38% of the remaining ice particles are largely intersecting the image border (≥10% cutoff) and therefore are considered unusable because of the inability to properly classify and dimensionalize. After this filtering, an unprecedented database of 1 560 364 images across all campaigns is available for parameter extraction and bulk statistics on specific particle types in a wide variety of storm systems, which can act to improve the current state of microphysical parameterizations.
Combined Mesonet and Tracker
Title: Combined Mesonet and Trackers (UNL Mobile Mesonets) Authors University of Nebraska PI: Adam Houston, UNL Professor (ahouston2@unl.edu) Mailing Address: 126 Bessey Hall P.O. Box 880340 Lincoln, NE 68588-0340 CoMeT Overview The University of Nebraska-Lincoln operates three Combined Mesonet and Tracker (CoMeTs). CoMeTs are Ford Explorers (model years 2015, 2017, and 2019) with forward-mounted suites of meteorological sensors and dual moonroofs, combining the capability of a mobile mesonet to collect near-surface observations with the capability of an unmanned aircraft systems (UAS) tracker vehicle, which enables an observer in the second row of seats to see the aircraft and maintain compliance with Federal Aviation Administration policies on UAS operation. The CoMeTs collect observations of slow temperature and humidity at ~2 m above ground level (AGL) using a Vaisala HMP155A, fast temperature at ~2 m AGL using a Campbell Scientific 109SS-L thermistor, pressure at ~2.5 m AGL using a Vaisala PTB210, wind speed and direction at ~3.25 m AGL using an R.M. Young 05103 propeller anemometer, and vehicle heading using a KVH Industries C-100 fluxgate compass (Barbieri et al. 2019). The HMP155A and 109SS-L thermistor are shielded and aspirated within a U-tube (Waugh and Frederickson 2010; Houston et al. 2016). This list of sensors is also included in the CoMeT data file metadata. Manufacturer specifications for these instruments are given in Table 1 of Hanft and Houston (2018). The reported measured quantities are summarized below.CoMeT-3 was funded through an equipment allocation included in the NSF TORUS award (AGS-1824649). Instrument Description The specific sensors included on each CoMeT are summarized in the table at the end of this section. In general each CoMeT collects observations of slow temperature and humidity at ~2 m above ground level (AGL) using a Vaisala HMP155, fast temperature at ~2 m AGL using a Campbell Scientific 109SS-L thermistor, pressure at ~2.5 m AGL using a Vaisala PTB210 barometer with a Gill pressure port, wind speed and direction at ~3.25 m AGL using an R.M. Young 05103 propeller anemometer, position using a Garmin 19x HVS receiver, and vehicle heading using a KVH Industries C-100 fluxgate compass. The HMP155 and 109SS are shielded and aspirated within a U-tube (Waugh and Frederickson 2010; Houston et al. 2016). Fast temperature and corrected RH measurements (using sensors housed within the U-tube) have a time constant of 10-12 s based on data collected across a temperature and RH shock during the CLOUD-MAP 2017 calibration/validation tests on June 26, 2017. Vehicle speed was < 10 kts for this test. CoMeT-1 CoMeT-2 CoMeT-3 Slow Temperature Slow RH Vaisala HMP155A-L20-PT Part #: 22280-7 Vaisala HMP155E Part #: E1AA11A0B1A1A0A Vaisala HMP155E Part #: E1AA11A0B1A1A0A Fast temperature Campbell Scientific 109SS-L20-PT Part #: 21448-3 Campbell Scientific 109SS-L12-PW Part #: 21448-109 Campbell Scientific 109SS-L12-PW Part #: 21448-150 Pressure Vaisala PTB-210 Part #: A1A1B Gill Pressure Port Part #: 61002 Vaisala PTB-210 Part #: A1A1B Gill Pressure Port Part #: 61002 Vaisala PTB-210 Part #: A1A1B Gill Pressure Port Part #: 61002 Wind RM Young 05103-L20-PT Part #: 18435-310 RM Young 05103-L20-PW Part #: 18435-244 RM Young 05103-L20-PW Part #: 18435-244 GPS Garmin GPS 19x HVS (NMEA 0183) Part #: 010-01010-00 Garmin GPS 19x HVS (NMEA 0183) Part #: 010-01010-00 Garmin GPS 19x HVS (NMEA 0183) Part #: 010-01010-00 Compass KVH C-100 Part #: 01-0177-15 KVH C-100 Part #: 01-0177-15 KVH C-100 Part #: 01-0177-15 Logger Campbell Scientific CR6-NA-XT-SW Part #: 28385-9 Campbell Scientific CR6-WIFI-XT-SW Part #: 28385-6 Campbell Scientific CR6-WIFI-XT-SW Part #: 28385-6 Data Collection and Real-Time Processing The reported measured quantities are summarized in the table below. Quantity Units Source Epoch time Seconds GPS Latitude and longitude Degrees GPS Altitude m GPS Pressure hPa PTB210 Temperature (fast) deg C 109SS-L Temperature (slow) deg C HMP155 RH (slow) % HMP155 Vehicle speed m/s GPS Vehicle heading deg C-100 and GPS In addition to the measured variables, several derived variables are calculated. Corrected/fast relative humidity (%) Relative humidity is adjusted to the fast temperature following Richardson et al. (1998) and Houston et al. (2016). Water vapor mixing ratio (g/kg) Dew point temperature (°C) Potential temperature (Kelvin) Virtual potential temperature (Kelvin) Equivalent potential temperature (Kelvin) Regular intercomparisons between all three CoMeTs were performed during TORUS 2019. Comparisons were also conducted between CoMeT-1 and CoMeT-2 during LAPSE-RATE (2018) on 14 July. In these intercomparisons, the vehicles were parked adjacent to each other aligned perpendicular to (and facing into) the wind. To minimize engine heating effects, intercomparisons were only conducted when the wind speed was >10 kts. Data Format Original data files for each deployment are saved as text files and then converted to NetCDF. NetCDF versions have units that are CF compliant and may not match the original units in the txt files. The naming convention for the NetCDF files is as follows: UNL.CoMeT3.{deployment date YYYYMMDD}.{start time of observation collection in UTC HHMM}.L2.{post-processing codes}.cdf example: UNL.CoMeT3.20190627.1931.L2.g1.f1.cdf Post-processing codes are included to track modifications to the raw data. These codes are closely connected to error flags associated with each record. Each letter corresponds to a particular instrument: g: GPS p: Barometer tf: Fast temperature ts: Slow temperature rh: Relative humidity f: Compass w: Wind monitor a: All instruments Each number corresponds to a particular post-processing action described more below. Measured and derived variables are included in the following table. Variable Heading Standard Name Units time Time seconds since 00:00:00, 01-01-1970 Alt Altitude meters lat Latitude degrees north lon Longitude degrees east fast_temp Air Temperature kelvin slow_temp Air Temperature kelvin pressure Air Pressure pascals logger_RH Relative Humidity percent calc_corr_RH Relative Humidity percent wind_speed Wind Speed meters per second wind_dir Wind From Direction degrees vehicle_dir Vehicle Direction degrees dewpoint Dew Point Temperature kelvin mixing_ratio Humidity Mixing Ratio g/g theta Air Potential Temperature kelvin theta_v Virtual Potential Temperature kelvin theta_e Equivalent Potential Temperature Kelvin error_flag The error_flag variable is a string that matches the post-processing codes listed above. All instruments will have an associated code, but will have a “0” if the datum is unchanged from the initial processed value. Error Codes The following table summarizes the error codes for data collected before 2020: Error Code Relevant CoMeT Description g1 1,2,3 Exact correction. GPS position and time reprocessed from raw data g2 1 As far as we can tell this is an exact correction to an error in the GPS time. During the correct time periods the time suddenly went backwards ~250s and stayed at this offset for 750s when it corrected itself. The offset was applied to the “time warp” period. p1 2 Approximate correction. Hole in the pressure tube connecting the pressure port to the barometer. Resulted in erroneously low air pressure measurements when the vehicle was in motion. Derived variables recalculated (dew point temperature [e depends on qv and p], water vapor mixing ratio, potential temperature, virtual potential temperature, equivalent potential temperature) a1 3 Exact correction. Missing data reprocessed from raw data a2 1 Bug fix to bias correction for ts1, ts2, and rh1: water vapor mixing ratio was off by a factor of 10 and virtual potential temperature was wrong because of this. f1 3 No correction, missing data. Fluxgate compass inoperable. Wind speed and direction calculated using GPS-derived vehicle heading instead. rh1 1 Approximate correction. Constant bias of +1.7% removed from relative humidity. Derived variables recalculated (corrected/fast relative humidity, dew point temperature, water vapor mixing ratio, virtual potential temperature, equivalent potential temperature) ts1 1 Approximate correction. Constant bias of +0.6 K removed from slow temperature. Derived variables recalculated (corrected/fast relative humidity, dew point temperature, water vapor mixing ratio, virtual potential temperature, equivalent potential temperature) ts2 1 Approximate correction. Constant bias of +1.0 K removed. Derived variables recalculated (corrected/fast relative humidity, dew point temperature, water vapor mixing ratio, virtual potential temperature, equivalent potential temperature) References Bolton, D., 1980: The Computation of Equivalent Potential Temperature. Mon. Wea. Rev., 108, 1046–1053, https://doi.org/10.1175/1520-0493(1980)108<1046:TCOEPT>2.0.CO;2. Hanft, W., and A. L. Houston, 2018: An Observational and Modeling Study of Mesoscale Air Masses with High Theta-E. Mon. Wea. Rev., 146, 2503–2524, https://doi.org/10.1175/MWR-D-17-0389.1.Wexler Houston, A. L., R. J. Laurence III, T. W. Nichols, S. Waugh, B. Argrow, and C. L. Ziegler, 2016: Intercomparison of unmanned aircraft-borne and mobile mesonet atmospheric sensors. Journal of Atmospheric and Oceanic Technology. 33, 1569-1582, doi: 10.1175/JTECH-D-15-0178.1. Lowe, P. R., 1977: An Approximating Polynomial for the Computation of Saturation Vapor Pressure. J. Applied Meteorology, 16, 100–103. Richardson, S. J., S. E. Frederickson, F. V. Brock, and J. A. Brotzge, 1998: Combination temperature and relative humidity probes: Avoiding large air temperature errors and associated relative humidity errors. Preprints, 10th Symp. On Meteorological Observations and Instrumentation, Phoenix, AZ, Amer. Meteor. Soc., 278–283. Waugh, S., and S. E. Frederickson, 2010: An improved aspirated temperature system for mobile meteorological observations, especially in severe weather. 25th Conf. on Severe Local Storms, Denver, CO, Amer. Meteor. Soc., P5.2. [Available online at https://ams.confex.com/ams/25SLS/techprogram/paper_176205.htm.]
An arbitrary Lagrange-Eulerian investigation of HRAM shallow jet pre-spurt formation and time sensitivities to impact plate dynamics
With dry bay fires persisting as a significant contributor to aircraft vulnerability despite chronicled developments in survivability technologies, an accurate fire prediction capability remains paramount for credible vulnerability assessments. Physics based modeling of the hydrodynamic ram (HRAM) fluid deposition process is a key component of such capability, wherein capturing the first instance of fluid spurt, referred to herein as shallow jet spurts, is a core focus. Such pre-spurts as they have been formerly identified have only been witnessed sporadically in HRAM spurt experiments. In this work, ALE3D, a first-principles multi-physics code was employed to model the shallow jet spurt phenomenon with spherical projectiles impacting water-filled tanks faced with aluminum panels, such that the underlying physics and sensitivities could be explored. Development and verification of the 2D axisymmetric model is described relative to trends observed in a prior experimental campaign. Results from the verified model suggest shallow jet spurts have at least a quadratic sensitivity to the fundamental vibrational mode of the impact plate across impact velocities 610–1829 m/s (2000–6000 ft/s). It is further explained how shallow jet spurts are arrested for impacts at the two extremes of plate rigidity. This research constitutes the first fluid-structure modeling of shallow jet spurts which future three-dimensional analyses will expound upon.
Air Blast Mesh Sensitivity and Pressure Mapping Study
Nose cone structural and aerodynamic characteristics are essential for intelligent design of aircraft, spacecraft, and ballistic systems. Finite element analysis can be used to help understand the structural integrity and flight characteristics of different nose cones. A mesh sensitivity study was undertaken for a particular nose cone geometry that was used in tests at LANL facilities in order to confirm the integrity of the meshed geometry. A simple cone that best matched closed-form theoretical solutions was modeled, and received good correlation to the theory. Complexity was then added back to the nose cone. Parameters applied to the simple cone were then implemented in the nose cone geometry giving assurance of accuracy after the geometry was changed. Nose cone results averaged 6.3% error for radial displacement when compared with the theoretical. Hoop stress averaged 6.0% error and meridional stress averaged 5.7% error at the finest mesh level. Meshes showed signs of convergence when compared to all three theoretical solutions. Finally, pressure time-history data from LANL computational fluid dynamics simulations was applied to the surface of the final nose cone geometry. The pressure data was interpolated from pressure gauge locations onto nearby meshed elements, which allowed for FEA software to run simulations on the cone with the pressure data as a loading condition. The pressure mapping resulted in the ability to understand the nose cone’s rigid body motion that in turn can inform design of future nose cones.
Enhanced Data Efficiency Using Deep Neural Networks and Gaussian Processes for Aerodynamic Design Optimization
Adjoint-based optimization methods are attractive for aerodynamic shape design primarily due to their computational costs being independent of the dimensionality of the input space and their ability to generate high-fidelity gradients that can then be used in a gradient-based optimizer. This makes them very well suited for high-fidelity simulation based aerodynamic shape optimization of highly parametrized geometries such as aircraft wings. However, the development of adjoint-based solvers involve careful mathematical treatment and their implementation require detailed software development. Furthermore, they can become prohibitively expensive when multiple optimization problems are being solved, each requiring multiple restarts to circumvent local optima. In this work, we propose a machine learning enabled, surrogate-based framework that replaces the expensive adjoint solver, without compromising on predicting predictive accuracy. Specifically, we first train a deep neural network (DNN) from training data generated from evaluating the high-fidelity simulation model on a model-agnostic design of experiments on the geometry shape parameters. The optimum shape may then be computed by using a gradient-based optimizer coupled with the trained DNN. Subsequently, we also perform a gradient-free Bayesian optimization, where the trained DNN is used as the prior mean. We observe that the latter framework (DNN-BO) improves upon the DNN-only based optimization strategy for the same computational cost. Overall, this framework predicts the true optimum with very high accuracy, while requiring far fewer high-fidelity function calls compared to the adjoint-based method. Furthermore, we show that multiple optimization problems can be solved with the same machine learning model with high accuracy, to amortize the offline costs associated with constructing our models. Our methodology finds applications in the early stages of aerospace design. (C) 2021 Published by Elsevier Masson SAS.
Low-Cost Aero Technology Demonstrations
The main focus of this work was to demonstrate the use of polymeric additive manufacturing (AM) to create tooling for both preforming and consolidation. Polymeric tooling was utilized where both modest and higher pressures are used for part consolidation. The key focus for the AM tooling development was for fabrication of complex structures such as ducting, C-channel stiffened skins, and airfoils where conventional male tooling would typically be trapped in the cured part. The AM tooling was evaluated for use as a tool master used to fabricate and re-shape deformable/re-formable mandrels based on SpinTech’s shape memory composite technology known as Smart Tooling. The AM tooling was also evaluated for use as a mold for composite infusion and consolidation. Key performance parameters were tracked for project schedule completion with each step comprising of “art to part” cycle time, cost, and model fidelity for dimensions, performance, and cost. The primary focus of this demonstration was to determine if a 50% cost reduction was achievable, for each AM tooling-set, as compared to conventional processes. UDRI leveraged project partner SpinTech, who manufactures tools and parts in these categories and thus provided a baseline regarding current best practices and provided valuable feedback during the entirety of this demonstration. This demonstration primarily focused on the use of AM tooling for fabrication of three composite component structures which are typically utilized in aircraft and comprise salient geometric features of broad interest. These components are often tooling intensive and have features requiring extraction of male tools which are usually trapped by the geometry. The three structures selected by the team included: 1) A one-piece airfoil shell comprised of compound contours where male tooling would be trapped unless the part were manufactured in two halves as is typically the case. 2) A one-piece duct used for air handling, comprised of compound contours where male tooling would be trapped unless the part were manufactured in two halves, or a washout mandrel were to be used. 3) A co-cured C-channel stiffened skin where typically C-channels would be individually manufactured and then bonded to a cured skin. The demonstration was comprised of three main tasks: • Task 1: AM Tool Feasibility Study – ensure the AM tooling meets the performance requirements as specified by SpinTech to match baseline performance. • Task 2: Complex Tool Demonstration – Fabricate tooling, preforms, and parts representative of an airfoil and duct. • Task 3: Large Aerostructure Fabrication Demonstration – Fabricate tooling, preforms, and part representative of a C-channel stiffened skin. With the conclusion of this project, a decision tree was developed to determine the key considerations necessary to determine if use of AM tooling for the three selected structures was able to attain the same quality as historically achieved on metallic tooling, while providing a significant cost reduction.
Studying Aerosol, Clouds, and Air Quality in the Coastal Urban Environment of Southeastern Texas
A multi-agency succession of field campaigns was conducted in southeastern Texas during July 2021 through October 2022 to study the complex interactions of aerosols, clouds and air pollution in the coastal urban environment. As part of the Tracking Aerosol Convection interactions Experiment (TRACER), the TRACER- Air Quality (TAQ) campaign the Experiment of Sea Breeze Convection, Aerosols, Precipitation and Environment (ESCAPE) and the Convective Cloud Urban Boundary Layer Experiment (CUBE), a combination of ground-based supersites and mobile laboratories, shipborne measurements and aircraft-based instrumentation were deployed. These diverse platforms collected high-resolution data to characterize the aerosol microphysics and chemistry, cloud and precipitation micro- and macro-physical properties, environmental thermodynamics and air quality-relevant constituents that are being used in follow-on analysis and modeling activities. We present the overall deployment setups, a summary of the campaign conditions and a sampling of early research results related to: (a) aerosol precursors in the urban environment, (b) influences of local meteorology on air pollution, (c) detailed observations of the sea breeze circulation, (d) retrieved supersaturation in convective updrafts, (e) characterizing the convective updraft lifecycle, (f) variability in lightning characteristics of convective storms and (g) urban influences on surface energy fluxes. The work concludes with discussion of future research activities highlighted by the TRACER model-intercomparison project to explore the representation of aerosol-convective interactions in high-resolution simulations.
Spread Spectrum Time Domain Reflectometry (SSTDR) and Frequency Domain Reflectometry (FDR) for Detection of Cable Anomalies Using Machine Learning
Cables are initially qualified for nuclear power plant use for 40 years. As plants extend their operating license to 60 and 80 years, continued use of these cables must shift to a performance-based approach since it is cost prohibitive to completely replace cables that are likely still capable of performing their design function. A variety of cable tests are available and are commonly applied during outages when the cables can be taken out of service. Frequency domain reflectometry (FDR) is one of these test methods that is being more broadly accepted and used because it not only detects anomalies along the cable with a low-voltage signal that does not stress the cable insulation, but the technique also locates the anomalies. This supports follow-up local inspection and local repair or partial replacement of a damaged cable segment. Currently, FDR testing is only applied to cables that are taken out of service since the test instrument would be damaged by operational voltages. A related technology that has found some acceptance in the aircraft and rail industry is spread spectrum time domain reflectometry (SSTDR). This technology has been implemented with a custom commercial instrument by LiveWire Innovation Inc. that is designed to operate on live cables up to 1000 volts. One of the main conclusions of a previous effort was that cable reflectometry plots can be difficult for humans to analyze due to baseline noise, low or noisy anomaly response peaks, or large responses from cable ends. Detection of cable anomalies for many of these frequencies and test conditions was challenging for manual analysis. This presented an ideal opportunity for ML analysis to distinguish undamaged cable indications from anomalous cable indications. This research discusses application of machine learning (ML) to reflectometry cable test methods. The goal was to assess feasibility to distinguish undamaged cable reflectometry responses from damaged or anomalous cable reflectometry responses. The assessment considered the 3 instruments, multiple frequency bandwidths from each instrument, multiple cable anomalies and test conditions, and both supervised and unsupervised ML approaches. Although approaches and analysis methods were not identical or directly comparable, both outputs were encouraging. The unsupervised prediction weighted accuracy was assessed by instrument and by frequency. It performed better at high frequencies with the highest prediction accuracy of 0.84 for the higher frequency FDR, 0.79 for the 48-MHz LiveWire SSTDR, and 0.77 for 300-MHz PNNL SSTDR. The initial weighted accuracy average across all frequencies for using supervised ML was 0.56 to 0.68. The supervised analysis was repeated with noisier training data removed resulting in weighted accuracies of 0.69 to 0.87. These weighted accuracies are not directly comparable due to differences in the supervised and unsupervised analysis details but do indicate an encouraging trend. Even with limited and unbalanced data, strong prediction accuracies seem encouraging for further work including more data under a wider range of conditions.
SiC-Based 5-kV Universal Modular Soft-Switching Solid-State Transformer (M-S4T) for Medium-Voltage DC Microgrids and Distribution Grids
Medium-voltage DC (MVDC) grids are attractive for electric aircraft and ship power systems, battery energy storage system (BESS), fast charging electric vehicle (EV), etc. Such EV or BESS applications need isolated bidirectional MVDC to LVDC or LVAC converters. However, the existing Si-based solutions cannot fulfill the requirements of a high-efficiency and robust converter for MVDC grids. This paper presents a 5 kV SiC-based universal modular solid-state transformer (SST). This universal current-source SST can interface either a LVAC or LVDC grid with a MVDC grid in single-stage power conversion, while the conventional dual active bridge (DAB) converter needs an additional inverter. The proposed SST module using 3.3 kV SiC MOSFETs and diodes is bidirectional and can serve as a building block in series or parallel for higher-voltage higher-power systems. The topology of each module is based on the soft-switching solid-state transformer (S4T) with reduced conduction loss, which features reduced EMI through controlled dv/dt, and high efficiency with full-range ZVS for main devices and ZCS for auxiliary devices. Operation principle of the modular S4T (M-S4T), capacitor voltage balancing control between the cascaded modules, design of components including a medium-voltage (MV) medium-frequency transformer (MFT) to realize a 50 kVA 5 kV DC to 600 V DC or 480 V AC M-S4T are presented. Importantly, the MV MFT prototype achieves very low leakage inductance (0.13%) and 15 kV insulation with coaxial cables and nanocrystalline cores. Here, the proposed universal modular SST is compared against the DAB solution and verified with DC-DC and DC-AC simulation and 4 kV experimental results. Significantly, the MV experimental results of a modular DC transformer with each module at MVDC are rarely covered in the literature and reported for the first time.
Extended Bandwidth Spread Spectrum Time Domain Reflectometry Cable Test for Thermal Aging, Low Resistance Fault, and Water Detection
In 2022, researchers at Pacific Northwest National Laboratory (PNNL) used the Accelerated and Real-Time Environmental Nodal Assessment (ARENA) cable and motor test bed to characterize spread spectrum time domain reflectometry (SSTDR) and compare the responses of an SSTDR instrument to those of a frequency domain reflectometry (FDR) instrument. Results showed both techniques could detect and locate cable anomalies such as phase-to-phase low resistance and shorts, thermal insulation damage, mechanical insulation damage, and the presence or absence of water in some conditions. The SSTDR tests used a commercial instrument provided by LiveWire Innovations Inc. This commercial instrument performed tests at 6, 12, 24, and 48 MHz bandwidth. The results of these tests were compared to FDR tests where bandwidths could be extended up to 1.3 GHz, although the best responses for cable tests were from 100 to 500 MHz. Lower bandwidth signals can propagate better along the cable while higher bandwidths have higher resolution for impedance change reflections allowing more precise indication of location and separation of anomalies. The 2022 research found that FDR responses were clearer than SSTDR and speculated that a higher bandwidth SSTDR could more successfully detect and locate cable anomalies. One advantage of the SSTDR system investigated was that it was designed for energized online use up to 1,000 volts, which may be a significant advantage for nuclear power plant use. The LiveWire SSTDR instrument is an established product in the rail and aircraft industry and updating the SSTDR hardware parameters is difficult to justify without more conclusive testing. Therefore, a software adjustable laboratory SSTDR instrument was developed by PNNL and was used to test extended bandwidth SSTDR cable tests. Within the ARENA test bed, 42 cable conditions were tested with the PNNL SSTDR, FDR, and the LiveWire SSTDR—each operating at four different bandwidths. Observations and conclusions regarding the relative performance of the three instruments over different bandwidths are note below. Responses of the PNNL SSTDR (at 50 MHz) and the LiveWire SSTDR (at 48 MHz) were similar. The PNNL SSTDR higher frequency bandwidths behaved as expected showing sharper peaks and higher noise. This validated the PNNL SSTDR as a reasonable implementation of the SSTDR technology. Lower bandwidth SSTDR responses (particularly 6 and 12 MHz) may have increased value for use within longer cables but were not particularly effective at identifying anomalous cable behavior in the 100 ft cables tested here. The higher bandwidths of the PNNL SSTDR (50, 100, 200, and 400 MHz) did not provide substantially clearer cable reflectometry responses, but having the higher frequency responses available did add to the cable test evaluation. Strong responses to shorts and low impedance faults between phases were particularly evident in the higher bandwidth PNNL SSTDR and the FDR data. Measurements were repeatable, with similar responses obtained from a thermally aged cable for tests taken a month apart. Signal noise was affected in the unshielded cable by the local in-tray cable arrangement including proximity to metal edges and rungs of the cable tray. Foam isolation of the cable from the tray metal reduced in both FDR and SSTDR responses. Cable condition monitoring in nuclear power plants will likely benefit from both more informative off-line testing methods and from the development of on-line methods for continuous monitoring of cables in use. The LWRS-funded ARENA test bed was a valuable resource for this development and direct comparison of nuclear electrical cable condition monitoring technologies. Test results are targeted to guide industry advancement of testing and monitoring tools for cable aging management.
Online Monitoring of Medium Voltage Cable Systems with Spread Spectrum Time Domain and Frequency Domain Reflectometry
In-service failures of wave energy convertor (WEC) cable systems can have a significant cost and power availability impact. Close parallel research 2019 data showed > 1B£ and 9 Terra-Watt-Hours associated with global off-shore wind (OSW) cable failures (Strang-Moran 2020). OSW is a closely related technology but currently is significantly cheaper than WEC technology. For wave energy to compete, the problem of reliable cable transmission must be mitigated. This project develops isolation technology to allow online high frequency reflectometry testing of medium voltage cables (1 to 10 kV and higher) without arcing or damage to the test instrument. Online spread spectrum time domain reflectometry (SSTDR) testing has been established for low voltage cable systems in the aircraft and rail industry and the ability to detect and locate cable flaws of interest is well understood. Extending reflectometry testing to medium voltage systems could enable detection of cable damage before failures occur thereby allowing repair and replacement of damaged cable segments to be scheduled and managed. The seedling project succeeded to pass and receive high frequency SSTDR signals onto a cable up to 1 kV using a parallel trace isolation circuit board that can be connected onto the test cable. The approach used a novel circuit design for which an invention disclosure has been filed. A proposed sapling project would extend the technology toward the higher operating voltages used by WEC systems, thereby enabling online SSTDR cable monitoring. The goal of the seedling project was to extend the capability of the ARENA cable/motor test bed to address medium voltages and to develop a high pass filter isolation architecture to protect the reflectometry instrument from the low frequency (DC – 60 Hz) line voltage while allowing the high frequency diagnostic signal to pass to and from the test instrument to the live line. Initial efforts focused on passive LCR filter circuits to reduce 60 Hz levels below 10 volts from a 10 kV line while allowing the MHz high frequency chirps to pass onto the cables and for mV signals to be detected. We discovered that the parasitic loss behavior of real high voltage components precluded this approach from working. An alternate approach was adapted for the electric field to couple between two parallel traces on a printed circuit board much like a radio-frequency coupler. The challenge here was and is to have the parallel traces close enough to each other to effectively pass the high frequency chirp onto the live line and receive any reflected signal from any encountered impedance change along the cable. This reflected signal will be in the mV range. The traces however must be far enough apart to not allow arcing on the board. A design with 3 mm spacing was determined to allow the high frequency signal to pass onto the live line and receive the mV signal back into the instrument while reducing the 60 Hz voltage amplitude by >80 dB (more than a factor of 10,000) without allowing arcing from across the parallel traces. This was confirmed by simulation and test.
Advancing Development of Emissions Detection (Final Report)
This document is the final report to the U.S. Department of Energy (DOE for contract DE-FE0031873) awarded to Colorado State University (CSU). CSU and partners at Harrisburg University of Science and Technology, University of Texas Arlington, and University of Texas at Austin organized several testing rounds to provide knowledge focused on advancing the detection capabilities of emissions monitoring devices. With this funding opportunity the research group began by establishing the Advancing the Development of Emission Detection (ADED) program, with the goal focused on enhancing the accuracy, reliability, and field applicability of methane detection technologies. This effort aimed to address the critical challenges of identifying and quantifying methane emissions while enabling industry stakeholders to meet regulatory compliance and environmental sustainability goals. The program engaged with industry, government, and technology stakeholders to promote adoption and consensus on testing techniques for methane detection solutions. Methane, a potent greenhouse gas, contributes significantly to global warming, and the oil and natural gas (O&G) sector is a primary source of methane emissions. Regulatory measures such as leak detection and repair (LDAR) programs have been implemented to address emissions. However, traditional LDAR approaches, reliant on handheld and component-level measurements, are resource-intensive. To address these limitations and move with evolving regulations, advanced methane technologies are emerging. These solutions include ground-based sensors, mobile systems (e.g., drones, vehicles, and aircraft), and satellite-based platforms. They offer innovative capabilities for autonomous monitoring, larger spatial coverage, and emission quantification using methods such as tracer gas techniques and inverse modeling with Gaussian plume analysis. The ADED program began with creating protocols for methane controlled release (CR) testing these continuous monitoring (CM) and survey technologies that detect and monitor methane emissions at O&G facilities. The protocols were then implemented throughout testing of CM and survey devices at CSU’s Methane Emissions Technology Evaluation Center (METEC) facility from 2021 through 2024. As apart of the protocol, solutions that tested under the ADED program installed their solutions at METEC, documented their system under test, and provided detection reports to the METEC team for analysis. The METEC team would provide the solutions with analyzed reports of their emissions and ground truth data of the releases conducted during their testing session. Under the ADED program, CMs were also tested at O&G facilities for a six week test run of challenge release (ChR) releases. The findings from the ADED program underscore the critical role of collaborative research and innovation in tackling methane emissions, offering a pathway for the oil and gas sector to achieve significant environmental and economic benefits. Results from METEC testing saw improvement of performance and accuracy across all solutions over the extent of the ADED experiments. The results also showed a variance in CM solution performance between CRs and ChRs. That variance pushed the team to further analyze the differences between CR testing environments and field conditions. With the drive from regulations and that variance in field conditions, the ADED team began designing a new CR testing protocol and additions to the METEC testing facility. The METEC team is furthering the progress made through the ADED program with awarded funding from DE-FE0032276. This funding pushes the development of METEC’s addition with new equipment, allowing for an updated facility layout. METEC still facilitates for traditional facilities, with a legacy pad, while expanding an new design based on how O&G infrastructure has Final Report - Contract Number: DE-FE0031873 been changed over the last decade. Throughout the ADED program the team has also been working with international partners to ensure staying in the trend globally. International partners have been essential in moving the new protocol forward to implement into CR testing at the METEC facility in Spring 2025.