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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 127 records · Page 7

Next-generation perovskite photovoltaics: improving, stabilizing, and lead-sealing of record-setting laboratory solar cells towards commercialization

Summary: In the proposed program we plan to improve perovskite photovoltaic performance by developing (1) orientational control of 3D/2D perovskite heterostructures to simplify device architectures, thus improving device efficiencies and stability; (2) high-throughput optical measurements and real-time device simulations for device optimization; (3) robust, dual-pronged lead-sealing and oxygen/moisture/UV barrier films for long-term stability. Specifically, we seek to develop an in-depth understanding of the perovskite film formation, interface passivation, device stability, and environmentally friendly encapsulation, which together will lead to perovskite devices with PCE of over 28%, stability of T80 at 85/85 (85% humidity at 85 degrees C) for 10,000, expected to be equivalent to T90 of 100 hours), and architectures that would satisfy the U.S. EPA and RoHS limits of lead-leaching. The knowledge generated with this project will be applicable to tandem devices with wider-bandgap perovskites.

14 SOLAR ENERGY↗

Lean Mission Operations Systems Design - Using Agile and Lean Development Principles for Mission Operations Design and Development

The Resource Prospector Mission seeks to rove the lunar surface with an in-situ resource utilization payload in search of volatiles at a polar region. The mission operations system (MOS) will need to perform the short-duration mission while taking advantage of the near real time control that the short one-way light time to the Moon provides. To maximize our use of limited resources for the design and development of the MOS we are utilizing agile and lean methods derived from our previous experience with applying these methods to software. By using methods such as "say it then sim it" we will spend less time in meetings and more time focused on the one outcome that counts - the effective utilization of our assets on the Moon to meet mission objectives.

Operations↗

Extravehicular Activity Testing in Analog Environments: Evaluating the Effects of Center of Gravity and Environment on Human Performance

Center of gravity (CG) is likely to be an important variable in astronaut performance during partial gravity extravehicular activity (EVA). The Apollo Lunar EVA experience revealed challenges with suit stability and control. The EVA Physiology, Systems and Performance Project (EPSP) in conjunction with the Constellation EVA Systems Project Office have developed plans to systematically understand the role of suit weight, CG and suit pressure on astronaut performance in partial gravity environments. This presentation based upon CG studies seeks to understand the impact of varied CG on human performance in lunar gravity.

Chappell, Steve P.↗

Control Technology Needs for Electrified Aircraft Propulsion Systems

Electrified aircraft propulsion (EAP) systems hold potential for the reduction of aircraft fuel burn, emissions, and noise. Currently, NASA and other organizations are actively working to identify and mature technologies necessary to bring EAP designs to reality. This paper specifically focuses on the envisioned control technology challenges associated with EAP designs that include gas turbine technology. Topics discussed include analytical tools for the dynamic modeling and analysis of EAP systems, and control design strategies at the propulsion and component levels. This includes integrated supervisory control facilitating the coordinated operation of turbine and electrical components, control strategies that seek to minimize fuel consumption and lessen the challenges associated with thermal management, and dynamic control to ensure engine operability during system transients. These dynamic control strategies include innovative control approaches that either extract or supply power to engine shafts dependent upon operating phase, which may improve performance and reduced gas turbine engine weight. Finally, a discussion of control architecture design considerations to help alleviate the propulsion/aircraft integration and certification challenges associated with EAP systems is provided.

Simon, Donald L.↗

Control Technology Needs for Electrified Aircraft Propulsion Systems

Electrified aircraft propulsion (EAP) systems hold potential for the reduction of aircraft fuel burn, emissions, and noise. Currently, NASA and other organizations are actively working to identify and mature technologies necessary to bring EAP designs to reality. This paper specifically focuses on the envisioned control technology challenges associated with EAP designs that include gas turbine technology. Topics discussed include analytical tools for the dynamic modeling and analysis of EAP systems, and control design strategies at the propulsion and component levels. This includes integrated supervisory control facilitating the coordinated operation of turbine and electrical components, control strategies that seek to minimize fuel consumption and lessen the challenges associated with thermal management, and dynamic control to ensure engine operability during system transients. These dynamic control strategies include innovative control approaches that either extract or supply power to engine shafts dependent upon operating phase, which may improve performance and reduced gas turbine engine weight. Finally, a discussion of control architecture design considerations to help alleviate the propulsion/aircraft integration and certification challenges associated with EAP systems is provided.

Engine Controls↗

Control Technology Needs for Electrified Aircraft Propulsion Systems

Electrified aircraft propulsion (EAP) systems hold potential for the reduction of aircraft fuel burn, emissions, and noise. Currently, NASA and other organizations are actively working to identify and mature technologies necessary to bring EAP designs to reality. This paper specifically focuses on the envisioned control technology challenges associated with EAP designs that include gas turbine technology. Topics discussed include analytical tools for the dynamic modeling and analysis of EAP systems, and control design strategies at the propulsion and component levels. This includes integrated supervisory control facilitating the coordinated operation of turbine and electrical components, control strategies that seek to minimize fuel consumption and lessen the challenges associated with thermal management, and dynamic control to ensure engine operability during system transients. These dynamic control strategies include innovative control approaches that either extract or supply power to engine shafts dependent upon operating phase, which may improve performance and reduced gas turbine engine weight. Finally, a discussion of control architecture design considerations to help alleviate the propulsion/aircraft integration and certification challenges associated with EAP systems is provided.

Gas Turbine Engines↗

Circulation Control Model Experimental Database for CFD Validation

A 2D circulation control wing was tested in the Basic Aerodynamic Research Tunnel at the NASA Langley Research Center. A traditional circulation control wing employs tangential blowing along the span over a trailing-edge Coanda surface for the purpose of lift augmentation. This model has been tested extensively at the Georgia Tech Research Institute for the purpose of performance documentation at various blowing rates. The current study seeks to expand on the previous work by documenting additional flow-field data needed for validation of computational fluid dynamics. Two jet momentum coefficients were tested during this entry: 0.047 and 0.114. Boundary-layer transition was investigated and turbulent boundary layers were established on both the upper and lower surfaces of the model. Chordwise and spanwise pressure measurements were made, and tunnel sidewall pressure footprints were documented. Laser Doppler Velocimetry measurements were made on both the upper and lower surface of the model at two chordwise locations (x/c = 0.8 and 0.9) to document the state of the boundary layers near the spanwise blowing slot.

Paschal, Keith B.↗

Development of algorithms for augmenting and replacing conventional process control using reinforcement learning

Here, this work seeks to allow for the online operation and training of model-free reinforcement learning (RL) agents but limit the risk to system equipment and personnel. The parallel implementation of RL alongside more conventional process control (CPC) allows for the RL algorithm to learn from CPC. The past performance of both methods are assessed on a continuous basis allowing for a transition from CPC to RL and, if needed, transitioning back to CPC from RL. This allows for the RL algorithm to slowly and safely assume control of the process without significant degradation in control performance. It is shown that the RL can derive a near optimal policy even when coupled with a suboptimal CPC. It is also demonstrated that the coupled RL-CPC algorithm learns at a faster rate than traditional RL methods of exploration while the algorithm’s performance does not deteriorate below CPC, even when exposed to an unknown operating condition.

30 DIRECT ENERGY CONVERSION↗

An Orifice Pulse Tube Cooler for CMOS Computer Cooling

The subject orifice pulse tube cooler employs dual opposed compressor pistons, clearance seals, moving coil linear motors, and flexible bearings cooling capacity is 100 watts at 200 K. A matrix of optimizations explored load temperatures and cooling capacities of 50 K, 100 K, 200 K, 1 watt, 10 watts, and 100 watts. The optimization process resulted in a design with zero second entrance flow and a non-resonant pulse tube. Topics include performance results, mechanical design, and development problems and solutions. The development seeks to use orifice pulse tube mechanical simplicity to achieve a computer cooler with acceptable efficiency, low materials cost, low labor cost, long life, high reliability, low vibration, operation at the standard 60 Hz U.S. grid frequency, and control through simple drive and control electronics.

Riggle, P.↗

Performance Evaluation of Intelligent Solar Control Software Through Hardware-in-the-Loop (CRADA Final Report)

Recent research has highlighted the potential for solar to act as a zero-marginal-cost and zero-emission flexibility resource on the bulk power system when operated with advanced control systems. To increase the performance of these systems, leading technologies, including machine learning (ML) and hierarchical inverter set point allocation, have been developed by Latimer Controls, Inc. to estimate the headroom of large PV plants for grid operation and control; however, these technologies lack comprehensive validation under real-world application scenarios. Latimer Controls, Inc. received two voucher awards for research at a national laboratory from the Department of Energy American Made Solar Prize Round 6. The National Renewable Energy Laboratory (NREL) was selected to collaborate with Latimer staff to conduct a performance evaluation of Latimer PV control software. The NREL team will develop a hardware-in-the-loop (HIL) testbed to perform testing and validation of the Latimer PV control technology in a de-risked yet realistic testbed environment. Latimer and NREL worked together to analyze the test data, draw conclusions from the results, and disseminate the resulting scientific findings. In this CRADA work, we propose to test and validate the real-world application of the Latimer Control solution in an HIL environment. We evaluate the performance of different flexible solar technologies in responding to automatic generation control signals in a closed-loop fashion. In particular, a data-driven potential high limit (PHL) estimation is developed for large solar plants to accurately estimate their headroom so that they have fast and short-time regulation and control capability to participate in grid services and respond to grid signals in real time (e.g., AGC). This PHL estimation algorithm is embedded in a hardware power plant controller (PPC) and tested with an IEEE-39 bus system model developed in RTDS. To account for the varying cloud conditions and diverse inverter dispatches, we developed a 135-MW PV plant with detailed modeling of 27 individual PV modules and inverters using RTDS. The real-world communications used in such big plants, such as ModBus TCP/IP for inverter level and DNP3 for plant level, were developed to emulate the real-world applications in big PV plants. The ML-based PHL estimation method is tested under nine separate weather scenarios against the ‘reference-control’ solution, hereafter referred to as the baseline solution. The baseline method reserves a subset of inverters (reference group) to operate at their PHL at all times and dispatches only the remaining inverters (control group) at curtailed levels to fulfill the flexibility need. Despite being successfully piloted by NREL in California in 2017 and Chile in 2020, there exist two gaps in the state of the art to fully unlock the flexibility of PV plants: a. There is a trade-off between the PHL estimation accuracy and the flexibility range. b. There lacks granularity in the PHL estimation to capture the variation across inverters. The Latimer solution seeks to address these gaps by applying machine learning methods to improve PHL estimation accuracy while accounting for variability at every inverter. Performance metrics were taken from the 2023 Georgia Power CARES utility-scale RFP. The results demonstrate that the ML-based approach outperforms the traditional baseline method in PHL estimation accuracy for 7 of 9 scenarios. The average PHL error across the nine scenarios was 7.40% for the ML-based method, 2.06% less than the 9.46% PHL error average across scenarios that was exhibited by the baseline method. Additionally, the PHL error was below 5% for at least 95% of the testing interval for 3 of 9 tested intervals with the ML approach, whereas it did not achieve this metric for any of the baseline tests. Overall, simulation results indicate the superior performance of an ML-based approach compared to the conventional baseline reference-control approach, showcasing its potential to support grid stability and operational efficiency. This laboratory HIL testing using real PPC, representative power system simulation models in real-time with detailed PV plant and inverter models, and real-world communication protocols gives us confidence that this machine learning based PHL estimation algorithm works well in the hardware PPC and therefore de-risks future field commissioning. The end goal of this project is to advance grid technology to address the grid operation challenges brought by solar plant’s variability and uncertainties in power generation.

14 SOLAR ENERGY↗

An intelligent value-driven scheduling system for Space Station Freedom with special emphasis on the electric power system

The Electric Power Control System (EPCS) created by Decision-Science Applications, Inc. (DSA) for the Lewis Research Center is discussed. This system makes decisions on what to schedule and when to schedule it, including making choices among various options or ways of performing a task. The system is goal-directed and seeks to shape resource usage in an optimal manner using a value-driven approach. Discussed here are considerations governing what makes a good schedule, how to design a value function to find the best schedule, and how to design the algorithm that finds the schedule that maximizes this value function. Results are shown which demonstrate the usefulness of the techniques employed.

Krupp, Joseph C.↗

Restructured Freedom configuration characteristics

In Jan. 1991, the LaRc SSFO performed an assessment of the configuration characteristics of the proposed pre-integrated Space Station Freedom (SSF) concept. Of particular concern was the relationship of solar array operation and orientation with respect to spacecraft controllability. For the man-tended configuration (MTC), it was determined that torque equilibrium attitude (TEA) seeking Control Moment Gyroscope (CMG) control laws could not always maintain attitude. The control problems occurred when the solar arrays were tracking the sun to produce full power while flying in an arrow or gravity gradient flight mode. The large solar array articulations that sometimes result from having the functions of the alpha and beta joints reversed on MTC induced large product of inertia changes that can invalidate the control system gains during an orbit. Several modified sun tracking techniques were evaluated with respect to producing a controllable configuration requiring no modifications to the CMG control algorithms. Another assessment involved the permanently manned configuration (PMC) which has a third asymmetric PV unit on one side of the transverse boom. Recommendations include constraining alpha rotations for MTC in the arrow and gravity gradient flight modes and perhaps developing new non-TEA seeking control laws. Recommendations for PMC include raising the operational altitude and moving to a symmetric configuration as soon as possible.

Troutman, Patrick A.↗

Development of Additive Manufacturing Technologies for 3D Printing of Spacecraft Heat Shields

Ablative heat shields are an enabling technology for entry into planetary atmospheres. From the PICA heatshields used for several Mars rovers to the carbon phenolic material used for Galileo’s Jupiter entry probe, the heat shield manages the heat load transferred to the payload, protecting the sensitive scientific instruments carried on entry probes. The Additive Manufacturing of Thermal Protection Systems (AMTPS) project, an Early Career Initiative (ECI) funded by NASA’s Space Technology Mission Directorate and led by NASA Johnson Space Center, seeks to develop materials and processes for 3D printing ablative heat shields for spacecraft. Current methods for producing ablative heat shields are extremely labor intensive and require extensive hands-on processes and quality control characterization. Additive manufacturing (AM) offers the possibility of reduced production times, improved reliability, and enhanced performance via graded compositions. Costs will also be reduced by reducing the time and labor required for heat shield production. Direct integration of the heat shield onto the structure during processing simplifies integration and reduces risk.

Nathaniel Olson↗

Development of Additive Manufacturing Technologies for 3D Printing of Spacecraft Heat Shields

Ablative heat shields are an enabling technology for entry into planetary atmospheres. From the PICA heatshields used for several Mars rovers to the carbon phenolic material used for Galileo’s Jupiter entry probe, the heat shield manages the heat load transferred to the payload, protecting the sensitive scientific instruments carried on entry probes. The Additive Manufacturing of Thermal Protection Systems (AMTPS) project, an Early Career Initiative (ECI) funded by NASA’s Space Technology Mission Directorate and led by NASA Johnson Space Center, seeks to develop materials and processes for 3D printing ablative heat shields for spacecraft. Current methods for producing ablative heat shields are extremely labor intensive and require extensive hands-on processes and quality control characterization. Additive manufacturing (AM) offers the possibility of reduced production times, improved reliability, and enhanced performance via graded compositions. Costs will also be reduced by reducing the time and labor required for heat shield production. Direct integration of the heat shield onto the structure during processing simplifies integration and reduces risk.

Nathaniel Olson↗

Development of Additive Manufacturing Technologies for 3D Printing of Spacecraft Heat Shields

Introduction: Ablative heat shields are an enabling technology for entry into planetary atmospheres. From the PICA heatshields used for several Mars rovers to the carbon phenolic material used for Galileo’s Jupiter entry probe, the heat shield manages the heat load transferred to the payload, protecting the sensitive scientific instruments carried on entry probes. The Additive Manufacturing of Thermal Protection Systems (AMTPS) project, an Early Career Initiative (ECI) funded by NASA’s Space Technology Mission Directorate and led by NASA Johnson Space Center, seeks to develop materials and processes for 3D printing ablative heat shields for spacecraft. Current methods for producing ablative heat shields are extremely labor intensive and re-quire extensive hands-on processes and quality control characterization. Additive manufacturing (AM) offers the possibility of reduced production times, improved reliability, and enhanced performance via graded compositions. Costs will also be reduced by reducing the time and labor required for heat shield production. Direct integration of the heat shield onto the structure during processing simplifies integration and reduces risk. Material Development: A critical challenge for the project is development of a material system that can (1) be printed in a near-net shape process and (2) perform well as an ablator. Achieving printability requires the material to flow under applied pressure, but maintain its shape once extruded from the printer nozzle. Ablative performance is measured by a multitude of markers, including char yield, char strength, thermal conductivity, and recession rate. Furthermore, there are several mechanical and thermal property considerations for vehicle integration including coefficient of thermal expansion (CTE) and residual stress. AM technology will be leveraged to grade the material formulation and properties through the thickness of the heat shield, an architecture not possible with current manufacturing processes. To this end, “robust” material formulations have been pre-pared with higher density for use on the surface where most ablation will occur. “Insulative” material formulations, with lower density and lower thermal conductivity, are prepared for use in the depth of the heat shield. This graded architecture will re-duce the overall mass of the heat shield and reduce costs and/or increase scientific payload capacities. To achieve a material system with the required properties, multiple resins have been investigated in collaboration with NASA Ames Research Center. To tune printability and performance, resin additives were studied to improve flexibility of the cured material while maintaining acceptable ablative performance. Material coupons were printed and studied via a suite of mechanical and thermal characterization methods. Arc jet testing was conducted at NASA Ames Research Center to evaluate ablative performance and thermal protection under conditions expected in atmospheric entry. Manufacturing Scale-Up: A partnership with Oak Ridge National Laboratory (ORNL) aims to enable full-scale fabrication of a 3D printed heat shield. Leveraging expertise in manufacturing and 3D printing at ORNL, a mid-scale manufacturing demonstration unit will be built and tested, using a dual-layer ablative system printed directly onto the titanium structure. Work on robotic system integration is ongoing and efforts to scale up material mixing with a material compound will ensure accurate and homogenous composition. Flight Test: A hypersonic sub-orbital flight test will provide a rigorous test of material performance ranging from ablation, thermal management, and mechanical integrity. Design of the capsule has taken place in collaboration with the University of Kentucky. Data collected from the flight will inform future design efforts in material formulation, printing methodology, and heat shield-capsule integration.

additive manufacturing↗

Characterization of spacecraft and environmental disturbances on a SmallSat

The objective of this study is to model the on-orbit vibration environment encountered by a SmallSat. Vibration control issues are common to the Earth observing, imaging, and microgravity communities. A spacecraft may contain dozens of support systems and instruments each a potential source of vibration. The quality of payload data depends on constraining vibration so that parasitic disturbances do not affect the payload's pointing or microgravity requirement. In practice, payloads are designed incorporating existing flight hardware in many cases with nonspecific vibration performance. Thus, for the development of a payload, designers require a thorough knowledge of existing mechanical devices and their associated disturbance levels. This study evaluates a SmallSat mission and seeks to answer basic questions concerning on-orbit vibration. Payloads were considered from the Earth observing, microgravity, and imaging communities. Candidate payload requirements were matched to spacecraft bus resources of present day SmallSats. From the set of candidate payloads, the representative payload GLAS (Geoscience Laser Altimeter System) was selected. The requirements of GLAS were considered very stringent for the 150 - 500 kg class of payloads. Once the payload was selected, a generic SmallSat was designed in order to accommodate the payload requirements (weight, size, power, etc.). This study seeks to characterize the on-orbit vibration environment of a SmallSat designed for this type of mission and to determine whether a SmallSat can provide the precision pointing and jitter control required for earth observing payloads.

Johnson, Thomas A.↗

On the Recoverability of Reactor Dynamics from Point Kinetics Data using SINDYc

Data driven models for reactor dynamics tend to face a few notable challenges. First, the broad range of timescales present across the various feedback mechanisms. Next, high standards for safety and importance of model performance in all operational domains. Finally, the correlations between state variables observed in most transients leads to difficulties when methods attempt to attribute certain dynamic phenomena to a particular cause. The current paper seeks to support efforts towards incorporating physics knowledge into one particular data-driven method for finding reactor dynamics called ``Sparse Identification of Nonlinear Dynamics with Control (SINDYc). The incorporation of physical knowledge into SINDYc will help address the challenges listed above by giving the model an initial understanding of the system being modeled. The demonstration of an exact representation of a set of point reactor dynamics equations in SINDYc is provided. Then, this allows for further discussion with mathematical justification as to why SINDYc, and other data-driven methods, may be difficult to apply to nuclear reactor dynamics due to correlations in the state variables. A particularly useful result of this work is the set of candidate functions required in SINDYc to exactly represent the reactor dynamics under a point approximation. In the future, SINDYc can be integrated with point models for reactor dynamics before being applied to the physical system to yield higher accuracy.

22 - GENERAL STUDIES OF NUCLEAR REACTORS↗