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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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All sourcesNASA NTRSDOE OSTI
NASA NTRS2008

Workstation-Based Avionics Simulator to Support Mars Science Laboratory Flight Software Development

The Mars Science Laboratory developed the WorkStation TestSet (WSTS) to support flight software development. The WSTS is the non-real-time flight avionics simulator that is designed to be completely software-based and run on a workstation class Linux PC. This provides flight software developers with their own virtual avionics testbed and allows device-level and functional software testing when hardware testbeds are either not yet available or have limited availability. The WSTS has successfully off-loaded many flight software development activities from the project testbeds. At the writing of this paper, the WSTS has averaged an order of magnitude more usage than the project's hardware testbeds.

WSTS↗
NASA NTRS2017

A Dynamic Calibration Method for Experimental and Analytical Hub Load Comparison

This paper presents the results from an ongoing effort to produce improved correlation between analytical hub force and moment prediction and those measured during wind-tunnel testing on the Aeroelastic Rotor Experimental System (ARES), a conventional rotor testbed commonly used at the Langley Transonic Dynamics Tunnel (TDT). A frequency-dependent transformation between loads at the rotor hub and outputs of the testbed balance is produced from frequency response functions measured during vibration testing of the system. The resulting transformation is used as a dynamic calibration of the balance to transform hub loads predicted by comprehensive analysis into predicted balance outputs. In addition to detailing the transformation process, this paper also presents a set of wind-tunnel test cases, with comparisons between the measured balance outputs and transformed predictions from the comprehensive analysis code CAMRAD II. The modal response of the testbed is discussed and compared to a detailed finite-element model. Results reveal that the modal response of the testbed exhibits a number of characteristics that make accurate dynamic balance predictions challenging, even with the use of the balance transformation.

Kreshock, Andrew R.↗
NASA NTRS2020

Experimental Validation of Model-Based Prognostics for Pneumatic Valves

Because valves control many critical operations, they are prime candidates for deployment of prognostic algorithms. But, similar to the situation with most other components, examples of failures experienced in the field are hard to come by. This lack of data impacts the ability to test and validate prognostic algorithms. A solution sometimes employed to overcome this shortcoming is to perform run-to-failure experiments in a lab. However, the mean time to failure of valves is typically very high (possibly lasting decades), preventing evaluation within a reasonable time frame. Therefore, a mechanism to observe development of fault signatures considerably faster is sought. Described here is a testbed that addresses these issues by allowing the physical injection of leakage faults (which are the most common fault mode) into pneumatic valves. What makes this testbed stand out is the ability to modulate the magnitude of the fault almost arbitrarily fast. With that, the performance of end-of-life estimation algorithms can be tested. Further, the testbed is mobile and can be connected to valves in the field. This mobility helps to bring the overall process of prognostic algorithm development for this valve a step closer to validation. The paper illustrates the development of a model-based prognostic approach that uses data from the testbed for partial validation.

Chetan S Kulkarni↗
NASA NTRS2018

Experimental Evaluation of BLI Propulsion: The Boundary Layer Ingesting Inlet/Distortion-Tolerant Fan Solution

NASA has successfully developed a new testbed configuration for experimentally evaluating embedded boundary layer ingesting aircraft propulsors in its 8'x6' Supersonic Wind Tunnel. This testbed meets the challenges of providing the necessary freestream flow Mach conditions and desired range and distribution of boundary layer thickness for embedded aircraft propulsion systems. The testbed consists of a 48ft long raised wind tunnel floor aircraft surface simulator and a boundary layer regulation system to produce propulsion-local aircraft aerodynamic flow fields. This durable special test equipment is designed to be installed in the wind tunnel's transonic test section and is capable of evaluating a wide range of subcritical and supercritical airframe-propulsion integration configurations for subsonic cruise aircraft. The wind tunnel and testbed are well suited for meeting the test requirements of these propulsors in the most cost efficient way and has been aerodynamically calibrated and proven through tests of a first-of-its-kind boundary layer ingesting propulsor.

Arend, David J.↗
NASA NTRS2019

Overview of NASA's Solar Electric Propulsion Project

NASA is continuing to develop and qualify a state of the art 13 kW-class Advanced Electric Propulsion System (AEPS) for NASA exploration missions through a contract with Aerojet Rocketdyne. An objective of the AEPS project is to empower the US space industry to accelerate the adoption of high power electric propulsion technologies by reducing the risk and uncertainty of integrating Solar Electric Propulsion (SEP) technologies into space flight systems. NASA and AEPS contract has recently initiated engineering hardware testing of the Hall Current Thruster (HCT), Power Processing Unit (PPU), and Xenon Flow Controller (XFC) at both the component and system levels. The successful completion of these tests will provide the required information to advance the AEPS system towards Critical Design Review. In support of the AEPS contract, NASA and JPL have been performing risk reduction activities to address specific concerns of the state of the art higher power Hall thruster propulsion system. These risk reduction activities have included long duration wear testing of the Technology Demonstration Unit (TDU) Hall thruster and cathode hardware, thermal cycling testing of TDU cathode heaters and coils, plasma plume measurements, and investigating PPU design. In addition to NASA propulsion development, the SEP project is developing the Plasma Diagnostic Package (PDP) and the SEP Testbed. The PDP is designed for use in conjunction with a high powered EP system to characterize in-space operation. The SEP Testbed system is developed for demonstration of Abstract: NASA is continuing to develop and qualify a state of the art 13 kW-class Advanced Electric Propulsion System (AEPS) for NASA exploration missions through a contract with Aerojet Rocketdyne. An objective of the AEPS project is to empower the US space industry to accelerate the adoption of high power electric propulsion technologies by reducing the risk and uncertainty of integrating Solar Electric Propulsion (SEP) technologies into space flight systems. NASA and AEPS contract has recently initiated engineering hardware testing of the Hall Current Thruster (HCT), Power Processing Unit (PPU), and Xenon Flow Controller (XFC) at both the component and system levels. The successful completion of these tests will provide the required information to advance the AEPS system towards Critical Design Review. In support of the AEPS contract, NASA and JPL have been performing risk reduction activities to address specific concerns of the state of the art higher power Hall thruster propulsion system. These risk reduction activities have included long duration wear testing of the Technology Demonstration Unit (TDU) Hall thruster and cathode hardware, thermal cycling testing of TDU cathode heaters and coils, plasma plume measurements, and investigating PPU design. In addition to NASA propulsion development, the SEP project is developing the Plasma Diagnostic Package (PDP) and the SEP Testbed. The PDP is designed for use in conjunction with a high powered EP system to characterize in-space operation. The SEP Testbed system is developed for demonstration of an integrated SEP end-to-end system performance. The paper will present an overview of the NASA and the AEPS contract activities and a summary of the associated NASA in-house activities.

Plasma Diagnostics Package↗
NASA NTRS2021

Propellant Delivery via VDC Driven Pump

The SMART (Scalable Mobile Autonomous Rocket engine Test) testbed system initiative at SSC was conceived to attempt to address many of the principal cost drivers in developing and maintaining a rocket engine test facility. The system (optimized to test engines and components generating up to 10K lbf nominal thrust) is serving as a testbed for innovative technologies and processes to provide lower cost test services with a rapid test cadence and expedient turnaround times. The system can also potentially be used as a testbed to test other related technologies relevant to surface situations (e.g., moon, Mars associated with crogenic fluid management, engine/component testing, autonomous operations, etc.). This FY20 CIF project, being conducted as part of the SMART testbed system, is developing and testing a propellant delivery system via electrically driven centrifugal pumps (obviating dependence upon Multi-Layer Pressure Vessels) with configuration and operation by a minimal number of personnel. During FY20 the team identified the requirements and worked with P3 and Masten Space Systems to develop the long lead (9 months after receipt of order) items, the 400 VDC pumps, for delivery in mid FY21. Since control of the 400 VDC pump motor is not well developed the team has established heuristics to control flows in LN2 at off nominal shaft speeds to allow deep throttling of the pump in flow test scenarios. Various test scenarios including nominal i.e. high flow high pressure, high flow low pressure, low flow high pressure, low flow low pressure, minimum throttle step change, and low inlet pressure cavitation testing were developed ahead of the anticipated hardware delivery and test. FY20 COVID Stage 3 conditions restricted access to the center and hindered lab work, so efforts focused on the system design and testing plans along with the project procurement paperwork for the hardware... now with its anticipated delivery in spring FY21. Some limited access to the center is expected by spring/summer FY21 for the continuing second year (FY21) CIF project effort meant to be focused upon system integration and initial testing.

Aaron Head↗
NASA NTRSDate not supplied

Mitigation of Silver Ion Loss from Solution by Polymer Coating of Metal Surfaces, Part IV

“Spacecraft potable water systems require a biocidal agent that effectively provides both immediate and residual disinfection over long periods of time. Ionic silver (Ag+) is a leading candidate for this application, but suffers from rapid concentration loss due to interactions with the metallic storage containers and tubing. In order to maintain biocidal efficacy in systems with long periods of dormancy and to reduce the required rate of Ag+ injection, it is necessary to develop alternative materials and coatings for certified metal alloys that significantly reduce the Ag+ loss.” In previous reports, we have described our investigations addressing Ag+ loss mitigation and adhesion performance of parylene barrier coatings on coupons of several metal alloys and 316L tubing under static immersion. In such conditions, parylene-C and AF4 coatings have shown excellent Ag+ loss mitigation performance, and mixed long-term adhesion performance, depending on parylene species and substrate surface chemistry/structure. In Part IV of this series, we begin to address the performance of parylene-C barrier coatings under more challenging and realistic conditions, in order to evaluate potential suitability in flight systems. Using two testbeds, we characterized coating performance under dynamic mechanical operation. In the Flow/Pressure Testbed System, Ag+ solution is pumped through internally coated 316L tubing, with optional pressure cycling. In the Bellows Tank Testbed System, an internally coated edge-welded 316L bellows containing Ag+ solution is cyclically extended and compressed, analogous to the operation of bellows tanks used for potable water storage and delivery on the International Space Station. Periodic determinations of Ag+ loss with testbed cycling/time and visual observation of the parylene-C coatings were conducted. In addition, we characterized parylene-C coating resilience and Ag+ loss with 316L tubing and multiple fitting types under long-term immersion and repeated fitting dis/reassembly.

Lance Dean Delzeit↗
NASA NTRSDate not supplied

Mitigation of Silver Ion Loss from Solution by Polymer Coating of Metal Surfaces, Part IV

Ionic silver (Ag+) biocide is a leading candidate to provide residual microbial control in spacecraft potable water systems, but suffers from rapid concentration loss due to interactions with the metallic storage containers and tubing. One approach to resolve this problem is the coating of metal surfaces with an inert barrier film. In previous reports, we have described our investigations addressing Ag+ loss mitigation and adhesion performance of parylene barrier coatings on coupons of several metal alloys and 316Ltubing under static immersion. In such conditions, parylene-C and -AF4 coatings have shown excellent Ag+loss mitigation and mixed long-term adhesion performance, depending on parylene species and substrate surface chemistry/structure. In Part IV of this series, we report on our work to investigate the performance of parylene-C barrier coatings, under more challenging and realistic conditions, in order to evaluate potential suitability for use. The resilience and associated Ag+ loss with Parylene-C coating on½” (12.7 mm)316L tubing and fittings under medium-term immersion and repeated fitting dis/reassembly were investigated. Potential mechanical challenges to barrier coatings in spacecraft potable water systems were investigated, with two main focuses being identified: liquid flow/pressure cycling in tubing and cyclic operation of bellows in positive-expulsion storage tanks. Two corresponding testbeds for experimental characterization of coating performance were developed. In the Flow/Pressure Testbed System, Ag+ solution will be pumped through internally coated 316L tubing, with optional pressure cycling. In the Bellows Tank Testbed System, an internally coated edge-welded 316L bellows containing Ag+ solution will be cyclically extended and compressed, analogous to the operation of bellows tanks used for potable water storage and delivery on the International Space Station. The design and operation of these testbeds are described. Finally, the Ag+ adsorption and saturation behaviors of Kalrez and Viton, for potential use as seal materials in fittings and other connections, were characterized in limited experiments.

mitigation↗
NASA NTRSDate not supplied

Experimental Verification of the Parabolic Deformable Mirror for the ExoSpec Project

For the Habitable Worlds Observatory, it is essential to broaden the controllable wavelength bandwidth for high-contrast imaging and spectroscopy to increase the exoEarth yield and characterization. The Parabolic Deformable Mirrors (PDM) under the NASA Headquarters directed ExoSpec Work package is specifically tailored to do so. We have successfully procured a generation 1 (Gen 1) PDM device and completed in-depth characterization of the device. This robust evaluation has become instrumental in informing subsequent stages of development, particularly in shaping the design and specifying requirements for the next generation, Gen2, PDM device. We have built a testbed in an environmentally controlled cleanroom to experimentally demonstrate the use of a parabolic DM in a coronagraph instrument as well an integral field spectrograph (IFS). This versatile testbed is designed to test different DM architectures, various low-order wavefront schemes, and a lenslet based IFS. This provides us with a basis for comparison with different DM configurations – 1) flat DM, 2) parabolic DMs, and 3) a flat DM and parabolic DMs. In this communication, we will discuss the testbed design and updates, parabolic DM characterization, Gen 2 requirement definitions, and different tests planned for the testbed.

Hari Subedi↗
NASA NTRSDate not supplied

Development of a Digital Twin for Electrified Aircraft Powertrain Health Management

The augmentation of aircraft powertrains with electrical power systems is a promising path to reducing aircraft fuel consumption, emissions, and noise. Like conventional propulsion systems, electrified aircraft propulsion (EAP) systems will be subject to wear and tear throughout their lifecycles. System health management for EAP will enable efficient flight and maintenance scheduling, realizing economic, safety, and reliability benefits. A digital twin is, broadly, a dynamically updated virtual representation of an individual physical asset. This paper presents a Kalman filter-based approach for the development of a digital twin for an electrified powertrain and applies the approach to an EAP controls testbed. Measurements from nominal testbed operations are used to update a nonlinear model of the testbed. A Kalman filter is then created and used to identify and isolate anomalous testbed behavior based on measurements from off- nominal operations. Results show that the Kalman filter-based digital twin can monitor individual powertrain components’ health for degradation or other changes in performance. The applicability of the presented digital twin approach to any hybrid- or fully-electrified powertrain is emphasized.

Electrified Aircraft Propulsion↗
DOE OSTI2026

Designing resilient IoT and Edge Computing with federated tinyML

The rapid growth of the Internet of Things (IoT) and Edge Computing (EC) has brought significant conveniences to modern society but has also greatly expanded the cyber attack surfaces, particularly as these technologies are being increasingly integrated into critical systems such as power grids, healthcare, and smart homes. Here, to improve IoT/EC’s cybersecurity posture, we leveraged Artificial Intelligence (AI) and Machine Learning (ML) by employing tinyML to monitor voluminous IoT data for cyber threats while addressing devices’ resource constraints, and utilizing Federated Learning (FL) to share local detection knowledge across the system while preserving privacy. Building on our three-layer architecture combining tinyML and FL to enhance autonomous cyber attack detection, this paper demonstrated that the architecture improves detection accuracy, reduces resource consumption, and enables lightweight, secure IoT device monitoring. These results were validated using the public N-BaIoT dataset as well as real IoT network traffic data collected under multiple attack scenarios from our testbeds. Additionally, we introduced an enhanced FL methodology with a novel preprocessing stage, including federated feature selection and global preprocessor construction, to address IoT/EC data heterogeneity. We developed a physical IoT testbed for attack simulations and data collection, implemented a tinyML-powered detector for realistic model validation, and also built a virtual testbed for scalable evaluations of FL models across diverse network environments.

Cognitive cyber↗
DOE OSTI2022

Anomaly Detection and Mitigation in FACTS-based Wide-Area Voltage Control Systems using Machine Learning

With the increasing deployment of Flexible AC Transmission System (FACTS) devices in wide-area voltage control systems (WAVCS) for achieving improved voltage stability of bulk power systems, the possibility for cyber attacks on these systems is also increasing. Successful stealthy cyber attacks that are difficult to detect by traditional informational technology (IT)-based cybersecurity solutions or threshold-based bad data detectors can lead to a voltage collapse in power grid. This paper presents the testbed-based attacks implementation and real-time evaluation of machine learning (ML) algorithm for detecting and mitigating stealthy cyber attacks on FACTS-based WAVCS on a hardware-in-the-loop (HIL) testbed. Initially, we discuss the implementation of a fuzzy logic controller (FLC) that controls a Static VAR Compensator (SVC) device deployed in a two-area four-machine Kundur power system for improving transient voltage stability. Later, the ML-based Anomaly Detection and Mitigation (ADM) system is implemented on the cyber-physical HIL testbed to detect and mitigate various stealthy cyber attacks, which are injected in real-time over the wide-area network (WAN). The experimental results show accurate and effective performance of ADM system in detecting and mitigating anomalies while keeping the grid stable and within the system operating limits, as defined by the North America Electric Reliability Corporation (NERC).

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2022

Quantum Networks for Resilient Power Grids: Theory and Simulated Evaluation

Quantum networks are considered the future of secure communication in the coming quantum era. Yet there lack significant efforts on developing practical quantum networks for power grids. Here, in this paper, we establish a quantum network-based power grid (QNetGrid) framework and develops a real-time, reliable, flexible, programmable, and cost-effective QNetGrid software testbed containing repeater-based quantum communication, quantum routing, real software-defined networking (SDN) switches, and real-time networked microgrids (NMs) operations. It makes the following contributions: 1) a repeater and routing based quantum network simulator (QNSim) is developed, 2) repeaters with and without quantum memories are respectively simulated in QNSim, 3) different routing scenarios in QNetGrid are investigated, 4) a real-time QNetGrid software testbed is built in RTDS incorporating QNSim and real SDN switches, and 5) various test cases are designed, and experimental results produced with the QNetGrid testbed provide valuable insights for building quantum networks in power grids.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2020

TRUST-EABM Sensors in Environments (SE) Report: Release FY20

The objective of the Delivery Environments (DE) Testbeds to Reduce Uncertainties in Simulations and Tests (TRUST) project is to support the efficient and responsive development of experimental, modeling, and simulation capabilities for future systems by developing representative testbeds that can be exercised more easily and efficiently than a WR like assembly for the purposes uncertainty quantification [1][2][3]. The testbeds are intended to be experimentally exercised in current and future relevant engineering environments with complementary modeling and simulation.

47 OTHER INSTRUMENTATION↗
DOE OSTI2024

Practical Insights on Applying Simulation-Based Control Methods in Experimental Studies

Advanced nuclear reactors are crucial to the future of energy both in the United States and around the globe. In contrast to the current operating fleet, they are characterized as being deployable in remote locations and able to operate in semi-autonomous or autonomous fashion. This leap forward necessitates a new reactor control paradigm. Because advanced nuclear reactors are still under development in the United States, the creation of new control methods to achieve autonomous operations has been based on systems modeling and simulation. However, an important factor in successfully deploying these new control methods is the ability to seamlessly transition from simulation environments to real-world settings. Control methods tested in both simulation and experimental settings need to be investigated in the context of advanced reactor applications. This work developed a series of simple controllers for Idaho National Laboratory (INL)’s Microreactor Applications Research Validation and Evaluation (MARVEL) microreactor operating in load-following scenarios. These controllers were tested in both simulation and experimental settings, and a comparative performance analysis was performed. The simulation tests leveraged the Control and Optimization Modular Modeling Application for Nuclear Deployment (COMMAND) software developed in a previous stage of the current effort, along with the MARVEL Reactor Excursion and Leak Analysis Program (RELAP5-3D) and Monte Carlo N-Particle (MCNP) models. The experimental tests leveraged the COMMAND software, MARVEL models, and the U.S. Department of Energy Microreactor Program’s Microreactor Automated Control System (MACS). MACS was developed to serve as a control method testbed. It was customized to mirror the MARVEL microreactor, and COMMAND enabled MACS to emulate the physics of MARVEL. The load-following controller was developed using the simulation platform, with efforts to emulate real systems by introducing actuator saturation and noise. These factors were incrementally accounted for in the controller design. After finalizing the controller design, it was implemented with the experimental setup. The experimental conditions tested included an initial test under conditions similar to the final simulation test, and two additional scenarios. The first scenario introduced additional actuator saturation to account for equipment aging over time, which was unknown to the controller. The second scenario introduced sensor delay, a phenomenon anticipated with the use of remote operations or wireless communication in advanced reactors. These tests revealed several notable differences. While the controller performed well in simulation, it exhibited several limitations when transitioning to hardware. The main challenges involved maintaining the steady-state target power, as evidenced by larger error values between the true reactor power and setpoint power, as well as persistent oscillations in controlled reactor power. These issues could lead to unacceptable transient conditions in real reactor testing. Introducing actuator aging and stochastic delays in the experimental setup significantly impacted controller performance, resulting in increased overshoot and undershoot, and exacerbated error and oscillations previously mentioned. These findings underscore the importance of experimental testbeds for testing and validating control methods, as controllers developed using only theory and/or simulation may perform unexpectedly when applied to actual hardware. This research emphasizes the need for an experimental testbed for achieving such validation.

46 - INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AN↗
DOE OSTI2016

Cyber-Physical System Security of a Power Grid: State-of-the-Art

Here, as part of the smart grid development, more and more technologies are developed and deployed on the power grid to enhance the system reliability. A primary purpose of the smart grid is to significantly increase the capability of computer-based remote control and automation. As a result, the level of connectivity has become much higher, and cyber security also becomes a potential threat to the cyber-physical systems (CPSs). In this paper, a survey of the state-of-the-art is conducted on the cyber security of the power grid concerning issues of: the structure of CPSs in a smart grid; cyber vulnerability assessment; cyber protection systems; and testbeds of a CPS. At Washington State University (WSU), the Smart City Testbed (SCT) has been developed to provide a platform to test, analyze and validate defense mechanisms against potential cyber intrusions. A test case is provided in this paper to demonstrate how a testbed helps the study of cyber security and the anomaly detection system (ADS) for substations.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2018

ATP3 Unified Field Study Data

ATP3 Unified Field Study DataThe Algae Testbed Public-Private Partnership ATP3 was established with the goal of investigating open pond algae cultivation across different geographic climatic seasonal and operational conditions while setting the benchmark for quality data collection analysis and dissemination. Identical algae cultivation systems and data analysis methodologies were established at testbed sites across the continental United States and Hawaii. Within this framework the Unified Field Studies UFS were designed to characterize the cultivation of different algal strains during all 4 seasons across this testbed network. The dataset presented here is the complete curated climatic cultivation harvest and biomass composition data for each season at each site. These data enable others to do in-depth cultivation harvest techno-economic life cycle resource and predictive growth modeling analysis as well as develop crop protection strategies for the nascent algae industry.NREL Sub award Number DE-AC36-08-GO28308

09 BIOMASS FUELS↗
NASA NTRS2012

Comparative Modal Analysis of Sieve Hardware Designs

The CMTB Thwacker hardware operates as a testbed analogue for the Flight Thwacker and Sieve components of CHIMRA, a device on the Curiosity Rover. The sieve separates particles with a diameter smaller than 150 microns for delivery to onboard science instruments. The sieving behavior of the testbed hardware should be similar to the Flight hardware for the results to be meaningful. The elastodynamic behavior of both sieves was studied analytically using the Rayleigh Ritz method in conjunction with classical plate theory. Finite element models were used to determine the mode shapes of both designs, and comparisons between the natural frequencies and mode shapes were made. The analysis predicts that the performance of the CMTB Thwacker will closely resemble the performance of the Flight Thwacker within the expected steady state operating regime. Excitations of the testbed hardware that will mimic the flight hardware were recommended, as were those that will improve the efficiency of the sieving process.

flight hardware↗