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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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DOE OSTI2015

Evaluation of Variable Refrigerant Flow Systems Performance and the Enhanced Control Algorithm on Oak Ridge National Laboratory's Flexible Research Platform

A research project “Evaluation of Variable Refrigerant Flow (VRF) Systems Performance and the Enhanced Control Algorithm on Oak Ridge National Laboratory’s (ORNL’s) Flexible Research Platform” was performed to (1) install and validate the performance of Samsung VRF systems compared with the baseline rooftop unit (RTU) variable-air-volume (VAV) system and (2) evaluate the enhanced control algorithm for the VRF system on the two-story flexible research platform (FRP) in Oak Ridge, Tennessee. Based on the VRF system designed by Samsung and ORNL, the system was installed from February 18 through April 15, 2014. The final commissioning and system optimization were completed on June 2, 2014, and the initial test for system operation was started the following day, June 3, 2014. In addition, the enhanced control algorithm was implemented and updated on June 18. After a series of additional commissioning actions, the energy performance data from the RTU and the VRF system were monitored from July 7, 2014, through February 28, 2015. Data monitoring and analysis were performed for the cooling season and heating season separately, and the calibrated simulation model was developed and used to estimate the energy performance of the RTU and VRF systems. This final report includes discussion of the design and installation of the VRF system, the data monitoring and analysis plan, the cooling season and heating season data analysis, and the building energy modeling study

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2020

Design of the DUNE APATF cryogenic system

Fermi National Accelerator Laboratory (FNAL) is developing the international Long- Baseline Neutrino Facility (LBNF) and Deep Underground Neutrino Experiment (DUNE) to advance neutrino science. The flagship of the DUNE project consists of a large particle detector constructed one-mile (1.6 km) beneath the surface at the Sanford Underground Research Facility (SURF) in Lead, SD. The SURF detector is the largest of its type ever built and is comprised of four cryostats totaling 70,000 tons of liquid argon (LAr) to record neutrino interactions with unprecedented precision. Each cryostat houses a detector, the first includes 150 Anode Panel Assemblies (APA) submersed within 17,500 tons of LAr. Before installing 150 APA within the SURF detector they will be cryogenically cooled to nominally 90 K at the APA Test Facility (APATF) utilizing nitrogen flows. The APATF cryogenic system is entirely located one-mile underground at the SURF facility and includes nominally 13 kW of refrigeration at 80 K, cryogenic transfer lines, APA test cryostats, a cryogenic control system, and various control and pressure safety elements to ensure performance and safety requirements are achieved. The APATF preliminary design is in progress and major considerations include an efficient, costeffective mechanism to deliver the required refrigeration to the APATF underground, support of rigid testing intervals to support the DUNE operating schedule, temperature stability of the APA and electronics within cryostats, efficient cryogenic system operation to minimize heat leak and/or liquid nitrogen consumption, thermo-mechanical stability and flexibility of components, and pressure safety of the APATF cryogenic system. Installation and integration of the APATF cryogenic system within the footprint and to adjacent sub-systems is also discussed.

43 PARTICLE ACCELERATORS↗

NASA NTRS2000

An Architecture for Real-Time Interpretation and Visualization of Structural Sensor Data in a Laboratory Environment

A visualization system is being developed out of the need to monitor, interpret, and make decisions based on the information from several thousand sensors during experimental testing to facilitate development and validation of structural health monitoring algorithms. As an added benefit the system will enable complete real-time sensor assessment of complex test specimens. Complex structural specimens are routinely tested that have hundreds or thousands of sensors. During a test, it is impossible for a single researcher to effectively monitor all the sensors and subsequently interesting phenomena occur that are not recognized until post-test analysis. The ability to detect and alert the researcher to these unexpected phenomena as the test progresses will significantly enhance the understanding and utilization of complex test articles. Utilization is increased by the ability to halt a test when the health monitoring algorithm response is not satisfactory or when an unexpected phenomenon occurs, enabling focused investigation potentially through the installation of additional sensors. Often if the test continues, structural changes make it impossible to reproduce the conditions that exhibited the phenomena. The prohibitive time and costs associated with fabrication, sensoring, and subsequent testing of additional test articles generally makes it impossible to further investigate the phenomena. A scalable architecture is described to address the complex computational demands of structural health monitoring algorithm development and laboratory experimental test monitoring. The researcher monitors the test using a photographic quality 3D graphical model with actual sensor locations identified. In addition, researchers can quickly activate plots displaying time or load versus selected sensor response along with the expected values and predefined limits. The architecture has several key features. First, distributed dissimilar computers may be seamlessly integrated into the information flow. Second, virtual sensors may be defined that are complex functions of existing sensors or other virtual sensors. Virtual sensors represent a calculated value not directly measured by particular physical instrument. They can be used, for example, to represent the maximum difference in a range of sensors or the calculated buckling load based on the current strains. Third, the architecture enables autonomous response to preconceived events, where by the system can be configured to suspend or abort a test if a failure is detected in the load introduction system. Fourth, the architecture is designed to allow cooperative monitoring and control of the test progression from multiple stations both remote and local to the test system. To illustrate the architecture, a preliminary implementation is described monitoring the Stitched Composite Wing recently tested at LaRC.

Doggett, William↗

DOE OSTI2020

Scaling arguments for a plasma experiment relevant to an interplanetary coronal mass ejection

We present the design of a plasma experiment scaled to be relevant to an interplanetary coronal mass ejection (ICME) traveling from the Sun to the Earth. The experiment would launch a compact torus of plasma (the scaled analog of the coronal mass ejected by the Sun) into a magnetized background plasma (the scaled analog of the interplanetary medium, the diffuse magnetized plasma that fills the Solar System). We present the complete process of scaling the ICME system to a laboratory experiment: beginning with the ICME features that we aim to replicate with a laboratory experiment, explaining how these desired features are translated into specific design constraints, and presenting a set of experimental parameters that meet those constraints. We find that the experiment would be possible with plasma conditions typically achieved in large-scale facilities such as the Big Red Ball at the University of Wisconsin or the LArge Plasma Device at the University of California, Los Angeles.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2017

Side-by-Side Testing of Water Heating Systems: Results from the 2013-2014 Evaluation

The Florida Solar Energy Center (FSEC) has completed a fourth year-long evaluation on residential hot water heating systems in a laboratory environment (east central Florida, hot-humid climate). This report contains a summary of research activities regarding the evaluation of two residential electric heat pump water heaters (HPWHs), a solar thermal system utilizing a polymer glazed absorber and a high efficiency natural gas system.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

NASA NTRS2012

On-Shore Central Hydraulic Power Generation for Wind and Tidal Energy

Tidal energy, offshore wind energy, and onshore wind energy can be converted to electricity at a central ground location by means of converting their respective energies into high-pressure hydraulic flows that are transmitted to a system of generators by high-pressure pipelines. The high-pressure flows are then efficiently converted to electricity by a central power plant, and the low-pressure outlet flow is returned. The Department of Energy (DOE) is presently supporting a project led by Sunlight Photonics to demonstrate a 15 kW tidal hydraulic power generation system in the laboratory and possibly later submerged in the ocean. All gears and submerged electronics are completely eliminated. A second portion of this DOE project involves sizing and costing a 15 MW tidal energy system for a commercial tidal energy plant. For this task, Atlantis Resources Corporation s 18-m diameter demonstrated tidal blades are rated to operate in a nominal 2.6 m/sec tidal flow to produce approximately one MW per set of tidal blades. Fifteen units would be submerged in a deep tidal area, such as in Maine s Western Passage. All would be connected to a high-pressure (20 MPa, 2900 psi) line that is 35 cm ID. The high-pressure HEPG fluid flow is transported 500-m to on-shore hydraulic generators. HEPG is an environmentally-friendly, biodegradable, watermiscible fluid. Hydraulic adaptations to ORPC s cross-flow turbines are also discussed. For 15 MW of wind energy that is onshore or offshore, a gearless, high efficiency, radial piston pump can replace each set of top-mounted gear-generators. The fluid is then pumped to a central, easily serviceable generator location. Total hydraulic/electrical efficiency is 0.81 at full rated wind or tidal velocities and increases to 0.86 at 1/3 rated velocities.

wind energy↗

NASA NTRS2015

Space Environment Testing of Photovoltaic Array Systems at NASA's Marshall Space Flight Center

CubeSats, Communication Satellites, and Outer Planet Science Satellites all share one thing in common: Mission success depends on maintaining power in the harsh space environment. For a vast majority of satellites, spacecraft power is sourced by a photovoltaic (PV) array system. Built around PV cells, the array systems also include wiring, substrates, connectors, and protection diodes. Each of these components must function properly throughout the mission in order for power production to remain at nominal levels. Failure of even one component can lead to a crippling loss of power. To help ensure PV array systems do not suffer failures on-orbit due to the space environment, NASA's Marshall Space Flight Center (MSFC) has developed a wide ranging test and evaluation capability. Key elements of this capability include: Testing: a. Ultraviolet (UV) Exposure b. Charged Particle Radiation (Electron and Proton) c. Thermal Cycling d. Plasma and Beam Environments Evaluation: a. Electrostatic Discharge (ESD) Screening b. Optical Inspection and easurement c. PV Power Output including Large Area Pulsed Solar Simulator (LAPSS) measurements This paper will describe the elements of the space environment which particularly impact PV array systems. MSFC test capabilities will be described to show how the relevant space environments can be applied to PV array systems in the laboratory. A discussion of MSFC evaluation capabilities will also be provided. The sample evaluation capabilities offer test engineers a means to quantify the effects of the space environment on their PV array system or component. Finally, examples will be shown of the effects of the space environment on actual PV array materials tested at MSFC.

Schneider, Todd A.↗

DOE OSTI2017

Building America Case Study: Side-by-Side Testing of Water Heating Systems: Results from the 2013–2014 Evaluation Final Report

BA-PIRC↗

DOE OSTI2017

Building America Case Study: Side-by-Side Testing of Water Heating Systems: Results from 2013-2014 Evaluation Final Report, Cocoa, FL

30 DIRECT ENERGY CONVERSION↗

NASA NTRS1989

JPL control/structure interaction test bed real-time control computer architecture

The Control/Structure Interaction Program is a technology development program for spacecraft that exhibit interactions between the control system and structural dynamics. The program objectives include development and verification of new design concepts - such as active structure - and new tools - such as combined structure and control optimization algorithm - and their verification in ground and possibly flight test. A focus mission spacecraft was designed based upon a space interferometer and is the basis for design of the ground test article. The ground test bed objectives include verification of the spacecraft design concepts, the active structure elements and certain design tools such as the new combined structures and controls optimization tool. In anticipation of CSI technology flight experiments, the test bed control electronics must emulate the computation capacity and control architectures of space qualifiable systems as well as the command and control networks that will be used to connect investigators with the flight experiment hardware. The Test Bed facility electronics were functionally partitioned into three units: a laboratory data acquisition system for structural parameter identification and performance verification; an experiment supervisory computer to oversee the experiment, monitor the environmental parameters and perform data logging; and a multilevel real-time control computing system. The design of the Test Bed electronics is presented along with hardware and software component descriptions. The system should break new ground in experimental control electronics and is of interest to anyone working in the verification of control concepts for large structures.

Briggs, Hugh C.↗

DOE OSTI2023

Improvements in Reflected Target Non-intrusive Assessment (ReTNA)

Accurate optical surfaces are a primary driver of concentrated solar power plant performance. Errors in pointing and tracking mirrors, the canting of individual mirror facets, and the surface slope of the mirror itself can be caused by errors during assembly, transportation, wind loading, gravity, and many other sources. The tools that exist to measure these error sources today largely rely on fringe deflectometry (SOFAST, QDec, others), or photogrammetry with targets attached to the mirror surface. In 2022, NREL presented a new indoor optical measurement system to measure fully assembled heliostats during development and on the assembly line for quality assurance purposes, which has undergone significant development in the last year, including the installation of a new, larger laboratory setup. This system, called ReTNA (Reflected Target Non-intrusive Assessment), uses a printed pattern as a deflectometry target. Using printed pattern features as deflectometry targets instead of fringes allows the software to measure the surface slope in two dimensions, eliminating the need to for changing, projected targets. In the last year, NREL's ReTNA tool has been adapted to use a tall, thin target, that only spans one dimension of the mirror, and a camera moving on an automatic track system. We will present these new developments, including the new setup, target patterns, software methodology for fast, automatic optical analysis, and important lessons learned throughout the process. ReTNA results will be compared to established tools, to establish the uncertainty of this new method. ReTNA leverages recent improvements in computer vision and photogrammetry to remove as much careful calibration from the setup process as possible, making the tool low cost, simple, and portable. While it will not achieve the resolution of a fringe deflectometry system, its advantages make it well suited for CSP evaluation, and allow it to fill a different industry need.

concentrating solar power↗

DOE OSTI2026

Autonomous elemental characterization enabled by a low cost robotic platform built upon a generalized software architecture

Despite the rapidly growing applications of robots in industry, the use of robots to automate tasks in scientific laboratories is less prolific due to the lack of generalized methodologies and the high cost of hardware. This paper focuses on the automation of characterization tasks necessary for reducing cost while maintaining generalization and proposes a software architecture for building robotic systems in scientific laboratory environments. A dual-layer (Socket.IO and ROS) action server design is the basic building block, which facilitates the implementation of a web-based front end for user-friendly operation and the use of ROS Behavior Trees for convenient task planning and execution. A robotic platform for automating mineral and material sample characterization is built upon the architecture, with an open-source, low-cost three-axis computer numerical control gantry system serving as the main robot. A handheld laser induced breakdown spectroscopy (LIBS) analyzer is integrated with a 3D printed adapter, enabling (1) automated 2D chemical mapping and (2) autonomous sample measurement (with the support of an RGB-Depth camera). We demonstrate the utility of automated chemical mapping by scanning the surface of a spodumene-bearing pegmatite core sample with a 1071-point dense hyperspectral map acquired at a rate of 1520 bits per second. Furthermore, we showcase the autonomy of the platform in terms of perception, dynamic decision-making, and execution, through a case study of LIBS measurement of multiple mineral samples. The platform enables controlled and autonomous chemical quantification in the laboratory that complements field-based measurements acquired with the same handheld device, linking resource exploration and processing steps in the supply chain for lithium-based battery materials.

Cao, Xuan [Lawrence Berkeley National Laboratory (↗

DOE OSTI2019

Screening of Gel Formation Methods in Paraffin Based Systems

The Savannah River National Laboratory (SRNL) has evaluated gel formation in kerosene using a lecithin-based system, the aluminum soap of naphthenic and palmitic acid or derivatives, and an acrylamide copolymerization. Some gelling was observed in the lecithin system, but not sufficient gelling to meet the customer’s needs. The napthenic systems provided a good degree of gelling yet required a larger wt.% than the customer desires. The acrylamide copolymerization gels easily in aqueous systems yet does not extend to an organic system.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2021

About the Complex Natural and Engineered Systems Pillar

Los Alamos National Laboratory is a world leader in applying multi-disciplinary science to complex systems within the Complex Natural and Engineered Systems (CNES) challenge areas. Our search for solutions requires science and technology innovation, as well as an integrated experiment, theory, and modeling and simulation approach. Our research and development spans from improving engineered systems such as nuclear weapons and the power grid, to understanding the interface of human and engineered systems from the subsurface to space, to studying how complex natural systems such as disease and climate impact humanity.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

NASA NTRS2017

A Comparison of System Architectures for a Mechanically Pumped Two-Phase Thermal Control System

The NASA Jet Propulsion Laboratory is developing a mechanically pumped two-phase fluid loop thermal control system to enable novel mission designs and greater science return. Pumped two-phase fluid loops have the potential to provide robust and effective thermal control that combine the best aspects of passive two-phase systems (heat pipes) and mechanically pumped single-phase fluid loops. The current program requirements include the development of a system with multiple 1 sq.m evaporators, each of which is capable of remaining spatially and temporally isothermal while accommodating heat loads of up to 500 W and local fluxes of up to 5 W/sq.cm. The goal is to attain this using less than 5 W of power. Such a system would be able to accommodate the next generation of payload and bus electronics while using minimal resources. This paper compares two different mechanically pumped two-phase fluid loop architectures in the context of these requirements. A mixed flow and separated flow architecture are compared on a theoretical and experimental basis. Test data from sub-scale, single evaporator/single condenser, mixed flow and separated flow testbeds are presented. In addition, a model is introduced to better understand separated flow systems and some expressions for the theoretical performance limits of such systems are developed. To date, the investigation suggests that a separated flow architecture is better suited to the program requirements. Separated flow systems have the potential to accommodate an isothermalizing two-phase evaporator while using lower levels of power than would be required for a mixed flow system. In addition, it is argued that separated flow systems are more robust and amenable to analysis than mixed flow systems, since they significantly reduce the occurrence of two-phase flow by separating phases in the evaporator. Future work will include developing a full-scale testbed that includes multiple evaporators and condensers in a representative flight configuration.

Furst, Benjamin↗

DOE OSTI2024

Dynamic cycling enhances battery lifetime

Laboratory aging campaigns benchmark and elucidate the complex degradation behavior of lithium-ion batteries, and are critical not only for developing new battery chemistries and cell designs but also for engineering reliable battery management systems. Critically, these laboratory experiments aim to quantify and capture realistic aging mechanisms. In this study, we systematically compare dynamic discharge profiles representative of electric vehicle driving to the well-accepted constant-current profiles. Surprisingly, we discovered that dynamic discharge enhances lifetime substantially compared to constant current discharge. Specifically, for the same average current and voltage window, varying the dynamic discharge profile leads to an increase of up to 38 % in equivalent full cycles at end-of-life. Explainable machine learning reveals the importance of low-frequency current pulses as well as time-induced aging under these realistic discharge conditions. Our work quantifies the importance of evaluating new battery chemistries and designs with realistic load profiles, and highlights the opportunities to revisit our understanding of aging mechanisms at the chemistry, materials, and cell levels.

25 ENERGY STORAGE↗

NASA NTRS1994

Development of a Model Following Control Law for Inflight Simulation and Flight Controls Research

The U.S. Army and NASA are currently developing the Rotorcraft Aircrew Systems Concepts Airborne Laboratory (RASCAL) at the Ames Research Center. RASCAL, shown in Figure 1, is a UH-60, which is being modified in a phased development program to have a research fly-by-wire flight control system, and an advanced navigation research platform. An important part of the flight controls and handling qualities research on RASCAL will be an FCS design for the aircraft to achieve high bandwidth control responses and disturbance rejection characteristics. Initially, body states will be used as feedbacks, but research into the use of rotor states will also be considered in later stages to maximize agility and maneuverability. In addition to supporting flight controls research, this FCS design will serve as the inflight simulation control law to support basic handling qualities, guidance, and displays research. Research in high bandwidth controls laws is motivated by the desire to improve the handling qualities in aggressive maneuvering and in severely degraded weather conditions. Naturally, these advantages will also improve the quality of the model following, thereby improving the inflight simulation capabilities of the research vehicle. High bandwidth in the control laws provides tighter tracking allowing for higher response bandwidths which can meet handling qualities requirements for aggressive maneuvering. System sensitivity is also reduced preventing variations in the response from the vehicle due to changing flight conditions. In addition, improved gust rejection will result from this reduced sensitivity. The gust rejection coupled with a highly stable system will make more precise maneuvering and pointing possible in severely degraded weather conditions. The difficulty in achieving higher bandwidths from the control laws in the feedback and in the responses arises from the complexity of the models that are needed to produce a satisfactory design. In this case, high quality models that include rotor dynamics in a physically meaningful context must be available. A non-physical accounting of the rotor, such as lumping the effect as a time delay, is not likely to produce the desired results. High order simulation models based on first principals are satisfactory for the initial design phase in order to work out the control law design concept and get an initial set of gains. These models, however, have known deficiencies, which must be resolved in the final control law design. The error in the pitch-roll cross coupling is one notable deficiency that even sophisticated rotorcraft models including complex wake aerodynamics have yet to capture successfully. This error must be accounted for to achieve the desired decoupling. The approach to design the proposed inflight simulation control law is based on using a combination of simulation and identified models. The linear and nonlinear higher order models were used to develop an explicit model following control structure. This structure was developed to accommodate the design of control laws compliant to many of the quantitative requirements in ADS-33C. Furthermore, it also allows for control law research using rotor-state feedback and other design methodologies such as Quantitative Feedback and H-Infinity. Final gain selection will be based on higher order identified models which include rotor degrees of freedom.

Takahashi, Mark↗

NASA NTRS2004

Selection of a Data Acquisition and Controls System Communications and Software Architecture for Johnson Space Center's Space Environment Simulation Laboratory Thermal and Vacuum Test Facilities

Upgrade of data acquisition and controls systems software at Johnson Space Center's Space Environment Simulation Laboratory (SESL) involved the definition, evaluation and selection of a system communication architecture and software components. A brief discussion of the background of the SESL and its data acquisition and controls systems provides a context for discussion of the requirements for each selection. Further framework is provided as upgrades to these systems accomplished in the 1990s and in 2003 are compared to demonstrate the role that technological advances have had in their improvement. Both of the selections were similar in their three phases; 1) definition of requirements, 2) identification of candidate products and their evaluation and testing and 3) selection by comparison of requirement fulfillment. The candidates for the communication architecture selection embraced several different methodologies which are explained and contrasted. Requirements for this selection are presented and the selection process is described. Several candidates for the software component of the data acquisition and controls system are identified, requirements for evaluation and selection are presented, and the evaluation process is described.

Jordan, Eric A.↗