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Measurement and Controls Data Acquisition System

Measurement and Controls Data Acquisition System (MCDAS) is an application program that integrates the functions of two stand-alone programs: one for acquisition of data, the other for controls. MCDAS facilitates and improves testing of complex engineering systems by helping to perform calibration and setup of test systems and acquisition, dissemination, and processing of data. Features of MCDAS include an intuitive, user-friendly graphical user interface, a capability for acquiring data at rates greater than previously possible, cooperation between the data-acquisition software subsystem and alarm-checking and analytical components of the control software subsystem, and a capability for dissemination of data through fiber optics and virtual and wide-area networks, including networks that contain hand-held display units. The integration of the data acquisition and control software offers a safety advantage by making alarm information available to the control software in a more timely manner. By enabling the use of hand-held devices, MCDAS reduces the time spent by technicians asking for screen updates to determine effects of setup actions. Previously recorded data can be processed without interruption to current acquisition of data. Analysts can continue to view test parameters while test-data files are being generated.

Hall, Rick↗

Characterization of the Vectron PX-570 Crystal Oscillator for Use in Harsh Environments

Computing hardware, data-acquisition systems, communications systems, and many electronic control systems require well-controlled timing signals for proper and accurate operation. These signals are, in most cases, provided by circuits that employ crystal oscillators due to availability, cost, ease of operation, and accuracy. In some cases, the electronic systems are expected to survive and operate under harsh conditions that include exposure to extreme temperatures. These applications exist in terrestrial systems as well as in aerospace products. Well-logging, geothermal systems, and industrial process control are examples of ground-based applications, while distributed jet engine control in aircraft, space-based observatories (such as the James Webb Space Telescope), satellites, and lunar and planetary landers are typical environments where electronics are exposed to harsh operating conditions. To ensure these devices produce reliable results, the digital heartbeat from the oscillator must deliver a stable signal that is not affected by external temperature or other conditions. One such solution is a recently introduced commercial-off-the-shelf (COTS) oscillator, the PX-570 series from Vectron International. The oscillator was designed for high-temperature applications and as proof, the crystal oscillator was subjected to a wide suite of tests to determine its ruggedness for operation in harsh environments. The tests performed by Vectron included electrical characterization under wide range of temperature, accelerated life test/aging, shock and vibration, internal moisture analysis, ESD threshold, and latch-up testing. The parametric evaluation was performed on the oscillator's frequency, output signal rise and fall times, duty cycle, and supply current over the temperature range of -125 C to +230 C. The evaluations also determined the effects of thermal cycling and the oscillator's re-start capability at extreme hot and cold temperatures. These thermal cycling and restart tests were performed at the NASA Glenn Research Center. Overall, the crystal oscillator performed well and demonstrated very good frequency stability. This paper will discuss the test procedures and present details of the performance results.

Li, Jacob↗

Plant Water Profiler: A Tool for Understanding Water Use, Cost and Savings Potential for Manufacturing Plants

In the 1746 Poor Richard’s Almanack, Benjamin Franklin published “When the well’s dry, we know the worth of water” (Franklin, 1746); industrial water users have begun to see the truth in these words as they examine the potential and reality of water scarcity becoming a significant business risk. Through the authors’ interactions with manufacturers via the U.S. Department of Energy’s Better Plants program and Strategic Analysis projects, they realized that manufacturing facilities often do not fully understand the risks to the water supply and the consequential risks to their business. The authors’ also noticed that many facilities do not know how their water is used (baselining), how they compare with their peers (benchmarking), the actual cost impacts of water use (true cost of water), and potential areas for water savings. This results in a lack of motivation and ability to identify and implement effective water-efficiency measures.The Plant Water Profiler Tool (PWP) was created to help manufacturing plant management address these issues by identifying and accounting for water use in manufacturing operations, helping determine the true cost of water, and providing some high-level estimates for peer comparison. The PWP uses a water mass balance and common engineering equations to estimate water use by each of the facility’s systems (e.g., differentiating process water use from cooling and restroom water use), even when no submetering data is available. This new tool also helps users identify possible areas for water savings and associated water and energy cost savings, making it a potentially useful resource for corporations conducting water assessments. Additionally, governments and private organizations can use the methodology behind this tool to design a survey to help build a database of industrial water use. This paper and corresponding presentation provide an overview of current industrial water use practices and tools, as well as the value of determining the true cost of water. It also briefly describes the methodology behind the tool, then focuses on its functionality through an industrial case study and lessons learned from implementing the case study.

Armstrong, Kristina O.↗

Efficient utilization of graphics technology for space animation

Efficient utilization of computer graphics technology has become a major investment in the work of aerospace engineers and mission designers. These new tools are having a significant impact in the development and analysis of complex tasks and procedures which must be prepared prior to actual space flight. Design and implementation of useful methods in applying these tools has evolved into a complex interaction of hardware, software, network, video and various user interfaces. Because few people can understand every aspect of this broad mix of technology, many specialists are required to build, train, maintain and adapt these tools to changing user needs. Researchers have set out to create systems where an engineering designer can easily work to achieve goals with a minimum of technological distraction. This was accomplished with high-performance flight simulation visual systems and supercomputer computational horsepower. Control throughout the creative process is judiciously applied while maintaining generality and ease of use to accommodate a wide variety of engineering needs.

Panos, Gregory Peter↗

A Framework for Performing V&V within Reuse-Based Software Engineering

Verification and validation (V&V) is performed during application development for many systems, especially safety-critical and mission-critical systems. The V&V process is intended to discover errors, especially errors related to critical processing, as early as possible during the development process. Early discovery is important in order to minimize the cost and other impacts of correcting these errors. In order to provide early detection of errors, V&V is conducted in parallel with system development, often beginning with the concept phase. In reuse-based software engineering, however, decisions on the requirements, design and even implementation of domain assets can be made prior to beginning development of a specific system. In this case, V&V must be performed during domain engineering in order to have an impact on system development. This paper describes a framework for performing V&V within architecture-centric, reuse-based software engineering. This framework includes the activities of traditional application-level V&V, and extends these activities into domain engineering and into the transition between domain engineering and application engineering. The framework includes descriptions of the types of activities to be performed during each of the life-cycle phases, and provides motivation for the activities.

Addy, Edward A.↗

The crustal dynamics intelligent user interface anthology

The National Space Science Data Center (NSSDC) has initiated an Intelligent Data Management (IDM) research effort which has, as one of its components, the development of an Intelligent User Interface (IUI). The intent of the IUI is to develop a friendly and intelligent user interface service based on expert systems and natural language processing technologies. The purpose of such a service is to support the large number of potential scientific and engineering users that have need of space and land-related research and technical data, but have little or no experience in query languages or understanding of the information content or architecture of the databases of interest. This document presents the design concepts, development approach and evaluation of the performance of a prototype IUI system for the Crustal Dynamics Project Database, which was developed using a microcomputer-based expert system tool (M. 1), the natural language query processor THEMIS, and the graphics software system GSS. The IUI design is based on a multiple view representation of a database from both the user and database perspective, with intelligent processes to translate between the views.

Short, Nicholas M., Jr.↗

Anatomy of a Security Operations Center

Many agencies and corporations are either contemplating or in the process of building a cyber Security Operations Center (SOC). Those Agencies that have established SOCs are most likely working on major revisions or enhancements to existing capabilities. As principle developers of the NASA SOC; this Presenters' goals are to provide the GFIRST community with examples of some of the key building blocks of an Agency scale cyber Security Operations Center. This presentation viII include the inputs and outputs, the facilities or shell, as well as the internal components and the processes necessary to maintain the SOC's subsistence - in other words, the anatomy of a SOC. Details to be presented include the SOC architecture and its key components: Tier 1 Call Center, data entry, and incident triage; Tier 2 monitoring, incident handling and tracking; Tier 3 computer forensics, malware analysis, and reverse engineering; Incident Management System; Threat Management System; SOC Portal; Log Aggregation and Security Incident Management (SIM) systems; flow monitoring; IDS; etc. Specific processes and methodologies discussed include Incident States and associated Work Elements; the Incident Management Workflow Process; Cyber Threat Risk Assessment methodology; and Incident Taxonomy. The Evolution of the Cyber Security Operations Center viII be discussed; starting from reactive, to proactive, and finally to proactive. Finally, the resources necessary to establish an Agency scale SOC as well as the lessons learned in the process of standing up a SOC viII be presented.

Wang, John↗

Pterodactyl: Trade Study for an Integrated Control System Design of a Mechanically Deployed Entry Vehicle

This paper presents a trade study method used to evaluate and down-select from a set of guidance and control (G&C) system designs for a mechanically deployable entry vehicle (DEV). The Pterodactyl project, funded by NASA's Space Technology Mission Directorate (STMD), was prompted by the challenge to develop an effective G&C system for a vehicle without a backshell, which is the case for DEVs. For the DEV, the project assumed a specific aeroshell geometry pertaining to an Adaptable, Deployable, Entry Placement Technology (ADEPT) vehicle, which was successfully developed by STMD prior to this study. The Pterodactyl project designed three different G&C systems for the vehicle's precise entry, which this paper briefly discusses. This paper details the Figures of Merit (FOMs) and metrics used during the course of the project's G&C system assessment. Each G&C configuration was traded against the three FOMs categories: G&C system performance, affordability and life cycle costs, and safety and mission success. The relative importance of the FOMs was determined from the Analytical Hierarchy Process (AHP), which was used to develop weights that were combined with quantitative design metrics and engineering judgement to rank the G&C systems against one another. This systematic method takes into consideration the project's input while simultaneously reducing unintentional judgement bias and ultimately was used to select a single G&C design for the project to continue pursuing in the next prototyping and testing phase.

Alunni, Antonella I.↗

Unconventional Catalytic Approaches to Ammonia Synthesis

Ammonia is a critically important industrial chemical and is largely responsible for sustaining the growing global population. To provide ammonia to underdeveloped regions and/or regions far from industrial production hubs, modular systems have been targeted and often involve unconventional production methodologies. These novel approaches for ammonia production can tap renewable resources at smaller scales located at the point of use, while decreasing the CO 2 footprint. Plasma-assisted catalysis and electrochemical ammonia synthesis have promise owing to their atmospheric pressure and low-temperature operation conditions and the ability to construct units at scales desired for modularization. Fundamental and applied studies are underway to assess these processes, although many unknowns remain. In this review, we discuss recent developments and opportunities for unconventional ammonia synthesis with a focus on plasma-stimulated systems.

42 ENGINEERING↗

Process-based balance of system cost modeling for offshore wind power plants in the United States

This paper describes the development of a process-based and open-source balance of system cost model that provides the capability to evaluate both existing and novel offshore wind technologies. Individual design and installation steps are represented with bottom-up engineering models that compute times and costs associated with the process; furthermore, operational constraints are assigned to each process so that delays caused by weather and presence of marine mammals may be accounted for in the overall project timeline. The model structure, assumptions, inputs, and results are vetted with industry partners and compared against actual projects for validation. Installation times show reasonable agreement with real data. Project cost sensitivities are investigated to compute the system-level impact of different design choices. First, individual vessel efficiencies are computed for varying numbers of installation vessels and weather time series to show the diminishing returns of more than two feeder barges. Then, array cable capital costs and installation times are determined for a representative project with different turbine sizes. These values quantify the cost-benefit tradeoffs and show a net-cost savings of decreasing numbers of turbines, increased turbine spacing, and fewer turbine terminations. These results demonstrate that the balance of system model features the accuracy, functionality, and accessibility to serve as the foundation for a wide range of analyses to identify cost reduction potentials for offshore wind energy in the United States.

17 WIND ENERGY↗

Multi-Physics Investigation of a Natural Circulation Molten Salt Micro-Reactor that Utilizes an Experimental In-Pile Device to Improve Core Physics and System Thermal-Hydraulic Performance.

INL employee PhD Dissertation - The Molten Salt Reactor (MSR) concept is a rapidly evolving Generation IV design that has recently attracted favorable attention due to the potential for reducing waste generation, realizing passive safety features, and seizing on the opportunity for cost effective economics. This thesis investigates the performance benefit of a new device invented by the doctoral candidate. The device is referred to as a Wrapped Helix around an Inclined Plane or WHIP. The WHIP is protected under a provisional patent filed with the USA Patent Office on 28 September 2021 under application number 63/261,776, BEA docket number BA-1254. The WHIP device can be located in-core or near-core to promoted enhanced thermal-hydraulics and neutronics performance. While the WHIP can be employed in a variety of solid or liquid fuel designs, this thesis investigates the device’s benefit in the application of a natural-circulation, micro-molten salt nuclear battery concept (MsNB). This thesis will specifically investigate the temperature coefficient of the MsNB fuel (FLiNaK) using novel temperature sensitivity techniques unique to Serpent particle transport code, evaluate the WHIP’s thermal-hydraulic and neutronic performance effects using both established (STAR-CCM+) and novel (Python code developed to estimate the circulation effective delayed neutron fraction, ßef f ) analytical and numerical methods, evaluate the neutron noise behavior of the MsNB and how the WHIP may alter the character of the MsNB’s transfer function, and how the WHIP affects the autonomous, load-following performance under transient power conditions using Python code developed by the candidate. The sum body of this work, in part, has been published in three journal articles as the timing of the provisional patent process has allowed. Results show that creative utilization of WHIP engineering design and function reduces reactor system volume, fuel loading, control/stability in the buoyant regime

buoyant flow↗

Materials and processes for Shuttle engine, external tank, and Solid Rocket Booster

The paper deals with the materials and processes for three Space Shuttle elements: Space Shuttle Main Engines (SSME), the External Tank (ET), and the Solid Rocket Boosters (SRB), beginning with an overview of the materials selection, tracking and control system. SSME materials and processes are considered with emphasis on hydrogen environment embrittlement, LOX/GOX compatibility, stress corrosion cracking, and hydraulic fluid testing and qualification. The ET is examined with attention given to welding and fracture mechanics, and the thermal protection system. The SRB is discussed with emphasis on corrosion prevention, stress corrosion and fracture toughness, the integrated test bed for in situ corrosion protection verification, aluminum processing, and the thermal protection system.

Schwinghamer, R. J.↗

Speed in Information Processing with a Computer Driven Visual Display in a Real-time Digital Simulation

Information transfer between the operator and computer-generated display systems is an area where the human factors engineer discovers little useful design data relating human performance to system effectiveness. This study utilized a computer-driven, cathode-ray-tube graphic display to quantify human response speed in a sequential information processing task. The performance criteria was response time to sixteen cell elements of a square matrix display. A stimulus signal instruction specified selected cell locations by both row and column identification. An equal probable number code, from one to four, was assigned at random to the sixteen cells of the matrix and correspondingly required one of four, matched keyed-response alternatives. The display format corresponded to a sequence of diagnostic system maintenance events, that enable the operator to verify prime system status, engage backup redundancy for failed subsystem components, and exercise alternate decision-making judgements. The experimental task bypassed the skilled decision-making element and computer processing time, in order to determine a lower bound on the basic response speed for given stimulus/response hardware arrangement.

Kyle, R. G.↗

Aerocapture Technologies

Aeroassist technology development is a vital part of the NASA In-Space Propulsion Technology (ISPT) Program. One of the main focus areas of ISPT is aeroassist technologies through the Aerocapture Technology (AT) Activity. Within the ISPT, the current aeroassist technology development focus is aerocapture. Aerocapture relies on the exchange of momentum with an atmosphere to achieve thrust, in this case a decelerating thrust leading to orbit capture. Without aerocapture, a substantial propulsion system would be needed on the spacecraft to perform the same reduction of velocity. This could cause reductions in the science payload delivered to the destination, increases in the size of the launch vehicle (to carry the additional fuel required for planetary capture) or could simply make the mission impossible due to additional propulsion requirements. The AT is advancing each technology needed for the successful implementation of aerocapture in future missions. The technology development focuses on both rigid aeroshell systems as well as the development of inflatable aerocapture systems, advanced aeroshell performance sensors, lightweight structure and higher temperature adhesives. Inflatable systems such as tethered trailing ballutes ('balloon parachutes'), clamped ballutes, and inflatable aeroshells are also under development. Aerocapture-specific computational tools required to support future aerocapture missions are also an integral part of the ATP. Tools include: engineering reference atmosphere models, guidance and navigation, aerothermodynamic modeling, radiation modeling and flight simulation. Systems analysis plays a key role in the AT development process. The NASA in-house aerocapture systems analysis team has been taken with multiple systems definition and concept studies to complement the technology development tasks. The team derives science requirements, develops guidance and navigation algorithms, as well as engineering reference atmosphere models and aeroheating specifications. The study team also creates designs for the overall mission spacecraft. Presentation slides are provided to further describe the aerocapture project.

Keys, Andrew S.↗

A Scenario-Based Process for Requirements Development: Application to Mission Operations Systems

The notion of using operational scenarios as part of requirements development during mission formulation (Phases A & B) is widely accepted as good system engineering practice. In the context of developing a Mission Operations System (MOS), there are numerous practical challenges to translating that notion into the cost-effective development of a useful set of requirements. These challenges can include such issues as a lack of Project-level focus on operations issues, insufficient or improper flowdown of requirements, flowdown of immature or poor-quality requirements from Project level, and MOS resource constraints (personnel expertise and/or dollars). System engineering theory must be translated into a practice that provides enough structure and standards to serve as guidance, but that retains sufficient flexibility to be tailored to the needs and constraints of a particular MOS or Project. We describe a detailed, scenario-based process for requirements development. Identifying a set of attributes for high quality requirements, we show how the portions of the process address many of those attributes. We also find that the basic process steps are robust, and can be effective even in challenging Project environments.

MOS↗

Even Higher-Level Synthesis: An Exploration of AI Hardware Accelerators using HLS4ML

With the rise of artificial intelligence, the popularization of deep learning, and a constantly evolving industry, the demand for flexible and efficient tools has never been greater. As algorithms grow more complex, their runtime and energy consumption increase exponentially. Customized hardware accelerators, long used for specific mathematical operations, remain essential for managing modern applications' computational and power demands. Hardware accelerators can speed up complex computations by orders of magnitude, but their manual design and verification processes are often challenging and time-consuming. High-Level Synthesis (HLS) provides a solution by transforming high-level algorithm descriptions, typically written in C++ or SystemC, into synthesizable RTL suitable for hardware implementation. This approach reduces development time for RTL engineers while offering flexibility beyond what traditional handwritten RTL can provide. We extended this capability to the machine-learning domain with the open-source framework hls4ml, which allows neural networks trained in Python frameworks like Tensorflow or PyTorch to be synthesized into efficient hardware representations for the traditional FPGA and ASIC flows. This breakthrough addresses the growing need for reduced design turnaround and easy verification of ML hardware accelerators with low latency and power efficiency constraints. During this tutorial, we will demonstrate how Python complements HLS by simplifying the ML design process, bridging the gap between software and hardware development. Attendees will explore how we translate neural networks modeled in Python into fixed-point C++ models suitable for HLS workflows. We will dive into strategies like Value-Range Analysis and Quantization-Aware Training, which optimize these designs for deployment and evaluate their accuracy, power consumption, and energy efficiency. To exemplify these concepts, experts from Fermilab will share their experiences applying this technology to high-energy physics experiments, where real-time, low-latency processing is critical. Over the years, Fermilab engineers have demonstrated how deep neural networks, optimized for hardware using hls4ml, can meet the stringent requirements of trigger systems at the CERN Large Hadron Collider. These systems rely on rapid decision-making to process immense data volumes while retaining only the most relevant events for further analysis. The application of hls4ml has also been extended to innovative technologies like smart pixel arrays. These smart pixels integrate ML inference capabilities directly into sensor devices, enabling localized data processing at the pixel level. This approach drastically reduces the need to transmit raw data to external processing units, significantly decreasing power consumption and latency. By embedding neural networks within the pixel architecture, the smart pixels can identify and prioritize relevant data in real time, providing a highly efficient solution for edge computing in scenarios such as particle detectors and imaging systems. Fermilab's work highlights the potential of hardware-accelerated ML in scenarios where both speed and power efficiency are mission-critical. Through this tutorial, attendees will gain valuable insights into the challenges and solutions of deploying ML in hardware. Understanding how HLS and hls4ml streamline the development of neural network-based hardware accelerators is fundamental for the industry's future. Participants will learn how these technologies are shaping the future of AI and scientific computing.

Di Guglielmo, Giuseppe [Fermilab]↗

SSME propulsion performance reconstruction techniques

In view of the complex flight operation of the Space Shuttle propulsion system together with an expected launch rate increase, the flight performance reconstruction process needs to be performed by automated computer programs. These programs must have the capability to quickly and reliably determine the true behavior of the various components of the propulsion system. For the flight reconstruction, measured values from the solid rocket motors, liquid engines, and trajectory are appraised through the Kalman filter technique to identify the most likely flight propulsion performance. A more detailed data collection program for the single SSME engine captive test firing evaluation is scheduled for startup in September of 1988. Engine performance evaluation for the captive test firing requires a reconstruction process that is similar to the process that is used for the flight reconstruction. Analytical tools that may be used to reconstruct a propulsion system's true performance under flight and/or test conditions are described.

Temple, Enoch C.↗