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Energy Systems Integration Facility Stewardship Summary: Fiscal Year 2025

A summary of NLR's stewardship of the nationally unique Energy Systems Integration Facility (ESIF) highlighting performance metrics, capability upgrades, and examples of R&D impact. 2025 brought a national focus on energy and ESIF is meeting the moment. All eyes are on data centers and domestic manufacturing and bringing the benefits of artificial intelligence to power system planning and operations. In step with national priorities, ESIF is building out capabilities that advance secure, reliable, and affordable power. ESIF hosted 190 multidisciplinary research projects, 855 high-performance computer users, and collaborated with 81 partners from industry, academia, research, and federal agencies. These research projects resulted in an AI method for detecting high-impedance faults with 90% accuracy, a grid controls demonstration in Connecticut, power quality validation of CorePower's flagship inductor, and a cybersecurity assessment of potential rogue capabilities in digitally connected energy devices. Facility infrastructure improvements enhanced the thermal research network, the SCADA system, the cyber range, power hardware-in-the-loop testing, and more. With support from the U.S Department of Energy (DOE), the ESIF laboratories continue to deliver leading solutions for secure, reliable, and affordable power.

24 POWER TRANSMISSION AND DISTRIBUTION

Resilience Measurement Framework For Post-deployment Artificial Intelligence (ai) Integrated Systems

Resilience is largely defined as the ability to adapt or recover from adverse conditions, stresses, attacks, or compromises on systems that use or are enabled by digital resources. In Artificial Intelligence Management and Research for Advanced Networked Testbed Hub (AMARANTH), resilience is measured in the amount of time it took from the beginning of a testing period for the model to reach predictions outside of the original 95% confidence interval or using the Kullback-Leibler (KL) divergence theorem, the Population Stability Index (PSI), and traditional methods such as root mean squared error (RMSE) threshold. Artificial Intelligence (AI) model drift is of significant concern when deploying AI-integrated systems into critical and/or secure environments. Drift can impact resilience of the AI-integrated system post-deployment and requires consistent maintenance and upkeep to ensure the model is accurate and precise. To quantify model drift and predict the point when a model's drift becomes unacceptable, we describe using Kullback-Leibler (KL) divergence, Population Stability Index (PSI) and/or confidence interval width estimations to determine the point of failure and time to failure of a model post-deployment. Through simple code functions, the KL-divergence, PSI, confidence interval, and root mean squared (RMSE) point of failures can be used to derive when a model needs to be maintained as well as the impact of adversarial action through statistical means.

Yockey, Patience [Idaho National Laboratory (INL),

Advanced Stirling Convertor Dual Convertor Controller Testing at NASA Glenn Research Center in the Radioisotope Power Systems System Integration Laboratory

NASA Glenn Research Center (GRC) developed a non-nuclear representation of a Radioisotope Power System (RPS) consisting of a pair of Advanced Stirling Convertors (ASC), a Dual Convertor Controller (DCC) EM (engineering model) 2 & 3, and associated support equipment, which were tested in the Radioisotope Power Systems System Integration Laboratory (RSIL). The DCC was designed by the Johns Hopkins University/Applied Physics Laboratory (JHU/APL) to actively control a pair of Advanced Stirling Convertors (ASC). The first phase of testing included a Dual Advanced Stirling Convertor Simulator (DASCS) which was developed by JHU/APL and simulates the operation and electrical behavior of a pair of ASC's in real time via a combination of hardware and software. RSIL provides insight into the electrical interactions between a representative radioisotope power generator, its associated control schemes, and realistic electric system loads. The first phase of integration testing included the following spacecraft bus configurations: capacitive, battery, and supercapacitor. A load profile, created based on data from several missions, tested the RPS and RSIL ability to maintain operation during load demands above and below the power provided by the RPS. The integration testing also confirmed the DCC's ability to disconnect from the spacecraft when the bus voltage dipped below 22 V or exceeded 36 V. Once operation was verified with the DASCS, the tests were repeated with actual operating ASC's. The goal of this integration testing was to verify operation of the DCC when connected to a spacecraft and to verify the functionality of the newly designed RSIL. The results of these tests are presented in this paper.

systems integration

Energy Systems Integration Facility Stewardship Summary: Fiscal Year 2024

A summary of NREL's good stewardship of the nationally unique Energy Systems Integration Facility (ESIF) highlighting performance metrics, infrastructure upgrades, and examples of R&D impact. In fiscal year 2024, we developed advanced energy security and resilience capabilities as we built a new test bed for power electronics and completed a 1-megawatt platform for studying energy systems with grid-forming inverters. Researchers collaborated with utilities, manufacturers, and communities to solve their pressing questions, such as a control architecture that heralds a new direction for distributed energy management systems. With support from the U.S Department of Energy (DOE), the work in the ESIF laboratories continues to advance national goals for resilient and affordable energy.

annual report

The circular bioeconomy: a driver for system integration

Background: Human and earth system modeling, traditionally centered on the interplay between the energy system and the atmosphere, are facing a paradigm shift. The Intergovernmental Panel on Climate Change’s mandate for comprehensive, cross-sectoral climate action emphasizes avoiding the vulnerabilities of narrow sectoral approaches. Our study explores the circular bioeconomy, highlighting the intricate interconnections among agriculture, forestry, aquaculture, technological advancements, and ecological recycling. Collectively, these sectors play a pivotal role in supplying essential resources to meet the food, material, and energy needs of a growing global population. We pose the pertinent question of what it takes to integrate these multifaceted sectors into a new era of holistic systems thinking and planning. Results: The foundation for discussion is provided by a novel graphical representation encompassing statistical data on food, materials, energy flows, and circularity. This representation aids in constructing an inventory of technological advancements and climate actions that have the potential to significantly reshape the structure and scale of the economic metabolism in the coming decades. In this context, the three dominant mega-trends—population dynamics, economic developments, and the climate crisis—compel us to address the potential consequences of the identified actions, all of which fall under the four categories of substitution, efficiency, sufficiency, and reliability measures. Substitution and efficiency measures currently dominate systems modeling. Including novel bio-based processes and circularity aspects might require only expanded system boundaries. Conversely, paradigm shifts in systems engineering are expected to center on sufficiency and reliability actions. Effectively assessing the impact of sufficiency measures will necessitate substantial progress in inter- and transdisciplinary collaboration, primarily due to their non-technological nature. In addition, placing emphasis on modeling the reliability and resilience of transformation pathways represents a distinct and emerging frontier that highlights the significance of an integrated network of networks. Conclusions: Existing and emerging circular bioeconomy practices can serve as prime examples of system integration. These practices facilitate the interconnection of complex biomass supply chain networks with other networks encompassing feedstock-independent renewable power, hydrogen, CO 2 , water, and other biotic, abiotic, and intangible resources. Elevating the prominence of these connectors will empower policymakers to steer the amplification of synergies and mitigation of tradeoffs among systems, sectors, and goals.

09 BIOMASS FUELS

Step 1: Human System Integration Simulation and Flight Test Progress Report

The Access 5 Human Systems Integration Work Package produced simulation and flight demonstration planning products for use throughout the program. These included: Test Objectives for Command, Control, Communications; Pilot Questionnaire for Command, Control, Communications; Air Traffic Controller Questionnaire for Command, Control, Communications; Test Objectives for Collision Avoidance; Pilot Questionnaire for Collision Avoidance; Plans for Unmanned Aircraft Systems Control Station Simulations Flight Requirements for the Airspace Operations Demonstration

Source record

Grand challenges in mass storage: A systems integrators perspective

Within today's much ballyhooed supercomputing environment, with its CFLOPS of CPU power, and Gigabit networks, there exists a major roadblock to computing success; that of Mass Storage. The solution to this mass storage problem is considered to be one of the 'Grand Challenges' facing the computer industry today, as well as long into the future. It has become obvious to us, as well as many others in the industry, that there is no clear single solution in sight. The Systems Integrator today is faced with a myriad of quandaries in approaching this challenge. He must first be innovative in approach, second choose hardware solutions that are volumetric efficient; high in signal bandwidth; available from multiple sources; competitively priced, and have forward growth extendibility. In addition he must also comply with a variety of mandated, and often conflicting software standards (GOSIP, POSIX, IEEE, MSRM 4.0, and others), and finally he must deliver a systems solution with the 'most bang for the buck' in terms of cost vs. performance factors. These quandaries challenge the Systems Integrator to 'push the envelope' in terms of his or her ingenuity and innovation on an almost daily basis. This dynamic is explored further, and an attempt to acquaint the audience with rational approaches to this 'Grand Challenge' is made.

Lee, Richard R.

Unifying Human Centered Design and Systems Engineering for Human Systems Integration

Despite the holistic approach of systems engineering (SE), systems still fail, and sometimes spectacularly. Requirements, solutions and the world constantly evolve and are very difficult to keep current. SE requires more flexibility and new approaches to SE have to be developed to include creativity as an integral part and where the functions of people and technology are appropriately allocated within our highly interconnected complex organizations. Instead of disregarding complexity because it is too difficult to handle, we should take advantage of it, discovering behavioral attractors and the emerging properties that it generates. Human-centered design (HCD) provides the creativity factor that SE lacks. It promotes modeling and simulation from the early stages of design and throughout the life cycle of a product. Unifying HCD and SE will shape appropriate human-systems integration (HSI) and produce successful systems.

Boy, Guy A.

System-Integrated Finite Element Analysis of a Full-Scale Helicopter Crash Test with Deployable Energy Absorbers

A full-scale crash test of an MD-500 helicopter was conducted in December 2009 at NASA Langley's Landing and Impact Research facility (LandIR). The MD-500 helicopter was fitted with a composite honeycomb Deployable Energy Absorber (DEA) and tested under vertical and horizontal impact velocities of 26-ft/sec and 40-ft/sec, respectively. The objectives of the test were to evaluate the performance of the DEA concept under realistic crash conditions and to generate test data for validation of a system integrated finite element model. In preparation for the full-scale crash test, a series of sub-scale and MD-500 mass simulator tests was conducted to evaluate the impact performances of various components, including a new crush tube and the DEA blocks. Parameters defined within the system integrated finite element model were determined from these tests. The objective of this paper is to summarize the finite element models developed and analyses performed, beginning with pre-test predictions and continuing through post-test validation.

Annett, Martin S.

A new simulation model building process for use in dynamic systems integration research

A framework to build simulation models for aircraft dynamic systems integration is described. The objective of the framework is increased simulation model fidelity and reduced time required to develop and modify these models. The equations of motion for an elastic aircraft and their impact on the framework are discussed in broad terms. A software tool which automatically generates FORTRAN routines for tabular data lookups, the language used to develop a simulation model, and the structures for passing information into a simulation are discussed. A simulation variable nomenclature is presented. The framework has been applied to build an open-loop F/A-18 simulation model. This example model is used to illustrate model reduction issues. Current deficiencies in the framework are identified as areas for future research.

Arbuckle, P. Douglas

Mach 6 Integrated Systems Tests of Lewis' Hypersonic Tunnel Facility

A series of 15 integrated systems tests were conducted at the NASA Lewis Research Center's Hypersonic Tunnel Facility (HTF) with test conditions simulating flight up to Mach 6. Facility stagnation conditions up to 3050 R and 1050 psia were obtained with typical test times of 20 to 45 sec.

Source record

Shared visions: Partnership of Rockwell International and NASA Cost Effectiveness Enhancements (CEE) for the space shuttle system integration program

As a result of limited resources and tight fiscal constraints over the past several years, the defense and aerospace industries have experienced a downturn in business activity. The impact of fewer contracts being awarded has placed a greater emphasis for effectiveness and efficiency on industry contractors. It is clear that a reallocation of resources is required for America to continue to lead the world in space and technology. The key to technological and economic survival is the transforming of existing programs, such as the Space Shuttle Program, into more cost efficient programs so as to divert the savings to other NASA programs. The partnership between Rockwell International and NASA and their joint improvement efforts that resulted in significant streamlining and cost reduction measures to Rockwell International Space System Division's work on the Space Shuttle System Integration Contract is described. This work was a result of an established Cost Effectiveness Enhancement (CEE) Team formed initially in Fiscal Year 1991, and more recently expanded to a larger scale CEE Initiative in 1992. By working closely with the customer in agreeing to contract content, obtaining management endorsement and commitment, and involving the employees in total quality management (TQM) and continuous improvement 'teams,' the initial annual cost reduction target was exceeded significantly. The CEE Initiative helped reduce the cost of the Shuttle Systems Integration contract while establishing a stronger program based upon customer needs, teamwork, quality enhancements, and cost effectiveness. This was accomplished by systematically analyzing, challenging, and changing the established processes, practices, and systems. This examination, in nature, was work intensive due to the depth and breadth of the activity. The CEE Initiative has provided opportunities to make a difference in the way Rockwell and NASA work together - to update the methods and processes of the organizations. The future success of NASA space programs and Rockwell hinges upon the ability to adopt new, more efficient and effective work processes. Efficiency, proficiency, cost effectiveness, and teamwork are a necessity for economic survival. Continuous improvement initiatives like the CEE are, and will continue to be, vehicles by which the road can be traveled with a vision to the future.

Bejmuk, Bohdan I.

The Build System - Integration and management of large software avionic systems

The Build System comprises the software tools and procedures creating the flight memory load for the Space Shuttle Backup Flight System. The system has six functions: (1) configuration management, which insures that the memory load contains the proper modules, all clearly marked; (2) source translation, which translates the source code into a relocatable machine code; (3) module integration, which combines and assigns memory locations to all the object modules produced in source translation; (4) static code analysis, which verifies the integration process; (5) deliverables generation, which yields release documentation and deliverable items; and (6) release maintenance, which controls all system patches subsequent to release. Further developments will include more automation in the producing of patches from source-code updates and system requirements for tracking.

Mayer, J. T. B.

Intelligent Sensors: Strategies for an Integrated Systems Approach

This paper proposes the development of intelligent sensors as an integrated systems approach, i.e. one treats the sensors as a complete system with its own sensing hardware (the traditional sensor), A/D converters, processing and storage capabilities, software drivers, self-assessment algorithms, communication protocols and evolutionary methodologies that allow them to get better with time. Under a project being undertaken at the Stennis Space Center, an integrated framework is being developed for the intelligent monitoring of smart elements. These smart elements can be sensors, actuators or other devices. The immediate application is the monitoring of the rocket test stands, but the technology should be generally applicable to the Intelligent Systems Health Monitoring (ISHM) vision. This paper outlines progress made in the development of intelligent sensors by describing the work done till date on Physical Intelligent Sensors (PIS) and Virtual Intelligent Sensors (VIS).

Chitikeshi, Sanjeevi

Development and Calibration of a System-Integrated Rotorcraft Finite Element Model for Impact Scenarios

Two full-scale crash tests of an MD-500 helicopter were conducted in 2009 and 2010 at NASA Langley's Landing and Impact Research Facility in support of NASA s Subsonic Rotary Wing Crashworthiness Project. The first crash test was conducted to evaluate the performance of an externally mounted composite deployable energy absorber (DEA) under combined impact conditions. In the second crash test, the energy absorber was removed to establish baseline loads that are regarded as severe but survivable. The presence of this energy absorbing device reduced the peak impact acceleration levels by a factor of three. Accelerations and kinematic data collected from the crash tests were compared to a system-integrated finite element model of the test article developed in parallel with the test program. In preparation for the full-scale crash test, a series of sub-scale and MD-500 mass simulator tests were conducted to evaluate the impact performances of various components and subsystems, including new crush tubes and the DEA blocks. Parameters defined for the system-integrated finite element model were determined from these tests. Results from 19 accelerometers placed throughout the airframe were compared to finite element model responses. The model developed for the purposes of predicting acceleration responses from the first crash test was inadequate when evaluating more severe conditions seen in the second crash test. A newly developed model calibration approach that includes uncertainty estimation, parameter sensitivity, impact shape orthogonality, and numerical optimization was used to calibrate model results for the full-scale crash test without the DEA. This combination of heuristic and quantitative methods identified modeling deficiencies, evaluated parameter importance, and proposed required model changes. The multidimensional calibration techniques presented here are particularly effective in identifying model adequacy. Acceleration results for the calibrated model were compared to test results and the original model results. There was a noticeable improvement in the pilot and copilot region, a slight improvement in the occupant model response, and an over-stiffening effect in the passenger region. One lesson learned was that this approach should be adopted early on, in combination with the building-block approaches that are customarily used, for model development and pretest predictions. Complete crash simulations with validated finite element models can be used to satisfy crash certification requirements, potentially reducing overall development costs.

Annett, Martin S.

Electric flight systems integration

Materials illustrating a presentation on the integration of components and subsystems of electric flight systems are presented. The technology issues are outlined, and near and far term implications of issues affecting the systems integration are outlined.

Hood, R. V.

Sensor Selection and Data Validation for Reliable Integrated System Health Management

For new access to space systems with challenging mission requirements, effective implementation of integrated system health management (ISHM) must be available early in the program to support the design of systems that are safe, reliable, highly autonomous. Early ISHM availability is also needed to promote design for affordable operations; increased knowledge of functional health provided by ISHM supports construction of more efficient operations infrastructure. Lack of early ISHM inclusion in the system design process could result in retrofitting health management systems to augment and expand operational and safety requirements; thereby increasing program cost and risk due to increased instrumentation and computational complexity. Having the right sensors generating the required data to perform condition assessment, such as fault detection and isolation, with a high degree of confidence is critical to reliable operation of ISHM. Also, the data being generated by the sensors needs to be qualified to ensure that the assessments made by the ISHM is not based on faulty data. NASA Glenn Research Center has been developing technologies for sensor selection and data validation as part of the FDDR (Fault Detection, Diagnosis, and Response) element of the Upper Stage project of the Ares 1 launch vehicle development. This presentation will provide an overview of the GRC approach to sensor selection and data quality validation and will present recent results from applications that are representative of the complexity of propulsion systems for access to space vehicles. A brief overview of the sensor selection and data quality validation approaches is provided below. The NASA GRC developed Systematic Sensor Selection Strategy (S4) is a model-based procedure for systematically and quantitatively selecting an optimal sensor suite to provide overall health assessment of a host system. S4 can be logically partitioned into three major subdivisions: the knowledge base, the down-select iteration, and the final selection analysis. The knowledge base required for productive use of S4 consists of system design information and heritage experience together with a focus on components with health implications. The sensor suite down-selection is an iterative process for identifying a group of sensors that provide good fault detection and isolation for targeted fault scenarios. In the final selection analysis, a statistical evaluation algorithm provides the final robustness test for each down-selected sensor suite. NASA GRC has developed an approach to sensor data qualification that applies empirical relationships, threshold detection techniques, and Bayesian belief theory to a network of sensors related by physics (i.e., analytical redundancy) in order to identify the failure of a given sensor within the network. This data quality validation approach extends the state-of-the-art, from red-lines and reasonableness checks that flag a sensor after it fails, to include analytical redundancy-based methods that can identify a sensor in the process of failing. The focus of this effort is on understanding the proper application of analytical redundancy-based data qualification methods for onboard use in monitoring Upper Stage sensors.

Garg, Sanjay