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In this paper, an analysis of the flexible printed circuit board (FPCB) windings is performed. A one-dimensional model of the flex-wire winding is introduced and an equation for the FPCB ac winding resistance is derived. Experimental verification of derived equations is performed, i.e., impedance and power loss measurements.
A dynamic flex test was performed on a spacecraft instrument harness composed of multiple individual flex cables, with each flex cable containing multiple copper traces. The purpose of the test was to demonstrate the capability of the harness to survive the number of expected flex cycles during the planned mission with appropriate margin. However, during testing, increased trace resistances and open circuits were observed beginning at approximately 10% of the total number of planned flex cycles. This paper discusses the various proximate causes that contributed to increased and open resistance in the flex cables and the subsequent redesign, manufacturing, reliability, and quality-related changes that were instituted. An analysis process, including failure analysis, non-destructive evaluation, digital imaging correlation, and parametric modeling, will also be discussed. The paper will cover the development of a robust dynamic flex harness design and include recommendations to extend flex harness life; make changes to the flex harness life test; and improve flex cable manufacturing, quality, and reliability.
A dynamic flex test was performed on a spacecraft instrument harness composed of multiple individual flex cables, with each flex cable containing multiple copper traces. The purpose of the test was to demonstrate the capability of the harness to survive the number of expected flex cycles during the planned mission with appropriate margin. However, during testing, increased trace resistances and open circuits were observed beginning at approximately 10% of the total number of planned flex cycles. This paper discusses the various proximate causes that contributed to increased and open resistance in the flex cables and the subsequent redesign, manufacturing, reliability, and quality-related changes that were instituted. An analysis process, including failure analysis, non-destructive evaluation, digital imaging correlation, and parametric modeling, will also be discussed. The paper will cover the development of a robust dynamic flex harness design and include recommendations to extend flex harness life; make changes to the flex harness life test; and improve flex cable manufacturing, quality, and reliability.
One of the lessons learned from the Fukushima Daiichi nuclear power plant (NPP) accident is strengthening the station blackout (SBO) mitigation capabilities by enhancing defense in depth for all existing and new NPPs. One of the possible remedies is diverse and flexible coping strategies (FLEX). The objective of this study is to address the benefits of FLEX in various accident scenarios in terms of both risk and cost. FLEX was originally devised against SBO accidents. In this research, we investigate the fundamental plant responses against accidents considering two fundamentally different cases: accidents that lead to high pressure on the primary side and accidents that lead to low pressure on the primary side. Several uncertainties are associated with the characteristics of the FLEX portable equipment. Specifically, the time for FLEX deployment may depend on several factors such as type of accident, point of injection, availability of safety systems, battery backup timings, and human actions. This study utilizes a dynamic risk assessment framework to analyze accident scenarios and suggests a novel importance measure, which is a cumulative distribution function– based importance metric that characterizes the influence of input distribution on complete output distribution. The importance of the existing and newly developed FLEX strategy based on risk significance is illustrated with examples. The suggested measure provides clear insight into how FLEX affects risk of the whole system and additional risk margins thanks to new safety systems.
Most current efforts have modified and applied existing human reliability analysis (HRA) methods to treat human actions related to beyond-design-basis external events in which diverse and flexible coping strategies (FLEX) equipment would be deployed. However, many questions remain regarding the suitability of legacy HRA methods to address FLEX human actions, sparking the need for a new method of reasonably evaluating them. In this context, Idaho National Laboratory (INL) researched a relatively new approach to treating FLEX human actions via Event Modeling Risk Assessment Using Linked Diagrams (EMRALD) software. EMRALD was developed to support the increasing need for dynamic probabilistic risk assessment (PRA) models that can respond to evolving plant conditions during simulations. A couple benefits were identified when analyzing FLEX human actions through this software. In general, it is especially useful for evaluating a strategy’s feasibility, including FLEX human actions that require a relatively long time to perform. In this paper, we suggest how FLEX human actions can be modeled using the EMRALD software. Two different HRA modeling approaches using EMRALD are introduced: (1) procedure-based modeling and (2) PRA/HRA-based modeling. The former approach was introduced in the authors’ previous paper, whereas this paper mainly discusses how the latter approach works for an extended loss of AC power (ELAP) scenario with relevant procedures and PRA models. A hybrid method combining the two modeling approaches is introduced at the paper’s conclusion.
Flex-Gears are being developed as an alternative to brushes and slip rings to conduct electricity across a rotating joint. Flex-Gears roll in the annulus of sun and ring gears for electrical contact while maintaining their position by using a novel application of involute gears. A single Flex-Gear is predicted to transfer up to 2.8 amps, thereby allowing a six inch diameter device, holding 30 Flex-Gears, to transfer over 80 amps. Semi-rigid Flex-Gears are proposed to decrease Flex-Gear stress and insure proper gear meshing.
The use of rigid-flex printed circuit board (PCB) as primary structure has the potential to reduce the weight and volume of robotic systems. In the case of robotics for interplanetary exploration, these systems can leverage origami-inspired folding for increased mobility options and reduced storage volume. Folding rigid-flex PCB robotics can be constructed with rigid PCB connected by short Nomex fabric hinges coupled with flex PCB ribbon cables that permits enhanced system flexibility and energy dissipation to promote impact survivability. This paper presents a design methodology of rigid-flex PCB systems with an emphasis on impact resistance. The design process considers solder joint adequacy, panel bending, and fracture using a finite element (FE) model. The proposed design methodology is developed using a case study with NASA JPL's Pop-Up Folding Flat Explorer Robot (PUFFER). First, the finite-element (FE) modeling methodology is presented with consideration to both frequency and time-domain modeling applications, which include operational self-contact analysis and high impact scenarios. The time-domain impact modeling methodology utilizes hyperelastic material properties for the Nomex hinges. This modeling method is validated using image correlation of PUFFER drop tests. A flowchart is presented to guide users through a validated Abaqus modeling procedure for highly flexible rigid-flex systems. Next, a case study is presented in which PUFFER is subject to drop heights representative of falls into Lunar pits and then the design is refined for a more optimum impact performance. Finally, the results of the case study are used to inform a generalized design methodology for rigid-flex PCB robotics subject to high-impact loads with the considerations presented.
The use of rigid-flex printed circuit board (PCB) as primary structure has the potential to reduce the weight and volume of robotic systems. In the case of robotics for interplanetary exploration, these systems can leverage origamiinspired folding for increased mobility options and reduced storage volume. Folding rigid-flex PCB robotics can be constructed with rigid PCB connected by short Nomex fabric hinges coupled with flex PCB ribbon cables that permits enhanced system flexibility and energy dissipation to promote impact survivability. This paper presents a design methodology of rigidflex PCB systems with an emphasis on impact resistance. The design process considers solder joint adequacy, panel bending, and fracture using a finite element (FE) model. The proposed design methodology is developed using a case study with NASA JPL’s Pop-Up Folding Flat Explorer Robot (PUFFER). First, the finite-element (FE) modeling methodology is presented with consideration to both frequency and time-domain modeling applications, which include operational self-contact analysis and high impact scenarios. The time-domain impact modeling methodology utilizes hyperelastic material properties for the Nomex hinges. This modeling method is validated using image correlation of PUFFER drop tests. A flowchart is presented to guide users through a validated Abaqus modeling procedure for highly flexible rigid-flex systems. Next, a case study is presented in which PUFFER is subject to drop heights representative of falls into Lunar pits and then the design is refined for a more optimum impact performance. Finally, the results of the case study are used to inform a generalized design methodology for rigid-flex PCB robotics subject to high-impact loads with the considerations presented.
Here we propose a multicriterion benefit evaluation (MCBE) methodology for evaluating costs and benefits of implementing safety enhancements in nuclear power plants. The MCBE methodology establishes a comprehensive evaluation scope using multiple evaluation criteria (including public risk, occupational risk, plant revenue, and plant cost) and multiple contexts (including plant normal operations, incidents, and accidents). The MCBE methodology formulates a benefit or cost element as the product of a monetary consequence and its occurrence-likelihood change. The MCBE methodology also incorporates a decision maker’ preferences toward occurrence likelihood and monetary consequence into cost and benefit estimations through a modified usage of cumulative prospect theory. This paper applies the MCBE methodology to the implementation of diverse and flexible coping strategy (FLEX) in a generic nuclear power plant as an illustrative example. The FLEX benefits are evaluated through three types of influence paths: plant safety enhancement, risk-informed activities, and potential additional credit of FLEX in supporting plant operation and maintenance-efficiency improvement. The benefit-to-cost ratio (BCR) of FLEX implementation is calculated. Sensitivity analyses are conducted to examine the impacts of modeling assumptions and input parameter values on the BCR.
After the Fukushima Daiichi Accident, the safety features such as accident tolerant fuel (ATF) and diverse and flexible coping strategies (FLEX) for existing nuclear fleets are being investigated by the US Department of Energy under the Light Water Reactor Sustainability Program. This research is being conducted to quantify the risk-benefit of these safety features. Dynamic probabilistic risk assessment (DPRA)-based response-surface approach has been presented to quantify the FLEX and ATF benefits by estimating the risk associated with each option. ATFs with multilayered silicon carbide (SiC), iron-chromium-aluminum, and chromium-coated zirconium cladding were considered in this study. While these ATF candidates perform better than the current zirconium cladding (Zr), they may introduce additional failure modes in some operating conditions. The fuel failure analysis modules (FAMs) were developed to investigate ATF performance. The dynamic risk assessments were performed using RAVEN, a DPRA tool, coupled with RELAP5 and FAMs. A cumulative distribution function-based index provided a mean of comparing the benefits of safety enhancements. For medium break loss of coolant accidents, FLEX operational timing window for each fuel type was estimated. Among these ATF candidates, SiC-type ATF was the most beneficial candidate for an increased safety margin than Zr-based fuel and was found to complement FLEX strategies in terms of risk and coping time.
The FLuorescence EXplorer (FLEX) satellite mission, selected as ESA's 8th Earth Explorer, has been designed forthe measurement of sun-induced fluorescence (F) spectra emitted by plants. This will be accomplished through amulti-sensor approach by placing it in a common orbit in tandem with the Sentinel-3 (S3) mission, which willhave two optical sensors on board, OLCI (Ocean and Land Colour Instrument) and SLSTR (Sea and Land SurfaceTemperature Radiometer) to complement FLEX. These S3 instruments will be used in combination with theimaging spectrometers on board FLEX to provide data useful for atmospheric correction of FLEX data. However,a fully synergetic approach, i.e. by exploiting the spectral and directional information from all tandem missioninstruments together, is an attractive alternative which is explored in this paper. By employing all combined topof-atmosphere (TOA) spectral radiance data, one can (i) characterize the relevant optical properties of the atmosphere,(ii) retrieve biophysical canopy properties including the associated reflectance anisotropy, and (iii)retrieve a more accurate and consistent canopy F.Regarding retrieval methods, Fraunhofer Line Depth (FLD) and Spectral Fitting (SF) are well-known techniquesapplied to hyperspectral data. Both methods depend on a high spectral resolution and assume aLambertian (isotropic) canopy reflectance. However, most vegetation canopies are non-Lambertian. This impliesthat, in particular when ignoring the anisotropic surface reflection, substantial retrieval errors can occur due tothe interaction between atmospheric absorption bands and surface reflectance anisotropy. In this paper, a novelmethod based on spectral radiative transfer (RT) modeling is proposed, in which coupled RT models are used tosimulate TOA radiance spectra. These are then matched with ‘measured' spectra in order to retrieve surfacefluorescence, along with a suite of biophysical parameters, by model inversion through optimization. By applyingcoupled RT models of the soil-leaf-canopy and the surface-atmosphere systems, TOA radiance spectra canbe simulated for all optical sensors of this tandem mission. In this way, complex effects due to surface reflectanceanisotropy and the spectral sampling by the various instruments, which are difficult to compensate for in the endproducts, are properly taken into account by their incorporation in the forward modeling. Next, by model inversionof TOA radiance data via optimization, the most accurate F retrievals can be achieved in a consistentmanner, along with important canopy level biophysical parameters that may help interpret the F spectrum, suchas chlorophyll content and leaf area index (LAI). The potential of this approach has been explored in a numericalexperiment, and the results are presented in this paper. We find that, with the assumed well-characterized andplausible FLEX/S3 instrument performances, the simultaneous retrieval of biophysical canopy parameters and Fspectra would be possible with a remarkable accuracy, provided the correct atmospheric characterization isavailable.
HP-FLEX MPC is control software developed by Lawrence Berkeley National Laboratory with support from the California Energy Commission (CEC) through EPIC-19-301. HP-FLEX aims to provide load flexibility for heat pumps (HPs) in response to dynamic grid signals (including Time-of-Use, Dynamic Pricing, and Critical Peak Pricing) while maintaining thermostat temperatures within user-specified bounds. The software includes a system-identification module, which models the dynamics of the building envelope with thermostat data, and a control module based on a model predictive controller (MPC) to make optimal decisions. HP-FLEX receives forecasts of outdoor air temperature, solar irradiation, and internal gain (if available), as well as trajectories of energy price, temperature lower and upper bounds over a prediction horizon. It then optimizes heating and cooling capacities to minimize energy cost and peak power (with a user-defined weight on peak power) over the prediction horizon, while maintaining room air temperature within the temperature constraints, and outputs the optimal thermostat setpoints.
Model Predictive Control (MPC) has demonstrated significant potential for optimizing building operations and enabling demand flexibility. However, the widespread adoption of MPC is hindered by complex manual configuration and commissioning processes that must be conducted by control experts working alongside building operators. These challenges drive up costs and reduce scalability, particularly when technical human resources and building automation systems are limited, such as in small and medium commercial buildings (SMCBs). This paper demonstrates how semantic standards, specifically ASHRAE 223P, can accelerate the adoption of MPC applications for load flexibility in SMCBs. The authors present a replicable control framework, titled “HP-FLEX” that leverages a building’s semantic model to bootstrap the required data configuration for an MPC controller developed for optimizing heat pump systems as flexible grid resources. The semantic model helps streamline the deployment workflow, particularly for site setup, data/control commissioning, and model setup. This integration enhances portability, transferability, and scalability of the HP-FLEX MPC, which has been developed to support MPC-based supervisory HVAC controllers in SMCBs. Additionally, the paper details the required building and thermostat metadata information to enable the HP-FLEX MPC based on field demonstrations. The new workflow was tested in a small commercial building located in California, U.S., and demonstrated a load shifting performance of 9% based on a dynamic pricing signal that varies by the hour. This work provides a practical pathway for transitioning sophisticated building applications from custom to standardized semantic representations, supporting the broader adoption of advanced control strategies like MPC. The framework also establishes a foundation for evolving metadata requirements as applications mature while maintaining compatibility with industry standards.
The authors examine the problem of how to provide a time code for staff to use in pursuit of innovation. Four potential options are explored ranging from not providing funds for this activity, to charging such efforts against existing or expanded program management and program development funds. One solution that provides funded time without raising laboratory overhead rates is identified and referred to as Innovation Flex Time. This would consist of capturing hours worked in excess of the standard work week but not charged to customers and making those hours available to fund time for exploring new ideas. A brief examination of labor relations laws, and laws regulating laboratory directed research and development suggests that Innovation Flex Time is a viable option for the laboratory. However, implementation of Innovation Flex Time would require NNSA approval and modification of the existing management and operations contract.
Model Predictive Control (MPC) has demonstrated significant potential for optimizing building operations and enabling demand flexibility. However, the widespread adoption of MPC is hindered by complex manual configuration and commissioning processes that must be conducted by control experts working alongside building operators. These challenges drive up costs and reduce scalability, particularly when technical human resources and building automation systems are limited, such as in small and medium commercial buildings (SMCBs). This paper demonstrates how semantic standards, specifically ASHRAE 223P, can accelerate the adoption of MPC applications for load flexibility in SMCBs. The authors present a replicable control framework, titled “HP-FLEX” that leverages a building’s semantic model to bootstrap the required data configuration for an MPC controller developed for optimizing heat pump systems as flexible grid resources. The semantic model helps streamline the deployment workflow, particularly for site setup, data/control commissioning, and model setup. This integration enhances portability, transferability, and scalability of the HP-FLEX MPC, which has been developed to support MPC-based supervisory HVAC controllers in SMCBs. Additionally, the paper details the required building and thermostat metadata information to enable the HP-FLEX MPC based on field demonstrations. The new workflow was tested in a small commercial building located in California, U.S., and demonstrated a load shifting performance of 9% based on a dynamic pricing signal that varies by the hour. This work provides a practical pathway for transitioning sophisticated building applications from custom to standardized semantic representations, supporting the broader adoption of advanced control strategies like MPC. The framework also establishes a foundation for evolving metadata requirements as applications mature while maintaining compatibility with industry standards.
The design and implementation of a real-time programming language called Flex, which is a derivative of C++, are presented. It is shown how different types of timing requirements might be expressed and enforced in Flex, how they might be fulfilled in a flexible way using different program models, and how the programming environment can help in making binding and scheduling decisions. The timing constraint primitives in Flex are easy to use yet powerful enough to define both independent and relative timing constraints. Program models like imprecise computation and performance polymorphism can carry out flexible real-time programs. In addition, programmers can use a performance measurement tool that produces statistically correct timing models to predict the expected execution time of a program and to help make binding decisions. A real-time programming environment is also presented.
This volume, Volume 2, of this Flex Bearing UUEC Final Report documents findings and data pertaining to Team B's tasks. Team B was organized as one of two sub-teams of the Unplanned/Unintended Event or Condition (UUEC) board established per InterOffice Memorandum (IOM) A100-FY93-072. Team A determined the cause of the unacceptable unbonds (referred to as 'heat-affect' unbonds), including the initial, light rust film, in the FSM #3 flex bearing was overheating of the Forward End Ring (FER) during cure, specifically in zone 8 of the mold. Team A's findings are documented in Volume 1 of this report. Team B developed flight rationale for existing bearings, based on absence or presence of an unpropitious unbond condition like that in FSM #3's flex bearing.
A plurality of flexible cylindrical members, termed flex-gears and having gear tooth type perimeters are located in an annular space between two concentric rotating gear members, one an inner gear member and the other an outer ring gear member, both of which have mutually facing toothed surfaces which engage the flex-gears. The flex-gears rotate and orbit around the annular space as planetary gears when the inner and outer gear members rotate with respect to one another. Pairs of these elements located in two mutually parallel planes and separated by insulators provide two electrical conductor paths across which an electrical signal source, AC or DC, can be connected and coupled to an electrical device. Alternatively, one set of elements including outer gears segmented into mutually insulated semicircles and inner gears segmented into mutually insulated quadrants can be used.