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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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Assessment and comparison of 100-MW coal gasification phosphoric acid fuel cell power plants

One of the advantages of fuel cell (FC) power plants is fuel versatility. With changes only in the fuel processor, the power plant will be able to accept a variety of fuels. This study was performed to design process diagrams, evaluate performance, and to estimate cost of 100 MW coal gasifier (CG)/phosphoric acid fuel cell (PAFC) power plant systems utilizing coal, which is the largest single potential source of alternate hydrocarbon liquids and gases in the United States, as the fuel. Results of this study will identify the most promising integrated CG/PAFC design and its near-optimal operating conditions. The comparison is based on the performance and cost of electricity which is calculated under consistent financial assumptions.

Lu, Cheng-Yi↗

Method and system for detecting a failure or performance degradation in a dynamic system such as a flight vehicle

A method and system for detecting a failure or performance degradation in a dynamic system having sensors for measuring state variables and providing corresponding output signals in response to one or more system input signals are provided. The method includes calculating estimated gains of a filter and selecting an appropriate linear model for processing the output signals based on the input signals. The step of calculating utilizes one or more models of the dynamic system to obtain estimated signals. The method further includes calculating output error residuals based on the output signals and the estimated signals. The method also includes detecting one or more hypothesized failures or performance degradations of a component or subsystem of the dynamic system based on the error residuals. The step of calculating the estimated values is performed optimally with respect to one or more of: noise, uncertainty of parameters of the models and un-modeled dynamics of the dynamic system which may be a flight vehicle or financial market or modeled financial system.

Miller, Robert H.↗

Flat H Frangible Joint Evolution

Space vehicle staging and separation events require pyrotechnic devices. They are single-use mechanisms that cannot be tested, nor can failure-tolerant performance be demonstrated in actual flight articles prior to flight use. This necessitates the implementation of a robust design and test approach coupled with a fully redundant, failure-tolerant explosive mechanism to ensure that the system functions even in the event of a single failure. Historically, NASA has followed the single failure-tolerant (SFT) design philosophy for all human-rated spacecraft, including the Space Shuttle Program. Following the end of this program, aerospace companies proposed building the next generation human-rated vehicles with off-the-shelf, non-redundant, zero-failure-tolerant (ZFT) separation systems. Currently, spacecraft and launch vehicle providers for both the Orion and Commercial Crew Programs (CCPs) plan to deviate from the heritage safety approach and NASA's SFT human rating requirements. Both programs' partners have base-lined ZFT frangible joints for vehicle staging and fairing separation. These joints are commercially available from pyrotechnic vendors. Non-human-rated missions have flown them numerous times. The joints are relatively easy to integrate structurally within the spacecraft. In addition, the separation event is debris free, and the resultant pyro shock is lower than that of other design solutions. It is, however, a serious deficiency to lack failure tolerance. When used for critical applications on human-rated vehicles, a single failure could potentially lead to loss of crew (LOC) or loss of mission (LOM)). The Engineering and Safety & Mission Assurance directorates within the NASA Johnson Space Center took action to address this safety issue by initiating a project to develop a fully redundant, SFT frangible joint design, known as the Flat H. Critical to the ability to retrofit on launch vehicles being developed, the SFT mechanisms must fit within the same three-dimensional envelope as current designs as well as meet structural loads requirements. There is increased mass associated with the redundant design, and the goal is to minimize the weight impact as much as possible. These requirements presented significant challenges, both technically and financially; these challenges will be explored in this paper. Perhaps greater than the technical issues confronted during this design process, were the financial considerations. These were a significant part of the story of this design and development plan. Insufficient financial and labor resources were formidable barriers to completing this project. Nevertheless, JSC personnel successfully conducted several test series at JSC with very useful results. The many lessons learned drove design improvements, performance efficiency, and increased functional reliability. This paper examines the significant technical and financial challenges that these requirements posed to the project team. It discusses the evolution of the SFT frangible joint design, including optimization, testing, and successful partnering of the Johnson Space Center (JSC) engineering and JSC safety organizations, to enhance the flight safety margin for America's next generation of human-rated space vehicles.

Diegelman, Thomas E.↗

Multi-Disciplinary Design Optimization Using WAVE

The current preliminary design tools lack the product performance, quality and cost prediction fidelity required to design Six Sigma products. They are also frequently incompatible with the tools used in detailed design, leading to a great deal of rework and lost or discarded data in the transition from preliminary to detailed design. Thus, enhanced preliminary design tools are needed in order to produce adequate financial returns to the business. To achieve this goal, GEAE has focused on building the preliminary design system around the same geometric 3D solid model that will be used in detailed design. With this approach, the preliminary designer will no longer convert a flowpath sketch into an engine cross section but rather, automatically create 3D solid geometry for structural integrity, life, weight, cost, complexity, producibility, and maintainability assessments. Likewise, both the preliminary design and the detailed design can benefit from the use of the same preliminary part sizing routines. The design analysis tools will also be integrated with the 3D solid model to eliminate manual transfer of data between programs. GEAE has aggressively pursued the computerized control of engineering knowledge for many years. Through its study and validation of 3D CAD programs and processes, GEAE concluded that total system control was not feasible at that time. Prior CAD tools focused exclusively on detail part geometry and Knowledge Based Engineering systems concentrated on rules input and data output. A system was needed to bridge the gap between the two to capture the total system. With the introduction of WAVE Engineering from UGS, the possibilities of an engineering system control device began to formulate. GEAE decided to investigate the new WAVE functionality to accomplish this task. NASA joined GEAE in funding this validation project through Task Order No. 1. With the validation project complete, the second phase under Task Order No. 2 was established to develop an associative control structure (framework) in the UG WAVE environment enabling multi-disciplinary design of turbine propulsion systems. The capabilities of WAVE were evaluated to assess its use as a rapid optimization and productivity tool. This project also identified future WAVE product enhancements that will make the tool still more beneficial for product development.

Irwin, Keith↗

JELC-LITE: Unconventional Instructional Design for Special Operations Training

Current special operations staff training is based on the Joint Event Life Cycle (JELC). It addresses operational level tasks in multi-week, live military exercises which are planned over a 12 to 18 month timeframe. As the military experiences changing global mission sets, shorter training events using distributed technologies will increasingly be needed to augment traditional training. JELC-Lite is a new approach for providing relevant training between large scale exercises. This new streamlined, responsive training model uses distributed and virtualized training technologies to establish simulated scenarios. It keeps proficiency levels closer to optimal levels -- thereby reducing the performance degradation inherent in periodic training. It can be delivered to military as well as under-reached interagency groups to facilitate agile, repetitive training events. JELC-Lite is described by four phases paralleling the JELC, differing mostly in scope and scale. It has been successfully used with a Theater Special Operations Command and fits well within the current environment of reduced personnel and financial resources.

Friedman, Mark↗

Rapid, Comprehensive, Mission Architecting at the Jet Propolusion Laboratory

One of the first multi-disciplinary optimization challenges a mission concept faces is finding an initial system level architecture that simultaneously satisfies the constraints of cost, the requirements of science, and the capabilities of engineering. Compounding this challenge, especially in the early formulation of an architecture, is communicating amongst all key stakeholders, in this multidimensional space of constraints and requirements, where the current architecture is not yet adequately defined, or if it is defined, where it is broken. Recently, a factor of two improvement in the speed of development of the engineering architecture, while also comprehensively considering scientific performance and cost, has been achieved through a single screen visualization dashboard (“S-Chart”), a cost allocation tool, segment level analogy databases and parametric relationships for segment technical capabilities and their technical (Size, Weight, Power, and Data) and financial (Cost) capabilities and/or accommodation requirements.

Nash, Alfred E.↗

Industry Consolidation and Future Airline Network Structures in Europe

In the current downturn in demand for air travel, major airlines are revising and rationalizing their networks in an attempt to improve financial performance and strengthen their defences against both new entrants and traditional rivals. Expansion of commercial agreements or alliances with other airlines has become a key reaction to the increasingly competitive marketplace. In the absence, for regulatory reasons, of cross-border mergers these are the principal means by which the industry can consolidate internationally. This paper analyzes the developments which have been taking place and attempts to itentify the implications for airline network structures and the function of different hub airports. The range of services available to passengers in long-haul markets to/from Europe is evaluated before and after recent industry reorganization. Hubs are crucial to interlink the route networks of parmers in an alliance. However, duplication between nearby hub airports that find themselves within the same airline alliance can lead to loss of service at the weaker locations. The extent to which the alliance hubs in Europe duplicate or complement each other in terms of network coverage is assessed and this methodology also enables the optimal partnerships for "unattached" airlines to be identified. The future role of the various European hubs is considered under different scenarios of global alliance development. The paper concludes by considering possible longer-term developments. In an environment where the low-cost carriers will provide a major element of customer choice, it is suggested that the traditional airlines will retrench around their hubs, surrendering many secondary cities to the low-cost sector. Further reduction in the number of alliances could threaten more of the European hubs. For both regulatory and commercial reasons, the end result may be just one airline alliance - so recreating in the deregulated market the historic rule of IATA.

Dennis, Nigel↗

Alternative, Green Processes for the Precision Cleaning of Aerospace Hardware

Precision cleaning is necessary to ensure the proper functioning of aerospace hardware, particularly those systems that come in contact with liquid oxygen or hypergolic fuels. Components that have not been cleaned to the appropriate levels may experience problems ranging from impaired performance to catastrophic failure. Traditionally, this has been achieved using various halogenated solvents. However, as information on the toxicological and/or environmental impacts of each came to light, they were subsequently regulated out of use. The solvent currently used in Kennedy Space Center (KSC) precision cleaning operations is Vertrel MCA. Environmental sampling at KSC indicates that continued use of this or similar solvents may lead to high remediation costs that must be borne by the Program for years to come. In response to this problem, the Green Solvents Project seeks to develop state-of-the-art, green technologies designed to meet KSCs precision cleaning needs.Initially, 23 solvents were identified as potential replacements for the current Vertrel MCA-based process. Highly halogenated solvents were deliberately omitted since historical precedents indicate that as the long-term consequences of these solvents become known, they will eventually be regulated out of practical use, often with significant financial burdens for the user. Three solvent-less cleaning processes (plasma, supercritical carbon dioxide, and carbon dioxide snow) were also chosen since they produce essentially no waste stream. Next, experimental and analytical procedures were developed to compare the relative effectiveness of these solvents and technologies to the current KSC standard of Vertrel MCA. Individually numbered Swagelok fittings were used to represent the hardware in the cleaning process. First, the fittings were cleaned using Vertrel MCA in order to determine their true cleaned mass. Next, the fittings were dipped into stock solutions of five commonly encountered contaminants and were weighed again showing typical contaminant deposition levels of approximately 0.00300g per part. They were then cleaned by the solvent or process being tested and then weighed a third time which allowed for the calculation of the cleaning efficiency of the test solvent or process.Based on preliminary experiments, five solvents (ethanol, isopropanol, acetone, ethyl acetate, and tert-butyl acetate) were down selected for further testing. When coupled with ultrasonic agitation, these solvents removed hydrocarbon contaminants as well as Vertrel MCA and showed improved removal of perfluorinated greases. Supercritical carbon dioxide did an excellent job dissolving each of the five contaminants but did a poor job of removing Teflon particles found in the perfluorinated greases. Plasma cleaning efficiency was found to be dependent on which supply gas was used, exposure time, and gas pressure. Under optimized conditions it was found that breathing air, energized to the plasma phase, was able to remove nearly 100% of the contamination.These findings indicate that alternative cleaning methods are indeed able to achieve precision levels of cleanliness. Currently, our team is working with a commercial cleaning company to get independent verification of our results. We are also evaluating the technical and financial aspects of scaling these processes to a size capable of supporting the future cleaning needs of KSC.

Vertrel MCA↗

Investigating Low-Altitude Constellations of Ad-Hoc Lunar PNT System for Distributed Spacecraft Autonomy

In this study, we examine a low-altitude Lunar Position, Navigation, and Timing (LPNT) constellations and the localization performance of Centralized Extended Kalman Filter (CEKF) and Decentralized Extended Kalman Filter (DEKF) algorithms. The primary investigation involves a 100-node swarm operating at a 100 km altitude, in contrast to previous studies that examined a 21-node asset in a frozen-orbit at 5,500 km. The autonomous operation of large-scale swarm is based on two-way Inter-Satellite Link (ISL) measurements, which involve pseudoranges and relative velocities among swarm nodes. We perform a numerical assessment of the two filtering approaches, utilizing ‘fully sampled’ measurements from all available assets as well as ‘two ISL’ measurements where each spacecraft is restricted to only two antennas. This research includes an analysis of CEKF under 2-ISL constraints and evaluates the performance of DEKF in a 100-node swarm, which has not been explored in previous studies. In addition, we examine the impact of increasing the sampling frequency for DEKF, showing that the update cycle can be shortened from a 10-minute interval. A novel approach for ‘2-ISL limited’ DEKF will also be introduced, using a matching formulation that exhaustively enumerates all potential matches. This study provides valuable insights into large-scale distributed swarm operations, considering various filter configurations, sampling frequencies, matching strategies, and scalability of CEKF and DEKF for low-altitude LPNT applications. The Lunar PNT technology plays a key role in providing reliable and robust navigation services on the Moon's surface and the South pole, where the primary Lunar missions are planned. To support upcoming Lunar missions, including small satellites from NASA's Commercial Lunar Payload Services program, the Lunar PNT system must be adaptable to smaller platforms like CubeSats. Driven by the growing involvement of public and private exploration partnerships, the traditional low Earth orbit missions are shifting to beyond geosynchronous orbit [1]. These upcoming missions aim to foster a sustainable and innovative exploration program, in collaboration with commercial and international partners, to facilitate human expansion throughout the solar system and return new knowledge and opportunities to Earth [2]. As part of this trend, there are increasing efforts to utilize science missions in Lunar orbit to develop a non-dedicated and ad-hoc PNT network system. Two traditional approaches, the Deep Space Network (DSN) and the weak signal Global Positioning System (GPS), are established deep-space navigation technologies for missions beyond the geosynchronous orbit. Beginning in 1958, the DSN was developed to communicate with the Explorer 1 spacecraft based on the use of radiometric tracking in spacecraft navigation [3]. The DSN is capable of providing nearly unfettered coverage to spacecraft beyond low-Earth orbit (LEO), however, increased space mission volume has created concerns about future expectations of DSN usage for spacecraft navigation [4]. For cislunar mission applications, the position accuracy using DSN achieves 100 m (3σ) with at least three geometrically diverse ground stations when using radiometric tracking alone [5]. The DSN's dependence on Earth-based ground stations restricts its operational capabilities to periods of Earth visibility. This limitation, coupled with its poor localization performance, renders the DSN unsuitable for future lunar missions that demand continuous tracking and precise positioning. To satisfy the increasing requirements of DSN in Lunar applications, spacecrafts are also required to improve their onboard antenna power and efficiency of the transmission. However, there is an important aggregate cost trade between adding capabilities to every spacecraft and adding to a capacity on the ground that serves multiple spacecraft [6]. A weak GPS system can provide PNT service while the user spacecraft is bound to the Moon, leveraging a single, steerable high gain antenna with the relatively narrow beam which includes all the sources in its field of view [7]. However, the higher the altitude the receiver is above the GPS constellations, the poorer and the weaker are the relative geometry and the received signal powers, respectively, leading to a significant navigation accuracy reduction [8]. The transmitted power becomes weaker with increasing distance from the Earth as well as signals tracked from one of the side lobes of the GPS antenna pattern. As a results, the number of visible satellites and relative geometric condition of the GPS satellites at very high altitude drops dramatically and reduces the navigation solution accuracy. Therefore, the weak GPS system is also not an ideal way to provide PNT service to upcoming Lunar missions when considering its limited geometric condition and the recued navigation accuracy. Another navigation approach on the Moon is being developed, similar to the Global Navigation Satellite System (GNSS) on Earth, aiming to offer navigation service with continuous 24/7 coverage across the entire Lunar surface. For example, lunar communications relay and navigation systems (LCRNS) by NASA and Lunar navigation satellite systems (LNSS) by JAXA are designed to serve as dedicated Position, Navigation, and Timing (PNT) systems for the Moon. However, designing a dedicated LNSS and PNT service involves additional challenges, which are unique to the lunar environment, including limited payload capacity for the CubeSat platform, i.e., the size, weight, and power (SWaP) of the onboard clock, limited lunar ground monitoring stations, and limited financial investment as compared to the legacy Earth-GPS [9]. NASA’s focus on utilizing CubeSat platforms on the Moon leads to an alternative Lunar navigation platform that leverages the existing Lunar science and exploration assets. The small satellites used in Lunar missions can be used to create a low-cost, autonomous, ad-hoc, and on-demand mission-centric Lunar PNT swarm capable of providing PNT services to these low-cost lunar missions [10]. As upcoming Lunar missions will often operate at low-altitude about 30 km to 100 km for scientific observations and mapping purposes, the low-altitude orbital constellations could be employed to create an ad-hoc Lunar PNT system. However, several issues must be addressed, such as the instability of these orbits, which often require maintenance or are only suitable for short-duration missions, operating for fewer than 90 days. Additionally, at an altitude of 100 km, the satellites have a limited period during which they are above the horizon and capable of providing PNT service to users. The implementation of a non-dedicated, ad-hoc Lunar navigation constellation facilitates on-demand PNT services. A preliminary study of ad-hoc Lunar PNT system was conducted using 21 spacecraft in 5,5000 km altitude frozen orbits to test its feasibility and a basic performance of orbital asset localization among ad-hoc Lunar constellations in small satellites format [10]. These swarm assets are designed for autonomous localization with minimal Earth interaction, reducing dependency on bandwidth and ground resources. The design in [10] demonstrated the feasibility of a decentralized PNT approach, specifically employing a DEKF approach for state estimation, which helps minimize onboard operating costs. The DEKF method distributes computation across individual satellites, which lightens the computational load while maintaining accuracy in orbit ephemeris and clock offsets, similar to centralized systems [11]. In a follow-on study [12], each spacecraft was limited to 2 communications antennae, forcing the selection of measurements and scheduling spacecraft activities to perform the measurements. A matching algorithm is implemented to select the best measurements and schedule position estimation updates. The decentralized localization performance is also investigated with increasing levels of network degradation for swarm assets considering the impact of intermittent and permanent communication failure, to demonstrate the robustness and fidelity of the decentralized Lunar PNT service [13]. This study confirmed that the ad-hoc PNT constellations in frozen orbit are highly robust and resilient to communication failures. However, unlike frozen orbit swarm assets, the low-altitude satellites have a limited ground view at an altitude of 100 km, where the ad-hoc Lunar constellation consists of 98 low-altitude satellites, evenly distributed across seven circular polar orbital planes, alongside two satellites in a frozen orbit at an altitude of 5,500 km (Figure 1). Therefore, the number of satellites visible to ground users is significantly limited in low-altitude orbit constellations. As each visibility of a spacecraft remains intact for only a few ticks before it moves out of the field of view, the ground user encounters challenges in maintaining continuous navigation service, resulting in sparse availability and provision of Lunar PNT system. Consequently, service availability is primarily restricted to the Lunar South Pole region (Figure 2). Given these limitations and concerns, the localization performance of low-altitude swarm assets will be assessed in this study. We focus on the investigation of the localization performance of low-altitude swarm assets and ground users near the Lunar South Pole. The overall flow of the Lunar PNT simulation incorporates the DEKF approach of asset localization and the weighted least-squares approach in user localization (Figure 3). The autonomous Lunar PNT simulation is primarily implemented in MATLAB, where the DEKF based on the matching scheduler is implemented with Google’s OR-tools as a model builder and Gurobi optimization tool as a backend solver. The General Mission Analysis Tool (GMAT) is utilized to generate ephemeris data for swarm assets, and accounts for satellite orbital details, mass, and perturbations like solar radiation pressure and drag coefficients. Each ephemeris dataset is produced in the Moon International Celestial Reference Frame (ICRF) inertial coordinate system. For state estimation, the distributed swarm assets rely on two-way Inter-Satellite Link (ISL) measurements, which involve tracking pseudoranges and relative velocities between visible satellites and anchor nodes during each observation. Numerical evaluations of the decentralized localization process are conducted to demonstrate the feasibility of the low-altitude PNT system in providing reliable navigation services. The main approach involves using DEKF and CEKF to localize 100 satellites in low-altitude constellations, where the CEKF is implemented to serve as a baseline for comparing the performance of distributed algorithms. In both cases, we evaluate ‘fully sampled’ measurements from all available assets, and ‘two ISL’ measurements when spacecraft are constrained to have only two antennas. We test four estimation techniques: CEKF fully sampled, CEKF two ISL, DEKF fully sampled, and DEKF two ISL filters. As the DEKF update cycle is comprised of network setup, communication, and computations, a global broadcast network and 2-way ISL network setup will take from 4 to 6 minutes as maximum [12]. In this simulation, the DEKF update cycle is set to 10 minutes, including a 4-minute latency for obtaining and computing the actual measurement updates. We experiment an increased update cycle to demonstrate the feasibility and evaluate the impact on localization performance using various tuning values for measurement noise covariances (Figures 4 and 5). By comparing centralized and decentralized approaches using a matching algorithm, we analyze the influence of cross-correlation factors in the covariance matrix, assuming 100% reliability of all assets and measurements. The increased frequency and the adjustments of tuning parameters reveal distinct error patterns between the two scenarios. The localization accuracy of the swarm assets and ground users is assessed by taking the median error across 100 assets and one ground user (84.9°S, 137.5°E) over 7-day simulation period (Table 1). Since the user localization accuracy is significantly affected by the performance of the swarm assets, it is crucial to maintain high localization accuracy within the swarm. This study will continue to explore decentralized filtering for autonomous LPNT operations, with further investigation of an 'iterative' matching approach which enumerates every valid matching pair, planned for the following month.

Yeji Kim↗