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At least 19 records

Robust constrained tension control for high-precision roll-to-roll processes

Tension control is critical for maintaining good product quality in most roll-to-roll (R2R) production systems. Previous work has primarily focused on improving the disturbance rejection performance of tension controllers. Here, a robust linear parameter-varying model predictive control (LPV-MPC) scheme is designed to enhance the tension tracking performance of a pilot R2R system for deposition of materials used in flexible thin film applications. The performance of a tension controller may degrade due to disturbances associated with model uncertainties and the slowly-changing dynamics in R2R systems. We introduce a method that separately treats these two sources of disturbance. The controller utilizes an incremental model to eliminate the errors caused by the mismatch between the nominal model and the actual system. A tube-based MPC formulation combined with scheduled parameters adequately updates models and corrects for the time-varying dynamics. Constraints on the rated motor torque are incorporated in the MPC to maintain the controller reliability and avoid machine failures. We illustrate the operation of our control algorithm through simulation of an actual R2R system. The controller outperforms the benchmarks in terms of fast transient response and offset-free tension tracking. Furthermore, it also demonstrates immunity from variations due to parametric uncertainties.

42 ENGINEERING↗

Particle image velocimetry for the surface tension driven convection experiment using a particle displacement tracking technique

The Surface Tension Driven Convection Experiment (STDCE) is a Space Transportation System flight experiment to study both transient and steady thermocapillary fluid flows aboard the USML-1 Spacelab mission planned for 1992. One of the components of data collected during the experiment is a video record of the flow field. This qualitative data is then quantified using an all electronic, two-dimensional particle image velocimetry technique called particle displacement tracking (PDT) which uses a simple space domain particle tracking algorithm. The PDT system is successful in producing velocity vector fields from the raw video data. Application of the PDT technique to a sample data set yielded 1606 vectors in 30 seconds of processing time. A bottom viewing optical arrangement is used to image the illuminated plane, which causes keystone distortion in the final recorded image. A coordinate transformation was incorporated into the system software to correct this viewing angle distortion. PDT processing produced 1.8 percent false identifications, due to random particle locations. A highly successful routine for removing the false identifications was also incorporated, reducing the number of false identifications to 0.2 percent.

Wernet, Mark P.↗

Particle image velocimetry for the Surface Tension Driven Convection Experiment using a particle displacement tracking technique

The Surface Tension Driven Convection Experiment (STDCE) is a Space Transportation System flight experiment to study both transient and steady thermocapillary fluid flows aboard the USML-1 Spacelab mission planned for 1992. One of the components of data collected during the experiment is a video record of the flow field. This qualitative data is then quantified using an all electronic, two-dimensional particle image velocimetry technique called particle displacement tracking (PDT) which uses a simple space domain particle tracking algorithm. The PDT system is successful in producing velocity vector fields from the raw video data. Application of the PDT technique to a sample data set yielded 1606 vectors in 30 seconds of processing time. A bottom viewing optical arrangement is used to image the illuminated plane, which causes keystone distortion in the final recorded image. A coordinate transformation was incorporated into the system software to correct this viewing angle distortion. PDT processing produced 1.8 percent false identifications, due to random particle locations. A highly successful routine for removing the false identifications was also incorporated, reducing the number of false identifications to 0.2 percent.

Wernet, Mark P.↗

Influence of Turbulence on the Restraint of Liquid Jets by Surface Tension in Microgravity Investigated

Microgravity poses many challenges to the designer of spacecraft tanks. Chief among these are the lack of phase separation and the need to supply vapor-free liquid or liquidfree vapor to the spacecraft processes that require fluid. One of the principal problems of phase separation is the creation of liquid jets. A jet can be created by liquid filling, settling of the fluid to one end of the tank, or even closing a valve to stop the liquid flow. Anyone who has seen a fountain knows that jets occur in normal gravity also. However, in normal gravity, the gravity controls and restricts the jet flow. In microgravity, with gravity largely absent, surface tension forces must contain jets. To model this phenomenon, a numerical method that tracks the fluid motion and the surface tension forces is required. Jacqmin has developed a phase model that converts the discrete surface tension force into a barrier function that peaks at the free surface and decays rapidly away. Previous attempts at this formulation were criticized for smearing the interface. This can be overcome by sharpening the phase function, double gridding the fluid function, and using a higher order solution for the fluid function. The solution of this equation can be rewritten as two coupled Poisson equations that also include the velocity. After the code was implemented in axisymmetric form and verified by several test cases at the NASA Glenn Research Center, the drop tower runs of Aydelott were modeled. Work last year with a laminar model was found to overpredict Aydelott's results, except at the lowest Reynolds number conditions of 400. This year, a simple turbulence model was implemented by adding a turbulent viscosity based on the mixing-length hypothesis and empirical measurements of previous works. Predictions made after this change was implemented have been much closer to experimentally observed flow patterns and geyser heights. Two model runs is shown. The first, without any turbulence correction, breaks through the free surface and strikes the far end of the tank. In the second, the turbulence spreads the jet momentum over more of the free surface, enabling the surface tension forces to turn the jet back into the bulk liquid. The model geyser height with the second model is 1.1 cm. This is quite close to the 1.5-cm geyser height measured by Aydelott.

Chato, David J.↗

Restraint of Liquid Jets by Surface Tension in Microgravity Modeled

Tension in Microgravity Modeled Microgravity poses many challenges to the designer of spacecraft tanks. Chief among these are the lack of phase separation and the need to supply vapor-free liquid or liquidfree vapor to the spacecraft processes that require fluid. One of the principal problems of phase separation is the creation of liquid jets. A jet can be created by liquid filling, settling of the fluid to one end of the tank, or even closing a valve to stop the liquid flow. Anyone who has seen a fountain knows that jets occur in normal gravity also. However, in normal gravity, the gravity controls and restricts the jet flow. In microgravity, with gravity largely absent, jets must be contained by surface tension forces. Recent NASA experiments in microgravity (Tank Pressure Control Experiment, TPCE, and Vented Tank Pressure Experiment, VTRE) resulted in a wealth of data about jet behavior in microgravity. VTRE was surprising in that, although it contained a complex geometry of baffles and vanes, the limit on liquid inflow was the emergence of a liquid jet from the top of the vane structure. Clearly understanding the restraint of liquid jets by surface tension is key to managing fluids in low gravity. To model this phenomenon, we need a numerical method that can track the fluid motion and the surface tension forces. The fluid motion is modeled with the Navier-Stokes equation formulated for low-speed incompressible flows. The quantities of velocity and pressure are placed on a staggered grid, with velocity being tracked at cell faces and pressure at cell centers. The free surface is tracked via the introduction of a color function that tracks liquid as 1/2 and gas as -1/2. A phase model developed by Jacqmin is used. This model converts the discrete surface tension force into a barrier function that peaks at the free surface and decays rapidly. Previous attempts at this formulation have been criticized for smearing the interface. However, by sharpening the phase function, double gridding the fluid function, and using a higher order solution for the fluid function, interface smearing is avoided. These equations can be rewritten as two coupled Poisson equations that also include the velocity. The method of solution is as follows: first, the phase equations are solved from this solution, a velocity field is generated, then a successive overrelaxation scheme is used to solve for a pressure field consistent with the velocity solution. After the code was implemented in axisymmetric form and verified by several test cases, the drop tower runs of Aydelott were modeled. The model handed the free-surface deformation quite nicely, even to the point of modeling geyser growth in the regime where the free surface was no longer restrained. A representative run is shown.

Chato, David J.↗

Contact Angle Influence on Geysering Jets in Microgravity Investigated

Microgravity poses many challenges to the designer of spacecraft tanks. Chief among these are the lack of phase separation and the need to supply vapor-free liquid or liquid-free vapor to the spacecraft processes that require fluid. One of the principal problems of phase separation is the creation of liquid jets. A jet can be created by liquid filling, settling of the fluid to one end of the tank, or even closing a valve to stop the liquid flow. Anyone who has seen a fountain knows that jets occur in normal gravity also. However, in normal gravity, the gravity controls and restricts the jet flow. In microgravity, with gravity largely absent, surface tension forces must be used to contain jets. To model this phenomenon, a numerical method that tracks the fluid motion and the surface tension forces is required. Jacqmin has developed a phase model that converts the discrete surface tension force into a barrier function that peaks at the free surface and decays rapidly away. Previous attempts at this formulation were criticized for smearing the interface. This can be overcome by sharpening the phase function, double gridding the fluid function, and using a higher-order solution for the fluid function. The solution of this equation can be rewritten as two coupled Poisson equations that also include the velocity.

Chato, David J.↗

Rigging Test Bed Development for Validation of Multi-Stage Decelerator Extractions

The Low Density Supersonic Decelerator project is developing new decelerator systems for Mars entry which would include testing with a Supersonic Flight Dynamics Test Vehicle. One of the decelerator systems being developed is a large supersonic ringsail parachute. Due to the configuration of the vehicle it is not possible to deploy the parachute with a mortar which would be the preferred method for a spacecraft in a supersonic flow. Alternatively, a multi-stage extraction process using a ballute as a pilot is being developed for the test vehicle. The Rigging Test Bed is a test venue being constructed to perform verification and validation of this extraction process. The test bed consists of a long pneumatic piston device capable of providing a constant force simulating the ballute drag force during the extraction events. The extraction tests will take place both inside a high-bay for frequent tests of individual extraction stages and outdoors using a mobile hydraulic crane for complete deployment tests from initial pack pull out to canopy extraction. These tests will measure line tensions and use photogrammetry to track motion of the elements involved. The resulting data will be used to verify packing and rigging as well, as validate models and identify potential failure modes in order to finalize the design of the extraction system.

Low Density Supersonic Decelerator (LDSD)↗

Micromechanics Modeling of Composites Subjected to Multiaxial Progressive Damage in the Constituents

The high-fidelity generalized method of cells composite micromechanics model is extended to include constituent-scale progressive damage via a proposed damage model. The damage model assumes that all material nonlinearity is due to damage in the form of reduced stiffness, and it uses six scalar damage variables (three for tension and three for compression) to track the damage. Damage strains are introduced that account for interaction among the strain components and that also allow the development of the damage evolution equations based on the constituent material uniaxial stress strain response. Local final-failure criteria are also proposed based on mode-specific strain energy release rates and total dissipated strain energy. The coupled micromechanics-damage model described herein is applied to a unidirectional E-glass/epoxy composite and a proprietary polymer matrix composite. Results illustrate the capability of the coupled model to capture the vastly different character of the monolithic (neat) resin matrix and the composite in response to far-field tension, compression, and shear loading.

Bednarcyk, Brett A.↗

Lightweight, economical solar concentrator

Concentrator consisting of aluminized polymeric film stretched over parallel tensioned wires that can be used with or without tracking drive promises to reduce cost of commercial and residential solar heating systems.

Simpson, J. G.↗

Computational Study of Surface Tension and Wall Adhesion Effects on an Oil Film Flow Underneath an Air Boundary Layer

The fringe-imaging skin friction (FISF) technique, which was originally developed by D. J. Monson and G. G. Mateer at Ames Research Center and recently extended to 3-D flows, is the most accurate skin friction measurement technique currently available. The principle of this technique is that the skin friction at a point on an aerodynamic surface can be determined by measuring the time-rate-of-change of the thickness of an oil drop placed on the surface under the influence of the external air boundary layer. Lubrication theory is used to relate the oil-patch thickness variation to shear stress. The uncertainty of FISF measurements is estimated to be as low as 4 percent, yet little is known about the effects of surface tension and wall adhesion forces on the measured results. A modified version of the free-surface Navier-Stokes solver RIPPLE, developed at Los Alamos National Laboratories, was used to compute the time development of an oil drop on a surface under a simulated air boundary layer. RIPPLE uses the volume of fluid method to track the surface and the continuum surface force approach to model surface tension and wall adhesion effects. The development of an oil drop, over a time period of approximately 4 seconds, was studied. Under the influence of shear imposed by an air boundary layer, the computed profile of the drop rapidly changes from its initial circular-arc shape to a wedge-like shape. Comparison of the time-varying oil-thickness distributions computed using RIPPLE and also computed using a greatly simplified numerical model of an oil drop equation which does not include surface tension and wall adhesion effects) was used to evaluate the effects of surface tension on FISF measurement results. The effects of surface tension were found to be small but not necessarily negligible in some cases.

Celic, Alan↗

Two-phase flow numerical analysis of electrode geometry for alkaline water electrolyzers

Hydrogen is a promising component of a future energy-secure and efficient economy, but its competitiveness depends on reducing production costs. One strategy is to operate alkaline water electrolyzers at higher current densities to increase output. However, this intensifies performance losses due to gas bubble accumulation, which blocks transport pathways and deactivates electrochemically active surfaces. Enhancing bubble evacuation through electrode design is therefore essential. Previous studies have explored various approaches — such as modifying surface morphology, applying sonication or pressure modulation, and introducing surfactants — but these efforts have addressed a limited range of conditions due to the complexity of two-phase flow and electrode geometries. Experiments have also largely been focused on either cell level improvements, which lack the information necessary to isolate each contributing factor, or on modified geometries that are not relevant to practical cell operation. From a modeling perspective, conventional Eulerian multiphase models do not track the complex gas–liquid interfacial dynamics and often neglect surface tension and contact angle effects, reducing their predictive accuracy. To provide insights on the effects of different electrode geometries on the performance of alklaine water electrolyzers this work employs an immersed boundary volume-of-fluid method to simulate bubble behavior in 3D porous electrodes. Multiple base electrode geometries, typically used in practice, with varying porosity are evaluated under a constant surface gas generation rate. Simulation data is analyzed to quantify electrode gas coverage, bubble size dynamics and other relevant metrics. Results show that porosity strongly influences bubble accumulation on electrode surfaces, with higher porosity reducing gas coverage, and its not strictly dependent on the electrode geometry. However, the electrode’s base geometry significantly affects gas accumulation at the separator gap, independent of porosity. A foam electrode geometry resulted in the lowest gas coverage of all electrodes with a median volumetric gas coverage of 11%, but at the cost of a 70% reduction in active area compared with the largest surface area electrode, while gyroid electrodes showed the best trade-off between gas coverage, particularly at the separator surface, and electrochemically active area. In conclusion, the results highlight the need for holistic electrode design strategies.

Alkaline↗

The influence of laser power modulation on melt pool dynamics in laser powder bed fusion

While the majority of laser powder bed fusion (LPBF) metal additive manufacturing uses a continuous wave (CW) laser heat source, some commercial applications of LPBF additive manufacturing instead involve the modulation of the laser power on tens-of-microsecond timescales as an adjustable process variable. This article reports the use of in situ, high speed x-ray and optical imaging to probe melt pool fluid flow, defect formation, and nearby powder motion during LPBF with both modulated and CW laser heat sources. We observe melt pool dynamics unique to modulated laser melting even at very high duty cycles that are related to fluctuations in vapor depression depth, complex pore formation mechanisms, and changes to denudation physics when compared to CW melting. These behaviors are present in Ti–6Al–4V, 316L stainless steel, and AL1100 alloys but vary slightly as a function of material, indicating a substantial dependence on the viscosity and surface tension of the liquid metal. While high duty cycles produce weld tracks of comparable quality to CW melting, lower duty cycles introduce substantial defect concentrations. At intermediate duty cycles, careful control of modulation parameters can repeatably and precisely yield one pore per laser pulse, suggesting a method for intentionally inserting engineered porosity at specific sites during an LPBF build.

3D printing↗

String-Breaking Dynamics in Quantum Adiabatic and Diabatic Processes

Confinement prohibits isolation of color charges, e.g., quarks, in nature via a process called string breaking : the separation of two charges results in an increase in the energy of a color flux, visualized as a string, connecting those charges. Eventually, creating additional charges is energetically favored, hence breaking the string. Such a phenomenon can be probed in simpler models, including quantum spin chains, enabling enhanced understanding of string-breaking dynamics. A challenging task is to understand how string breaking occurs as time elapses, in an out-of-equilibrium setting. This work establishes the phenomenology of dynamical string breaking induced by a gradual increase of string tension over time. It, thus, goes beyond instantaneous quench processes and enables tracking the real-time evolution of strings in a more controlled setting. We focus on domain-wall confinement in a family of quantum Ising chains. Our results indicate that, for sufficiently short strings and slow evolution, string breaking can be described by the transition dynamics of a two-state quantum system akin to a Landau-Zener process. For longer strings, a more intricate spatiotemporal pattern emerges: the string breaks by forming a superposition of bubbles (domains of flipped spins of varying sizes), which involve highly excited states. We finally demonstrate that string breaking driven only by quantum fluctuations can be realized in the presence of sufficiently long-ranged interactions. This work holds immediate relevance for studying string breaking in quantum-simulation experiments.

Ising model↗

Compact, Controlled Resistance Exercise Device

Spaceflight leads to muscle and bone atrophy. Isoinertial (free-weight) exercises provide a sufficient stimulus to elicit increases in both muscle strength and bone mineral density in Earth-based studies. While exercise equipment is in use on the International Space Station for crewmember health maintenance, current devices are too large to place in a transport vehicle or small spacecraft. Therefore, a portable computer controlled resistance exercise device is being developed that is able to simulate the inertial loading experienced when lifting a mass on Earth. This portable device weighs less than 50 lb and can simulate the resistance of lifting and lowering up to 600 lb of free-weights. The objective is to allow crewmembers to perform resistance exercise with loads capable of maintaining muscle and bone health. The device is reconfigurable and allows for the performance of typical Earth-based free-weight exercises. Forces exerted, volume of work, range of motion, time-under-tension, and speed/ acceleration of movement are recorded and can be remotely monitored to track progress and modify individual protocols based on exercise session data. A performance evaluation will be completed and data will be presented that include ground-reaction force comparisons between the device and free-weight dead-lifts over a spectrum of resistance levels. Movement biomechanics will also be presented.

Paulus, David C.↗

Beam Dynamics Challenges in the Muon g-2 Experiment

The muon&s;s anomalous magnetic moment $a_{\mu}$ has hinted at physics beyond the standard model for nearly 20 years. The Muon $g-2$ experiment at Fermilab aims to measure $a_{\mu}$ to 140 parts per billion (ppb) precision. The 460 ppb result from its first data run (Run-1), released in 2021, agreed with the previous 2006 Brookhaven Muon $g-2$ result. The experimental average stands in tension with the standard model theory $a_{\mu}$ prediction by $4.2 \sigma$. The result of Run-2/3 data analysis is set be released in summer 2023, and will improve on the Run-1 precision by a factor of two. With the data collected in all six runs, the experiment is on track to produce a 140 ppb measurement of $a_{\mu}$. If the experiment and theory central values are both unchanged, the tension would exceed $5 \sigma$. The measurement is accomplished by injecting muons into a magnetic storage ring and precisely measuring two observable frequencies: $\omega_a$, the muons&s; anomalous precession frequency, and $\tilde{\omega}&s;_p$, the precession frequency of protons which determines the magnetic field strength experienced by the muons. This thesis presents a selection of muon beam dynamics effects which are critical for reaching the experiment precision goal. A system of detectors assists with the challenging beam injection into the storage ring, and a measurement of the injected beam provides input for simulating the stored beam dynamics. A new method is introduced to reduce a critical systemic caused by time dependence in the stored beam momentum, enabled by a detector which directly profiles the stored beam. Finally the analysis of $\tilde{\omega}&s;_p$, the muon-weighted magnetic field, for the Run-2/3 result is presented. Systematics of $\tilde{\omega}&s;_p$ due to beam effects are evaluated in detail, and shown to be sub-dominant.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗

Numerical Simulations of Drop Collisions

Three-dimensional simulations of the off-axis collisions of two drops are presented. The full Navier-Stokes equations are solved by a Front-Tracking/Finite-Difference method that allows a fully deformable fluid interface and the inclusion of surface tension. The drops are accelerated towards each other by a body force that is turned off before the drops collide. Depending on whether the interface between the drops is ruptured or not, the drops either bounce or coalesce. For drops that coalesce, the impact parameter, which measures how far the drops are off the symmetry line, determines the eventual outcome of the collision. For low impact parameters, the drops coalesce permanently, but for higher impact parameters, a grazing collision, where the drops coalesce and then stretch apart again is observed. The results are in agreement with experimental observations.

Nobari, M. R. H.↗

Path dependence of J in three numerical examples

Three cracked geometries are studied with the aid of a new finite element model. The procedure employs a variable singularity at the crack tip that tracks changes in the material response during the loading process. Two of the problems are tension-loaded center-crack panels and the other is a three-point bend specimen. Results usually agree with other numerical and analytical analyses, except the finding that J is path dependent as a substantial plastic zone develops. Credible J values are obtained near the crack tip and J shows a significant increase as the radius of J path increases over two orders of magnitude. Incremental and deformation theories are identical provided the stresses exhibit proportionality found in the far field stresses but not near the tip.

Karabin, M. E., Jr.↗