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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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12 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Industrialized and Robotic Construction Advances in Terrestrial Construction and Opportunities in Space Construction

Advanced Building Construction (ABC) methods such as industrialized prefabrication and robotically controlled additive deposition are becoming promising technologies to support rapid construction of buildings at volume and scale. However, apart from the structural shell of the building, optimal integration of other systems – mechanical, electrical, plumbing, thermal, power generation, storage and distribution, is key to enabling functional buildings. Leveraging ABC methods to integrate such systems in the buildings requires the building design to be optimized for constructability constraints imposed by the industrialized and robotically controlled production setups entailing such ABC methods. The Industrialized Construction Innovation (ICI) team at the National Renewable Energy Laboratory (NREL) has been focusing on research and development of such ABC technologies and processes that can lead to production of buildings which are resilient to extreme climatic conditions at reduced cost and time. There is a potential synergy between such advancements in terrestrial construction, which can be leveraged for the benefit of space (orbital and extra-terrestrial) construction. Similarly, advances in space construction can lend itself to accelerated adoption of robotic construction methods in terrestrial construction. This presentation will give an overview of selective research efforts of the ICI team at NREL, along with a vision for potential collaborations with agencies like NASA.

3D printing↗
DOE OSTI2018

Under canopy light detection and ranging–based autonomous navigation

This study describes a light detection and ranging (LiDAR)–based autonomous navigation system for an ultralightweight ground robot in agricultural fields. The system is designed for reliable navigation under cluttered canopies using only a 2D Hokuyo UTM–30LX LiDAR sensor as the single source for perception. Its purpose is to ensure that the robot can navigate through rows of crops without damaging the plants in narrow row–based and high–leaf–cover semistructured crop plantations, such as corn ( Zea mays ) and sorghum ( Sorghum bicolor ). The key contribution of our work is a LiDAR–based navigation algorithm capable of rejecting outlying measurements in the point cloud due to plants in adjacent rows, low–hanging leaf cover or weeds. The algorithm addresses this challenge using a set of heuristics that are designed to filter out outlying measurements in a computationally efficient manner, and linear least squares are applied to estimate within–row distance using the filtered data. Moreover, a crucial step is the estimate validation, which is achieved through a heuristic that grades and validates the fitted row–lines based on current and previous information. The proposed LiDAR–based perception subsystem has been extensively tested in production/breeding corn and sorghum fields. In such variety of highly cluttered real field environments, the robot logged more than 6 km of autonomous run in straight rows. These results demonstrate highly promising advances to LiDAR–based navigation in realistic field environments for small under–canopy robots.

42 ENGINEERING↗
DOE OSTI2024

Flat and Level Analysis Tool (FLAT) for real-time automated segmentation and analysis of concrete slab point clouds

In the United States, the flatness and levelness of concrete floors during construction is traditionally specified by a maximum allowable gap under a 3 meter straightedge. However, the straightedge method is inexact and rarely representative of the entire floor since the technician is free to choose any location on the floor to perform the measurement. In cases requiring a higher degree of precision and repeatability, concrete floor flatness and levelness can be measured using the standard test method ASTM E1155. With the recent introduction of advanced surveying instruments such as robotic theodolites and terrestrial laser scanners (TLS), the means now exist to modernize and expedite the measurement of floor flatness and levelness. This paper details the development and demonstration of a digital tool, named the Flat and Level Analysis Tool (FLAT), to automate and expedite the segmentation and analysis of flatness and levelness from dense point cloud data of concrete floor slabs. Segmentation algorithms were developed using unsupervised machine learning to extract the set of points belonging to the concrete floor slab from a full 360 scan of a construction site. After segmentation, automated analysis algorithms report the results according to the standard method. The developed algorithms were demonstrated on a dense point cloud captured from a concrete slab-on-grade at a construction site. Results show that the digital tool can quickly provide estimates for floor flatness and levelness with minimal human involvement with comparable accuracy to manual methods.

Hayes, Nolan↗
DOE OSTI2026

Synthetic Digital Environments for Training Robots on Earth & Beyond [Poster]

Creating physical replicas of real-world environments to train robots for challenging outdoor tasks, whether constructing energy infrastructure like solar farms on Earth or on the Moon and Mars, is prohibitively expensive. This project will prototype a high-fidelity digital twin framework using NVIDIA IsaacSim to create realistic digital representations of robotic systems and their operating conditions, including varied terrains and environmental factors, allowing robots to learn and adapt in a faster, safer, and more affordable way to tackle unpredictable challenges in terrestrial and extraterrestrial applications. The Robotic Space Exploration (RoSE) Lab at Colorado School of Mines focused on the development and testing of synthetic digital twins to explore multi-physics interactions between robots and unstructured environments, with emphasis on lunar conditions such as deformable regolith, reduced gravity, and terrain-robot contact dynamics. The Industrialized Construction Innovation (ICI) team at National laboratory of the Rockies (NLR), simulated robotic apparatus and construction workflows using synthetic digital twins to inform real-world deployment, targeting application-driven use cases such as robotic construction of a scaled prototype of a photovoltaic energy infrastructure. Joint efforts between RoSE and ICI are continuing to explore how environment-scale multi-physics modeling and application-level robotic system simulation could be integrated to support robotic construction of energy infrastructure in highly unstructured environments, including scenarios relevant to the Lunar South Pole.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2026

Robotics for Energy Infrastructure Construction on Earth and Beyond: Pilot Study Exploring Level 3-4 Semi-Autonomous Installation of a Reduced-Scale Photovoltaic Power Plant Prototype: Preprint

There is a growing need to build energy infrastructure at massive scale on both Earth and in space. On Earth, increasing electricity demand from applications such as AI data centers is driving rapid expansion of power systems, while in space, long-duration missions such as lunar operations require reliable and resilient energy infrastructure that can be deployed quickly. These needs outpace the capabilities of conventional construction methods. Robotic construction offers a path to faster, lower-cost, and more consistent deployment, yet most existing approaches focus on automating individual tasks rather than end-to-end assembly. The Industrialized Construction Innovation (ICI) team at the National Laboratory of the Rockies (NLR), in collaboration with the Colorado School of Mines, has been investigating robotics and automation strategies for rapid end-to-end energy infrastructure construction. This paper presents a pilot study demonstrating level 3-4 semi-autonomous, end-to-end robotic assembly of a reduced-scale photovoltaic power plant prototype under terrestrial conditions. The approach combines hardware redesign of photovoltaic components for robotic compatibility, discrete-event and physics-based robotic simulations in synthetic environments, and sim-to-real deployment to execute end-to-end robotic assembly of[NM1.1][NM1.2] tracking components, structural members, photovoltaic modules, and embedded electrical connections. The pilot identifies key limitations like tolerance management, perception and localization, end effector capability, fastening methods, and multi-physics simulation fidelity, that must be addressed to enable end-to-end robotic assembly of full-scale energy infrastructure. The study highlights how these insights inform scaling strategies for terrestrial energy infrastructure and adaptation to unstructured and extreme environments, including off-world scenarios such as robotic assembly of vertical tall lunar towers.

14 SOLAR ENERGY↗
DOE OSTI2024

Robotics for Systems Integration in Buildings - Pilot Study of Viable Approaches to Install Hygrothermal and Rigid Electrical Systems: Preprint

The Industrialized Construction Innovation (ICI) team at the National Renewable Energy Laboratory (NREL) has been exploring the use of robotics to integrate hygrothermal, mechanical, electrical, and plumbing systems in prefabricated building assemblies (offsite construction) and 3D Printed buildings (onsite construction). Such multi-system integration tasks often require specialized robots and custom end-effectors for handling a range of rigid and non-rigid building components. This paper begins with a brief overview of the current state of robotics in construction, followed by a pilot study exploring the use of robotics to integrate a simple prototype multi-trade wall assembly composed of structural studs, hygrothermal layer, wall finishing, and electrical fixtures. The study was funded by the Department of Energy's (DOE) Advanced Materials and Manufacturing Technologies Office (AMMTO). Insights about the implementation of design for manufacturing and assembly (DfMA) principles in designing the prototype wall for robotic assembly, and selection of appropriate robotic end effector hardware for handling these components are included. Detailed comparison of computational toolpath simulations of the robotic assembly process and real-life demonstration of the same is presented. Finally, limitations and lessons learned from this study along with future research recommendations for robotic assembly of more complex multi-trade assemblies, including potential scenarios such as robotic outfitting of facilities in extra-terrestrial environments is included.

advanced manufacturing↗
DOE OSTI2017

Robotic Grasp Assistance for Decontamination and Decommissioning Tasks: Initial Applications with RoboGlove - 17310

RoboGlove, developed by NASA and General Motors, is a wearable robotic grasp assist device designed to augment human strength and endurance during manual tasks. Recent testing as part of the U.S. Department of Energy Office of Environmental Management's (DOE-EM's) Science of Safety Initiative has provided the opportunity to explore the glove's use within the context of decontamination and decommissioning work. Capable of providing a wearer with an additional 65-90 N (15-20 lb) of additional continuous grip strength, RoboGlove has the potential to decrease fatigue during long duration tasks, thereby reducing the risk of repetitive stress and other work related injuries. While current work at NASA focuses on integrating robotic grasp assistance with space suit gloves, the effort described herein focuses on the terrestrial application of RoboGlove to DOE-EM's cleanup mission. Following a brief technical description of RoboGlove, testing by United Steelworkers Union personnel at the Portsmouth Gaseous Diffusion Plant is described. Members of the workforce, in collaboration with NASA technologists, studied RoboGlove utility and performance while using tools common to the nuclear decontamination and decommissioning efforts at the plant. Results and feedback from this testing aim at identifying candidate activities for which RoboGlove holds particular promise as a workforce tool, in an effort to facilitate the infusion of robotic technology into routine workflow and processes across the DOE complex for the benefit of worker safety and health. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2016

Analysis of Dust Samples Collected from an In-Service Interim Storage System at the Maine Yankee Nuclear Site.

In July, 2016, the Electric Power Research Institute and industry partners performed a field test at the Maine Yankee Nuclear Site, located near Wiscasset, Maine. The primary goal of the field test was to evaluate the use of robots in surveying the surface of an in-service interim storage canister within an overpack; however, as part of the demonstration, dust and soluble salt samples were collected from horizontal surfaces within the interim storage system. The storage system is a vertical system made by NAC International, consisting of a steel-lined concrete overpack containing a 304 stainless steel (SS) welded storage canister. The canister did not contain spent fuel but rather greater-than-class-C waste, which did not generate significant heat, limiting airflow through the storage system. The surfaces that were sampled for deposits included the top of the shield plug, the side of the canister, and a shelf at the bottom of the overpack, just below the level of the pillar on which the canister sits. The samples were sent to Sandia National Laboratories for analysis. This report summarizes the results of those analyses. Because the primary goal of the field test was to evaluate the use of robots in surveying the surface of the canister within the overpack, collection of dust samples was carried out in a qualitative fashion, using paper filters and sponges as the sampling media. The sampling focused mostly on determining the composition of soluble salts present in the dust. It was anticipated that a wet substrate would more effectively extract soluble salts from the surface that was sampled, so both the sponges and the filter paper were wetted prior to being applied to the surface of the metal. Sampling was accomplished by simply pressing the damp substrate against the metal surface for two minutes, and then removing it. It is unlikely that the sampling method quantitatively collected dust or salts from the metal surface; however, both substrates did extract a significant amount of material. The paper filters collected both particles, trapped within the cellulose fibers of the filter, and salts, while the sponges collected only the soluble salts, with very few particles. Upon delivery to Sandia, both collection media were analyzed using the same methods. The soluble salts were leached from the substrates and analyzed via ion chromatography, and insoluble minerals were analyzed by scanning electron microscopy and energy dispersive X-ray spectroscopy. The insoluble minerals were found to consist largely of terrestrially-derived mineral fragments, dominantly quartz and biotite. Large (mm-sized) aggregates of calcium carbonate, calcium silicate, and calcium aluminum silicate were also present. The aggregates had one flat, smooth surface and one well crystallized surface, and were interpreted to be efflorescence on the inside of the overpack and in the vent, formed by seepage of cement pore fluids through joints in the steel liner of the overpack. Such efflorescence was commonly observed during the boroscope inspection of the storage system at the site. The material may have flaked off and fallen to the point where the dust was collected, or may have brushed off onto the sponges when the robot was retrieved through the inlet vent. Chemical analysis showed that the soluble salts on the shield plug were Ca- and Na-rich, with lesser K and minor Mg; the anionic component was dominated by SO 4 and Cl, with minor amounts of NO 3 . The cation composition of the soluble salts from the overpack shelf and the canister surface was similar to the filter samples, but the anions differed significantly, being dominantly NO 3 with lesser Cl and only trace SO 4 . The salts appear to represent a mixture of sea-salts (probably partially converted to nitrates and sulfates by particle-gas conversion reactions) and continental salt aerosols. Ammonium, a common component in continental aerosols, was not observed and may have been lost by degassing from the canister surface or after collection during sample storage and transportation. The demonstration at Maine Yankee has shown that the robot and sampling method used for the test can successfully be used to collect soluble salts from metal surfaces within an interim storage system overpack. The results were consistent from sample to sample, suggesting that a representative sample of the soluble salts was being collected. However, it is unlikely that the salt samples collected here represent quantitative sampling of the salts on the surfaces evaluated; for that reason, chloride densities per unit area are not presented here. It should also be noted that the relevance to storage systems at the site that contain SNF may be limited, because a heat- generating canister will result in greater airflow through the overpack, affecting dust deposition rates and possibly salt compositions.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2019

R and DE Robotic Sensor Intern Team: Advanced Sensor Suite Prototype

The Department of Energy (DOE) nuclear complex includes many hazardous and challenging environments that must be inspected remotely and routinely for structural integrity evaluation and long-term planning purposes. The H-Canyon Air Exhaust (HCAEX) Tunnel is an example of such an environment where a biannual inspection is currently performed. Presently inspections are performed by teleoperated robotic crawlers which provide low-res video feedback to the structural engineers. Advanced sensors: including Lidar and panospheric hi-res cameras have the potential to provide additional valuable data in future inspections. The primary goal of the sensor suite is to provide an internal 3D map of the HCAEX tunnel. Possible sensors were a stereo camera, a 3D Lidar, or a 2D Lidar that would need to be spun around. The issues with the stereo camera were that it does not have a large field-of-view and that its depth information was not nearly as accurate as even the baseline Lidars. The Hokuyo UTM-30LX-EW shown below provides a 270 deg. FOV with high accuracy and resolution while the largest FOV on a 3D Lidar is 40 deg. This was the reason a 2D Lidar was chosen over the 3D Lidar. Even though the 2D Lidar requires additional components and software to generate a 3D map, its FOV advantage is too great given that the HCAEX tunnel is a relatively confined space. Along with the Lidar, a camera sensor, IMU sensor, pan-tit unit, and on board computer needed to be identified. The two panospheric cameras allow for full 360 deg. FOV. The IMU will give data on the state of the robot inside the tunnel. The computer is used to gather and process data on board and to control the pan-tilt system. Mounts were designed and 3D printed to build the prototype of the sensor suite. It was designed to have the Lidar on top With its full FOV free while having the camera below and as close to together as possible while still leaving much of their FOV visible. The design also managed the cables such that they were unlikely to be damaged if in tension and so that they did not intrude much on the cameras vision. The sensor tree developed for the H-Canyon tunnel inspection project produces a large quantity of camera and Lidar data. a postprocessing pipeline was created to facilitate the analysis of these data. The pipeline follows the following routine: 1) Registration - Salient local features in subsequent scans are identified and used to align the scans With one another. This allows production of a single cohesive map of the tunnel. 2) Sensor Fusion - RGB camera data is 'painted' onto the depth data created by the Lidar. 3) Segmentation - Individual surfaces from within the scene are segmented out separately for individual analysis. 4) Degradation Analysis - Automatic mapping of local deviation from the plane in position or surface normal is performed, as is detection of exposed rebar using Lidar return intensity. 2) Obstacle Detection - Lidar data is also used in real time to detect obstacles in the environment. This could give feedback to the operator to successfully drive in the tunnel. 6) Graphic User Interface - a custom GUI was created to facilitate customer use of the system. The system provides real-time feedback from both the cameras and Lidar. The Lidar point-cloud data is also used for obstacle detection. As the Lidar spins, various algorithms are run to analyze the current 'slice' and obstacles in the environment are determined and registered on a cost-map. A Graphical User Interface (GUI) was developed to allow the user to easily command the crawler to set the rotational speed of the Lidar, perform a scan, and register and save the 3D generated cloud after a scan is done. For the good of the crawler, a critical aspect of the GUI design is to allow the user to cancel a scan any time after it is commanded and before it is saved. The sensor trees depth accuracy was evaluated in comparison to a high end commercial FARO Terrestrial Laser Scanner (TLS) with specifications for millimeter accuracy at distances above 10 m. For the purposes of these tests, the depth measurements produced by the TLS were taken as ground truth. Example test wall panels were scanned with the TLS and postprocessed with its proprietary software, and subsequently scanned with the sensor tree system. The two scans were manually aligned and for each point in the output cloud from the sensor tree, the distance to the nearest ground truth point in the FARO cloud was determined. 98.7% of all produced points were within the specified target range of 6 mm, with an average deviation of 1.75 mm. The test walls used have an overall in-wall depth variation of around 40 mm.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2020

Using CESM-RESFire to understand climate–fire–ecosystem interactions and the implications for decadal climate variability

Large wildfires exert strong disturbance on regional and global climate systems and ecosystems by perturbing radiative forcing as well as the carbon and water balance between the atmosphere and land surface, while short- and long-term variations in fire weather, terrestrial ecosystems, and human activity modulate fire intensity and reshape fire regimes. The complex climate–fire–ecosystem interactions were not fully integrated in previous climate model studies, and the resulting effects on the projections of future climate change are not well understood. Here we use the fully interactive REgion-Specific ecosystem feedback Fire model (RESFire) that was developed in the Community Earth System Model (CESM) to investigate these interactions and their impacts on climate systems and fire activity. We designed two sets of decadal simulations using CESM-RESFire for present-day (2001–2010) and future (2051–2060) scenarios, respectively, and conducted a series of sensitivity experiments to assess the effects of individual feedback pathways among climate, fire, and ecosystems. Our implementation of RESFire, which includes online land–atmosphere coupling of fire emissions and fire-induced land cover change (LCC), reproduces the observed aerosol optical depth (AOD) from space-based Moderate Resolution Imaging Spectroradiometer (MODIS) satellite products and ground-based AErosol RObotic NETwork (AERONET) data; it agrees well with carbon budget benchmarks from previous studies. We estimate the global averaged net radiative effect of both fire aerosols and fire-induced LCC at –0.59±0.52 W m –2 , which is dominated by fire aerosol–cloud interactions (–0.82±0.19 W m –2 ), in the present-day scenario under climatological conditions of the 2000s. The fire-related net cooling effect increases by ~170 % to –1.60±0.27 W m –2 in the 2050s under the conditions of the Representative Concentration Pathway 4.5 (RCP4.5) scenario. Such considerably enhanced radiative effect is attributed to the largely increased global burned area (+19 %) and fire carbon emissions (+100 %) from the 2000s to the 2050s driven by climate change. The net ecosystem exchange (NEE) of carbon between the land and atmosphere components in the simulations increases by 33 % accordingly, implying that biomass burning is an increasing carbon source at short-term timescales in the future. High-latitude regions with prevalent peatlands would be more vulnerable to increased fire threats due to climate change, and the increase in fire aerosols could counter the projected decrease in anthropogenic aerosols due to air pollution control policies in many regions. We also evaluate two distinct feedback mechanisms that are associated with fire aerosols and fire-induced LCC, respectively. On a global scale, the first mechanism imposes positive feedbacks to fire activity through enhanced droughts with suppressed precipitation by fire aerosol–cloud interactions, while the second one manifests as negative feedbacks due to reduced fuel loads by fire consumption and post-fire tree mortality and recovery processes. These two feedback pathways with opposite effects compete at regional to global scales and increase the complexity of climate–fire–ecosystem interactions and their climatic impacts.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2012

Small Reactor Designs Suitable for Direct Nuclear Thermal Propulsion (Interim Report)

Advancement of U.S. scientific, security, and economic interests requires high performance propulsion systems to support missions beyond low Earth orbit. A robust space exploration program will include robotic outer planet and crewed missions to a variety of destinations including the moon, near Earth objects, and eventually Mars. Past studies, in particular those in support of both the Strategic Defense Initiative (SDI) and the Space Exploration Initiative (SEI), have shown nuclear thermal propulsion systems provide superior performance for high mass high propulsive delta-V missions. In NASA's recent Mars Design Reference Architecture (DRA) 5.0 study, nuclear thermal propulsion (NTP) was again selected over chemical propulsion as the preferred in-space transportation system option for the human exploration of Mars because of its high thrust and high specific impulse (~900 s) capability, increased tolerance to payload mass growth and architecture changes, and lower total initial mass in low Earth orbit. The recently announced national space policy supports the development and use of space nuclear power systems where such systems safely enable or significantly enhance space exploration or operational capabilities. An extensive nuclear thermal rocket technology development effort was conducted under the Rover/NERVA, GE-710 and ANL nuclear rocket programs (1955-1973). Both graphite and refractory metal alloy fuel types were pursued. The primary and significantly larger Rover/NERVA program focused on graphite type fuels. Research, development, and testing of high temperature graphite fuels was conducted. Reactors and engines employing these fuels were designed, built, and ground tested. The GE-710 and ANL programs focused on an alternative ceramic-metallic 'cermet' fuel type consisting of UO 2 (or UN) fuel embedded in a refractory metal matrix such as tungsten. The General Electric program examined closed loop concepts for space or terrestrial applications as well as open loop systems for direct nuclear thermal propulsion. Although a number of fast spectrum reactor and engine designs suitable for direct nuclear thermal propulsion were proposed and designed, none were built. This report summarizes status results of evaluations of small nuclear reactor designs suitable for direct nuclear thermal propulsion.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2025

A Comprehensive Framework for Assessing Terrestrial Analogue Field Sites for Ocean Worlds

Field studies at terrestrial analogue sites represent an important contribution to the science of ocean worlds. The value of the science and technology investigations conducted at field analogue sites depends on the relevance of the analogue environment to the target ocean world. We accept that there are no perfect analogues for many of the unique environments represented by ocean worlds but suggest that a one‐to‐one matching of environmental characteristics and conditions is not crucial to the success or impact of the work. Instead, we must determine which processes and parameters are required to map directly to the target ocean world environment with high fidelity to address the science question. In this review paper, we discuss the outcomes of a workshop aimed at developing a new framework for evaluating the suitability of analogue field locations for ocean worlds research. Here we present a two‐step approach to (a) identify the most crucial processes and parameters associated with a given science question and (b) assess the fidelity of these processes and parameters at a proposed field site to those expected for the target ocean world. We demonstrate this approach in a test case evaluating three types of ocean world analogue environments with respect to a science question. The consensus document presented here equips veteran and new investigators with valuable tools to better assess and justify their analogue site selections.

58 GEOSCIENCES↗