Bradley Richardson

Lawrence Berkeley National Laboratory

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Lonnie Love

Oak Ridge National Laboratory

Mark Noakes

Oak Ridge National Laboratory

Brian Post

Oak Ridge National Laboratory

Randall F. Lind

Oak Ridge National Laboratory

Peter Lloyd

Oak Ridge National Laboratory

S.M. Killough

Oak Ridge National Laboratory

W.R. Hamel

University of Tennessee at Knoxville

Brian Gibson

Northeast Georgia Medical Center

J.F. Jansen

Electric Power Research Institute

Yashwanth Kumar Bandari

Oak Ridge National Laboratory

Cooperative Institutions

Oak Ridge National Laboratory

Office of Scientific and Technical Information

National Transportation Research Center

National Technical Information Service

Government of the United States of America

University of Tennessee at Knoxville

Knoxville College

National Renewable Energy Laboratory

GKN (United States)

United States Department of Energy

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Human-factors-based implementation of the remote characterization system high-level control station

Mark Noakes Bradley Richardson John Carlos Rowe J.V. Draper G.R. Sandness

The detection and characterization of buried objects and materials is an important first step in the restoration of the numerous US Department of Energy (DOE) and US Department of Defense waste disposal sites. DOE, through its Environmental Restoration and Waste Management Robotics and Technology Development Program, has developed the Remote Characterization System (RCS) to address the needs of remote subsurfacecharacterization. The RCS consists of a low-metal-content (low-metallic-signature) remotely piloted vehicle, a high-level control station (HLCS) where operators can remotely control the vehicle and analyze real-time data from sensors, and an array of sensors that can be chosen to meet the survey task at hand. Communication between the vehicle and the base station is handled by a radio link. Site mapping is made possible through the use of geopositioning satellite data. The primary mode of vehicle operation is teleoperation, but provision has been made for semiautonomous or supervisory control that allows for automated sitesurvey on simple sites. Data analysis and display is supported for both real-time observation and postprocessing of data. The particular emphasis of this paper documents the human-factors-based design influences on the HLCS and describes the design in detail.

Teleoperation

Remote Control

Control room

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Additive Manufacturing for Low Volume Bearings

John Tate Bradley Richardson Lonnie Love

ORNL worked with the Schaeffler Group USA to explore additive manufacturing techniques that might be appropriate for prototyping of bearing cages. Multiple additive manufacturing techniques were investigated, including e-beam, binder jet and multiple laser based processes. The binder jet process worked best for the thin, detailed cages printed.

Rapid Prototyping

Manufacturing process

10.2172/1410926

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Citations (12)

A Mobile Automated Characterization System (MACS) for indoor floor characterization

Bradley Richardson D. C. Haley A.M. Dudar C.R. Ward

The Savannah River Technology Center (SRTC) and Oak Ridge National Laboratory are developing an advanced Mobile Automated Characterization System (MACS) to characterize indoor contaminated floors. MACS is based upon Semi-Intelligent Mobile Observing Navigator (SIMON), an earlier floor characterization system developed at SRTC. MACS will feature enhanced navigation systems, operator interface, and an interface to simplify integration of additional sensors. The enhanced navigation system will provide the capability to survey large open areas much more accurately than is now possible with SIMON, which is better suited for hallways and corridors that provide the means for recalibrating position and heading. MACS operator interface is designed to facilitate MACS`s use as a tool for health physicists, thus eliminating the need for additional training in the robot`s control language. Initial implementation of MACS will use radiation detectors. Additional sensors, such as PCB sensors currently being developed, will be integrated on MACS in the future. Initial use of MACS will be focused toward obtaining comparative results with manual methods. Surveys will be conducted both manually and with MACS to compare relative costs and data quality. While clear cost benefits anticipated, data quality benefits should be even more significant.

Interface (matter)

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The Current State of Additive Manufacturing in Wind Energy Systems

Margaret Mann Sierra Palmer Dominic Lee Parthiv Kurup Timothy Remo

Wind power is an inexhaustible form of energy that is being captured throughout the U.S. to power the engine of our economy. A robust, domestic wind industry promises to increase U.S. industry growth and competitiveness, strengthen U.S. energy security independence, and promote domestic manufacturing nationwide. As of 2016, ~82GW of wind capacity had been installed, and wind power now provides more than 5.5% of the nation’s electricity and supports more than 100,000 domestic jobs, including 500 manufacturing facilities in 43 States. To reach the U.S. Department of Energy’s (DOE’s) 2015 Wind Vision study scenario of wind power serving 35% of the nation's end-use demand by 2050, significant advances are necessary in all areas of wind technologies and market. An area that can greatly impact the cost and rate of innovation in wind technologies is the use of advanced manufacturing, with one of the most promising areas being additive manufacturing (AM). Considering the tremendous promise offered by advanced manufacturing, it is the purpose of this report to identify the use of AM in the production and operation of wind energy systems. The report has been produced as a collaborative effort for the DOE Wind Energy Technology Office (WETO), between Oak Ridge National Laboratory (ORNL) and the National Renewable Energy Laboratory (NREL).

Energy Independence

Manufacturing

10.2172/1415918

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Citations (10)

Additive Manufacturing Advances to Facilitate Novel Robot and Remote System Construction

OSTI OAI (U.S. Department of Energy Office of Scientific and Technical Information) (2018)

Mark Noakes Bradley Richardson Andrzej Nycz Rodrigo Rimando

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A teleoperated system for remote site characterization

Gerald A. Sandness Bradley Richardson J. Pence

The detection and characterization of buried objects and materials is an important step in the restoration of burial sites containing chemical and radioactive waste materials at Department of Energy (DOE) and Department of Defense (DOD) facilities. By performing these tasks with remotely controlled sensors, it is possible to obtain improved data quality and consistency as well as enhanced safety for on-site workers. Therefore, the DOE Office of Technology Development and the US Army Environmental Center have jointly supported the development of the Remote Characterization System (RCS). One of the main components of the RCS is a small remotely driven survey vehicle that can transport various combinations of geophysical and radiological sensors. Currently implemented sensors include ground-penetrating radar, magnetometers, an electromagnetic induction sensor, and a sodium iodide radiation detector. The survey vehicle was constructed predominantly of non-metallic materials to minimize its effect on the operation of its geophysical sensors. The system operator controls the vehicle from a remote, truck-mounted, base station. Video images are transmitted to the base station by a radio link to give the operator necessary visual information. Vehicle control commands, tracking information, and sensor data are transmitted between the survey vehicle and the base station by means of a radio ethernet link. Precise vehicle tracking coordinates are provided by a differential Global Positioning System (GPS).

Ground-Penetrating Radar

Differential GPS

Teleoperation

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Additive Manufacturing of Wind Turbine Molds

Brian Post Bradley Richardson Peter Lloyd Lonnie Love Stephen Nolet

The objective of this project was to explore the utility of Big Area Additive Manufacturing (BAAM) for low cost manufacturing of wind turbine molds. Engineers at Oak Ridge National Laboratory (ORNL) and TPI Composites (TPI) collaborated to design and manufacture a printed mold that can be used for resin infusion of wind turbine components. Specific focus was on required material properties (operating temperatures and pressures, coefficient of thermal expansion (CTE), thermal conductivity), surface finish (accuracy and coatings) and system integration (integrated vacuum ports, and heating element). The project began with a simple proof of principle components, targeting surface coatings and material properties for printing a small section (approximately 4' x 4' x 2') of a mold. Next, the second phase scaled up and integrated with the objective of capturing all of the necessary components (integrated heating to accelerate cure time, and vacuum, sealing) for resin infusion on a mold of significant size (8' x 20' x 6').

10.2172/1376487

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Citations (18)

Analysis of manipulator arm steadiness during ship-hull mine neutralization by a UUV

Mathieu Kemp Bradley Richardson Lonnie Love Tony Rodgers Kurt Nelson

Accurate tool placement is an essential element of tele-operated ship-hull mine neutralization. In this article we present a framework to analyze the stability of a UUV-mounted manipulator arm during neutralization. Our principal result is a relationship between rate of arm motion and minimum vehicle thrust required to maintain steadiness.

Manipulator (device)

10.23919/oceans.2011.6106999

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Beyond the Toolpath: Site-Specific Melt Pool Size Control Enables Printing of Extra-Toolpath Geometry in Laser Wire-Based Directed Energy Deposition

Applied Sciences (2019)

Brian Gibson Bradley Richardson Tayler Sundermann Lonnie Love

A variety of techniques have been utilized in metal additive manufacturing (AM) for melt pool size management, including modeling and feed-forward approaches. In a few cases, closed-loop control has been demonstrated. In this research, closed-loop melt pool size control for large-scale, laser wire-based directed energy deposition is demonstrated with a novel modification, i.e., site-specific changes to the controller setpoint were commanded at trigger points, the locations of which were generated by the projection of a secondary geometry onto the primary three-dimensional (3D) printed component geometry. The present work shows that, through this technique, it is possible to print a specific geometry that occurs beyond the actual toolpath of the print head. This is denoted as extra-toolpath geometry and is fundamentally different from other methods of generating component features in metal AM. A proof-of-principle experiment is presented in which a complex oak leaf geometry was embossed on an otherwise ordinary double-bead wall made from Ti-6Al-4V. The process is introduced and characterized primarily from a controls perspective with reports on the performance of the control system, the melt pool size response, and the resulting geometry. The implications of this capability, which extend beyond localized control of bead geometry to the potential mitigations of defects and functional grading of component properties, are discussed.

Set point

Complex geometry

Component (thermodynamics)

Deposition

10.3390/app9204355

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Citations (17)

BAAM Additive Manufacturing of Magnetically Levitated Wind Turbine

Bradley Richardson Mark Noakes Alex Roschli

10.2172/1439341

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Citations (2)