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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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At least 181 records · Page 10

Safe Operations at Roadway Junctions: Intelligent Roadway Infrastructure as Functional Interlocking

Automated vehicle (AV) technology is quickly maturing, and the corresponding infrastructure systems that evaluate traffic and communicate to vehicles requires sophisticated sensing and perception technologies, referred to as intelligent roadway infrastructure (IRI), to complement emerging AV capabilities. IRI provides signals to vehicles, indicating right-of-way for vehicles and communicating to approaching AVs that no other vehicle is failing to yield. This capability, denoted as safety-affirmative signaling, provides a green light or a green arrow as appropriate and affirms through communication links to connected vehicles when it is safe to proceed. About 36% of collisions occur at intersections, with most occurring upon left turns (22.2%) or crossing over (12.6%), and only a small percentage (1.2%) while turning right at an intersection. Of all intersection crashes about half (52.5%) of those vehicles were traveling through a signalized intersection 2. Safety-affirmative signaling would guarantee safety of AV fleet vehicles, by providing the interlocking principle, a term from automated train control that only allows progression through a railway intersection after affirming no opportunity for a crash exists. IRI through safety-affirmative signaling would bring performance and safety to complex roadway intersections where AV transit fleet service is most needed, as well as safety benefits to traditional, non-automated vehicles and vulnerable road users. The implementation of IRI has functional, programmatic, and technical challenges. Research work performed at the National Renewable Energy Laboratory (NREL) in an integrative approach encapsulating these themes, and termed infrastructure perception and control (IPC) is motivated by improved performance (travel time), improved safety (reduced collisions), and improved energy efficiency (less fuel burned and minimized production of greenhouse gases). IPC is intended not only for roadway and intersection applications but also in extension to inform complementary buildings and grid systems to enable better co-management, as vehicles and their charging needs become increasingly integrated into the built environment. The NREL IPC project presents an open-source framework, architecture, and supporting technology to implement IRI, addressing critical issues such as fusion of data, reliability, standardization of data interfaces, and confidence of detection. The framework is informed by previous experience in U.S. Department of Defense research technology, specifically in the use of radar to detect, identify, and track aerial threats. These principles combined with multi-sensor fusion provides for a complete digital twin with known and measurable confidence and accuracy from which safety-affirmative signaling can be developed and deployed.

ADVANCED PROPULSION SYSTEMS,MATHEMATICS AND COMPUT↗

Field-Focused Load-Leveled Dynamic Wireless Charging System for Electric Vehicles

Electric vehicles offer much higher well-to-wheel efficiency than gasoline vehicles and can significantly reduce U.S. dependence on foreign oil, lower greenhouse gas emissions, improve local air quality, and support continued technological and economic growth. Despite these advantages, widespread adoption remains constrained by limitations in current battery technology, including high cost, limited driving range, and long charging times. One promising approach to address these challenges is to reduce onboard energy storage and instead deliver power wirelessly to vehicles while they are at a traffic stop or in motion.

33 ADVANCED PROPULSION SYSTEMS↗

Clean Cities and Communities Partnership 2024 Activity Report

Clean Cities and Communities (CC&C) is a U.S. Department of Energy (DOE) partnership that fosters collaboration and innovation to advance transportation energy choices nationwide. More than 75 DOE-designated CC&C coalitions work in urban, suburban, and rural areas to deliver objective technical expertise based on a unique understanding of local markets. As partners with DOE's Transportation Technologies Office (TTO), coalitions build bridges between national priorities and local needs to create transportation energy systems that are affordable, reliable, and secure. Together, coalitions create compounding impacts nationwide that support locally driven energy choices and benefit regional economic development and job growth. This report summarizes the success and impact of partnership activities based on data and information provided in their annual reports.

2024↗

Hydrogen Transportation and Distributed Energy Systems Risk Assessment for Airport Facilities (CRADA 555) (Final Report)

Portland International Airport (PDX), Oregon, operated by the Port of Portland (Port) is exploring the possibility of operating a fleet of 28 fuel cell electric buses and developing a distributed energy system to support airport operations during various operating modes including large-scale power outages. This study investigates the compatibility of these two missions, which will be key to resilience management at PDX. This study also investigated the risks associated with deploying a hydrogen system that could support bus operations and be utilized during an emergency to ensure continued operation of the airport. This will be a key innovation for the deployment of hydrogen systems at airports. Utilizing the unique benefits of hydrogen infrastructure for multiple roles will aid adopters in justifying new projects and serve to demonstrate the versatility of hydrogen as an energy-carrier to a wider market.

08 HYDROGEN↗

Thermal Evaluation of CCS and NACS Reference Devices and Adapters

A review of NLR's work in charging system reliability for charging inlets, connectors, and adapters. The review includes a detailed discussion on (a) the development of a reference device for the thermal performance of charging connectors and adapters, (b) evaluation of charging adapters and their thermal warning and shutdown response, (c) implications of side-load from real-world implementations, and (d) strengthening the conformance evaluation for end caps based on field data.

33 ADVANCED PROPULSION SYSTEMS↗

Scalable GPS Data Logging To Support Advanced Fleet Analysis

This highlight details the key takeaways from a project that utilized NLR's Fleet Research, Energy Data, and Insights (FleetREDI) data analysis pipeline. National Laboratory of the Rockies researchers developed and demonstrated low-cost, open-source Arduino data loggers with 3D-printed cases that are compatible with global navigational systems and built with components available ubiquitously worldwide, enabling cost-effective collection and analysis of fleet operational data. Validated on an overseas transit bus fleet, NLR analysis showed that, with sufficient charging opportunities, 90% of observed duty cycles could be accomplished by electric buses with no modifications to operations.

33 ADVANCED PROPULSION SYSTEMS↗

Two-Phase Cooling for High Packaging Density Planar Inverter: Cooperative Research and Development Final Report, CRADA Number CRD-15-00592

The project objective was to utilize two-phase heat transfer to enable compact and power-dense inverters. The high heat transfer capacity and near isothermal characteristics of two-phase cooling can enable higher power densities, reducing the size and cost of the power electronics system. This project focused on developing efficient, passive (no pump or compressor) two-phase cooling strategies that consist of an air-cooled condenser and evaporator. This report describes the modeling work conducted to design the evaporator and air-cooled condenser for a prototype inverter development work underway in the John Deere. Prototypes of the final evaporator and condenser designs were then fabricated via 3D printing for testing. Experiments on the evaporator confirmed that this component can meet the heat load and junction temperatures requirements for Si IGBT (insulated-gate bipolar transistor) inverter. Experiments with the air-cooled condenser were not possible due to leaks through the condenser walls.

33 ADVANCED PROPULSION SYSTEMS↗

Cobalt-Free Lithium and Manganese Rich Cathodes for Electric Vehicle Applications: Influence of Inherent Properties on Temperature-Dependent Performance

Lithium- and manganese-rich (LMR) oxides are attractive options as next-generation, earth-abundant cathodes. Despite inherent properties that result in less-than-ideal performance, advancements in this class of cathodes toward commercialization have been steady. Herein, we report a benchmark study on the influence these inherent properties exert on the discharge rate of Co-free, LMR//graphite (Gr) cells as a function of temperature. Because low-temperature performance is an essential consideration in the design of electric vehicle cells, understanding the limitations of current LMR systems is essential in understanding their current applicability as well as strategies for improvement. This work identifies two major limitations in the rate performance of LMR//Gr cells and suggests several areas of focus where practical strategies may provide improvements.

25 ENERGY STORAGE↗

Investigate the Security of Electric Vehicle (EV) Ecosystem Applications

Apps that run on mobile devices are one of critical components of the electric vehicle (EV) ecosystem and pose possible threat actor points of entry that may impact the trust and security of EV charging systems in the future. Mobile apps often rely on communication between cloud servers and users, thereby creating potential points of entry for cyberattacks. Although app stores such as Apple App Store or Google Play Store generally test the security of apps, the cyber aspects may not be sufficient for many entities including DOD, federal fleets, and commercial entities. A more thorough inspection and the ability to influence developers is imminently needed. This research studies security attributes and vulnerabilities of a sample of mobile applications that support key user functions in the EV ecosystem. The study shows that all analyzed apps have security risks, categorized as either high or medium or both and a comprehensive cybersecurity guideline for developing mobile apps is necessary.

33 ADVANCED PROPULSION SYSTEMS↗

NLR Core Modeling & Decision Support Capabilities: FASTSim, RouteE, T3CO & OpenPATH

This project is part of the program area to develop and improve core capabilities for the Energy-Efficient Mobility Systems (EEMS) program that enable research, development and deployment of advanced mobility solutions and enhance the EEMS Program's ability to address system-level transportation challenges. Advancements to the Future Automotive Systems Technology Simulator (FASTSim), Route Energy Prediction Model (RouteE), Transportation Technology Total Cost of Ownership (T3CO) and Open Platform for Agile Trip Heuristics (OpenPATH) core capabilities under this project supports the overall EEMS Program goals to effectively evaluate energy and mobility impacts of future transportation technologies and services, and to identify the most promising pathways to reduce transportation costs and environmental harms, and to improve mobility access. This presentation was prepared for the 2026 Annual Merit Review of this project.

33 ADVANCED PROPULSION SYSTEMS↗

Power Electronic Development Challenges for High Power Density Integrated Electric Drive Applications

The ever-increasing demand for compact, efficient, and high-performance traction drive systems for transportation applications has accelerated the development of integrated electric drives. In these systems, the electric machine and inverter are integrated within a single housing, offering significant advantages in electrical performance, volume, weight, cost, and overall system efficiency. Despite these benefits, such high levels of integration introduce a new set of challenges, particularly in power electronic design and component selection. This article presents an in-depth investigation of a highly integrated electric drive architecture with an internal stator-mounted inverter, highlighting key design considerations and trade-offs aimed exclusively at maximizing system power density.Based on a comprehensive review of the literature, the power density of a voltage-source-inverter-driven electric drive is primarily governed by the volumetric contributions of the power modules, heat sinks, and DC-link capacitors. Accordingly, this work focuses on the optimization of these three critical components to enhance the inverter's overall power density. The proposed design achieves a power density of 100 kW/L, demonstrating the effectiveness of the presented approach for next-generation integrated electric drive systems.

33 ADVANCED PROPULSION SYSTEMS↗

2025 InterPACK: Thermal Management and Reliability Aspects

The presentation will provide an overview of automotive power electronics and electric machines thermal management systems that are typical for light-duty vehicles. Unique thermal and environmental aspects related to medium and heavy-duty vehicle applications will then be discussed. Finally, advanced thermal management and packaging technologies that could be evaluated and used in this project will be described.

33 ADVANCED PROPULSION SYSTEMS↗

Optimal hybrid power plants for electric vehicle charging demand

Transmission constraints, increasing motivations to decarbonize, and concerns over peak electric vehicle (EV) load impacts on local grids have driven electric customers to consider behind-the-meter, hybrid power plant generation and storage at the distributed-grid level for EV charging. In this study, we develop capabilities to optimize hybrid power plant component capacities for EV charging. We then demonstrate these capabilities in a case study for Boulder, Colorado, using public EV charging data as well as wind and solar resource data. Our results show system designs that balance the cost of energy with load-meeting and peak shaving performance. Within the case study, systems designed for wind, solar photovoltaic (PV), and storage resulted in lower cost of energy than those optimized for PV and storage only. This indicates that in areas where wind resource exists, hybrid power plants that include wind, PV, and battery assets can better meet EV charging loads (including peak loads that are prone to overloading local grids) than PV and battery assets alone. Future work to address limitations in this paper include extending cost modeling to include performance losses (e.g., based on operations or weather) and charging station costs to estimate levelized cost of charging, and quantifying uncertainty and error in our aggregation methods for estimating EV charging loads at the hourly timescale.

14 SOLAR ENERGY↗

Recommendations for Minimum Required Diagnostics Information

The rapid growth of electrified transportation, including light- and medium-duty electric vehicles (EVs) as a mobility solution requires a reliable EV-charging infrastructure. To advance charging reliability, the ChargeX Consortium reports “Recommendations for Minimum Required Error Codes for Electric Vehicle Charging Infrastructure” and “Implementation Guide for Minimum Required Error Codes in Electric Vehicle Charging Infrastructure” provided recommendations for a set of minimum required error codes (MRECs), their functional and responsibility classifications, and a guide for their implementation, using Open Charge Point Protocol (OCPP) versions 1.6J4 and 2.0.1.5 These reports outline a recommended practice for consistent error reporting and interpretation, which is essential for communicating issues uniformly across the complex and diverse EV-charging ecosystem. However, MRECs are just one part of diagnosing issues; another critical part is obtaining enough information about the current state and performance of the various charging components to identify root causes for each of the error codes. This additional diagnostics data can be used by technicians or automated systems to understand the context around an issue, allowing for timely resolution, decreased maintenance costs, and increased charging reliability. During everyday operations, data are regularly collected and analyzed across the ecosystem. Although sharing of all that available data would be great for diagnostics, concerns on data ownership, privacy, and original equipment manufacturer (OEM) intellectual property pose a challenge. To overcome this obstacle, this report proposes a set of minimum required diagnostic information (MRDI) and recommends that the industry implement these uniformly across the North American EV charging ecosystem. MRDI provides a means to exchange only data deemed necessary for root cause determination.

33 ADVANCED PROPULSION SYSTEMS↗

A Vision–based Robust $\mathcal{H}$ ∞ Gain Scheduling Longitudinal and Lateral Following Controller for Autonomous Vehicles on Urban Curved Roads

Implementing advanced driver assistance systems (ADAS) in congested and intricate urban traffic scenarios poses significant challenges. To address the frequent stop–and–go motions exhibited by autonomous vehicles (AVs) navigating urban roads with changes in curvature, we propose a vision–based robust $\mathcal{H}$ ∞ adaptive cruise control system (ACC) for longitudinal control, plus a lane keeping assist system (LKAS) for lateral control. For the vision-based ACC, a weighted probability objective function for the vehicle following behavior is formulated. We incorporate $\mathcal{H}$ ∞ performance and gain scheduling techniques to mitigate the impact of uncertainty in visual sensor measurements. Furthermore, the optimal time headway is scheduled based on the velocity to ensure traffic flow efficiency and safety during the vehicle following process. For the LKAS, we introduce a road curvature estimation method that integrates lane and vehicle dynamics information to obtain the lateral and heading offsets. Next, the design criterion of the observer–based robust gain scheduling lateral motion controller is established by linear matrix inequality (LMI). Here, a series of experiments conducted within a camera–in–loop platform validate the proposed method.

33 ADVANCED PROPULSION SYSTEMS↗

A novel electro-hydraulic unit design based on a shaftless integration of an internal gear machine and a permanent magnet electric machine

In recent years, increasingly stringent emission regulations have spurred an electrification trend in off-highway vehicle technology. To address challenges such as the high cost of power electronics components, limited battery capacity, and the substantial modifications required for the vehicles, there is a pressing need to develop high-speed, cost-effective, compact, and efficient electro-hydraulic units capable of powering vehicle functions. In response to these demands, this paper introduces an innovative morphology for an electro-hydraulic unit and outlines the integration method for a crescent-type internal gear machine with a permanent magnet synchronous electric machine. The proposed morphology aims to minimize component count through a shaftless solution while incorporating a cooling system that utilizes the same working fluid as the hydraulic machine. The design approach utilizes a genetic algorithm optimization process to maximize overall energy efficiency and compactness. Insights gained from the optimization results shed light on the relationship between key design parameters and unit performance, enhancing the understanding of this electro-hydraulic unit. A prototype of the unit was manufactured and tested, demonstrating a volumetric efficiency ranging from 81 % to 97 % at a maximum rotational velocity of the pinion of 6000 rpm. Finally, these results validate both the morphology and the design approach, indicating the feasibility of designing compact electro-hydraulic units that leverage hydraulic machines with higher maximum rotational velocities than commercially available counterparts as a mean to enhance efficiency and compactness.

30 DIRECT ENERGY CONVERSION↗

High-Fidelity Analysis of EV Integration on Real Utility Feeders in Colorado

Residential electric vehicle (EV) charging has the potential to alter long-held assumptions on load characteristics impacting distribution grid planning, operations, and design standards. This study identifies analysis and control methods to increase the affordability of residential EV charging both for Xcel Energy and their customers. The project also provides solutions for more reliable grid interconnection that can support a reliable utility business model prepared for increasing EV charging load in the coming years. For this project, we referenced Level 2 alternating current (AC) onboard charging profiles for various vehicle models and high-fidelity charging data collected at the experimental setup established at the EV Research Infrastructure Laboratory at the National Renewable Energy Laboratory (NREL). Next, we developed EV adoption models for 2030 and 2040 for the Boulder and Aurora regions in Colorado. Moreover, we evaluated different smart charging control algorithms and compared their performance. We developed time-of-use (TOU)-based and grid-aware active EV charging control methods and integrated them within the study region to understand field impacts. Diving deeper, we selected 10 feeders in Boulder and Aurora for high-fidelity grid modeling down to the house level. We executed detailed grid analysis comparing the smart charge management (SCM) algorithms we developed. Finally, we created a novel tool, Electric Vehicle Infrastructure--Distribution System Integration Tool (EVI-DiST), to integrate all the approaches in a single software environment to provide easy integration, fast simulation, and detailed evaluation capability for utility engineers and other stakeholders.

33 ADVANCED PROPULSION SYSTEMS↗

High power density compact drive integrated motor for electric transportation

This project, initially part of OPEN 2018, and subsequently the ASCEND effort, targeted demonstration of significant enhancements in internal permanent magnet (IPM) motor torque and power density for current and future ground and air electric transportation applications. These were achieved through: (1) embedded two-phase system thermal management, (2) coupled, multi-scale electrical-electromagnetic-thermal-mechanical co-design and optimization, (3) size and weight reduction of motor and drive electronics through elimination of redundant cooling and coupling hardware, and (4) higher efficiency operation of SiC wide bandgap power electronics packaging through high temperature operation (200 oC). The proposed approach utilizes a single dielectric coolant for closed loop two-phase thermal management, and a combined heat rejection unit for the IPM and drive. Wick assisted liquid delivery for evaporative thermal management is utilized for the motor, and the drive electronics utilize the same coolant in flow boiling within the cold plate structures. Through the use of three-dimensional packaging for SiC, and novel drive topologies with reduced switching losses, significant increases in power density and compactness were targeted.

33 ADVANCED PROPULSION SYSTEMS↗