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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 217 records · Page 12
All sourcesNASA NTRSDOE OSTI
DOE OSTI2019

Topological order in matrix Ising models

We study a family of models for an N_1 \times N_2 N 1 × N 2 matrix worth of Ising spins S_{aB} S a B . In the large N_i N i limit we show that the spins soften, so that the partition function is described by a bosonic matrix integral with a single ‘spherical’ constraint. In this way we generalize the results of to a wide class of Ising Hamiltonians with O(N_1,\mathbb{Z})\times O(N_2,\mathbb{Z}) O ( N 1 , ℤ ) × O ( N 2 , ℤ ) symmetry. The models can undergo topological large N N phase transitions in which the thermal expectation value of the distribution of singular values of the matrix S_{aB} S a B becomes disconnected. This topological transition competes with low temperature glassy and magnetically ordered phases.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2020

Implementing Admittance Relaying for Microgrid Protection

An earlier study evaluated issues with microgrid protection. This highlighted the difficulties with microgrid protection, which include: 1. lack of fault current from inverter-interfaced generation, 2. varying fault current between grid-connected and islanded modes, 3. potential for normally-meshed operation and 4. unbalanced operation due to single-phase loads. It is worth noting that not all microgrid designs will include all these challenges. For example, microgrids could choose to omit meshed operation. Previous work identified differential protection based on the discrete S-transform for line protection and admittance protection for load protection as possible solutions . However, some severe limitations were identified. This included the potential for blinding of the discrete S-transform protection when fault contribution on either end of the line is similar, and loss of protection selectivity for admittance protection in the case of upstream line-ground faults. This report investigates admittance protection as a solution for line and load protection in greater detail by comparing analytical and simulated results. Section 2 describes the protection schemes analyzed and the behavior of inverter-interfaced microgrids under faults in more detail. Section 3 derives sequence networks for the fault cases considered. Section 4 presents a transient model constructed to validate the impedances calculated from the sequence networks. Section 5 compares the results from the sequence networks and transient model. Last, Section 6 presents the conclusions of this study in terms of the suitability of admittance relaying for protection of inverter-interfaced microgrids.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2020

Real-Time Adaptive Machine Learning Platform

As part of the Cyclotron Road program, Dauntless.io, Inc. extended its existing ultrafast (0.00001 – 0.001 second) real-time, adaptive machine learning platform for modeling & control of complex, high-value physical systems. Objectives included ability to scale ubiquitously & remain differentiated on a 5+ year horizon in the highly competitive, AI / machine learning market — a rapidly growing market that (overall) is estimated to be worth $191 B by 2024 at a CAGR of 37%.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2020

Molten Salt Reactor Experiment Benchmark Evaluation

As one of the six advanced reactor concepts selected by the 2002 Generation IV roadmap as a technology meriting future research, Molten Salt Reactors (MSRs) attracted broad attention and multiple private and public entities are working towards its commercialization. Facing stringent regulatory requirements, validations of computational codes used to calculate and prove the safety characteristics of MSRs play a key role. This project developed the world-first, MSR-related reactor physics benchmark based on a series of zero-power experiments conducted at the Molten Salt Reactor Experiment (MSRE). The benchmark was successfully reviewed by the International Reactor Physics Experiment Evaluation Project (IRPhEP) committee and is available in the IRPhEP handbook starting form the 2019 edition. To benchmark experimental data from the MSRE, a three-dimensional high-fidelity model was developed using the Monte Carlo neutron transport code Serpent 2 and ad-hoc methods have been implemented to account for the unique feature of fuel salt motion. The calculated effective multiplication factor, k eff , for the first criticality experiment, when 235 U was progressively added to the fuel salt in order to achieve criticality with stationary salt and isothermal conditions, was 1.02132 (±3 pcm). The total uncertainty for experimental k eff was estimated to be 420 pcm. The calculated k eff is 2.154% larger than the experimental and benchmark model value, which is approximately five times the benchmark model uncertainty. It is to be noted that, for systems containing large volume of graphite (or other carbonaceous materials), Monte Carlo codes tend to overestimate the keff of the benchmark model by 1% to 2%. The bias is possibly due to uncertainties in the impurity content of the graphite blocks, uncertainty in the neutron capture cross section of carbon or uncertainty in the properties of nuclear-grade graphite. The calculated reactivity coefficient of 235 U concentration (0.2228 ± 0.0014, represented as the change of reactivity over the relative change of 235 U mass in loop) matches well with the experimental value (0.223 ± 0.006), strengthening the confidence on the accurate representation of the fuel salt composition in the MSRE benchmark. Additional reactivity effect calculations, including the control rod bank worth, reactivity effects of fuel circulation and isothermal and fuel temperature coefficients show good agreement with the experimental values (within 1σ) as well.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2020

Dial-A-Cluster User Manual

The Dial-A-Cluster (DAC) model allows interactive visualization of multivariate time series data. A multivariate time series dataset consists of an ensemble of data points, where each data point consists of a set of time series curves. The example of a DAC dataset used in this guide is a collection of 100 cities in the United States, where each city collects a year's worth of weather data, including daily temperature, humidity, and wind speed measurements.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2020

A Handbook for Designing, Implementing, and Evaluating Successful Electric Utility Pilots

Since at least the late 1970s, electric utilities and their regulators have recognized the value of experimentation to motivate innovation. The industry has a long history of using pilots to help inform future decision making about electric utility rates, customer technology adoption and integration, and even changes to the utility’s regulatory or business model. Although utility pilots have become almost ubiquitous proving grounds for new rates, technologies, and alterations to the traditional utility regulatory and business model, some regulators are beginning to raise questions about what constitutes a “good” pilot. Much has been written about utility pilots over the years; however, what is missing from the literature is the identification of a comprehensive process for not only designing and evaluating a pilot, but also implementing, successful utility pilots that provide actionable outcomes upon which more informed decisions can be made. This report provides a step-by-step process that regulators, policymakers, and utilities can follow to help promote a more successful pilot, even if whatever is being tested fails to produce the intended or expected result(s). It is worth noting that this report is not intended to serve as a technical resource for those designing, implementing, and evaluating pilots. However, there are myriad references provided for those wishing to delve deeper into the technical details.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2020

EXPERIMENTAL INVESTIGATION OF IMPACT AND ABRASION EROSIONS AT LOW VELOCITIES AND COMPARISON TO CFD SIMULATIONS

Wear and erosion damage of materials due to interaction of the surface with solid particles is a major issue in various industries. This phenomenon is common in mining, and oil and gas production, causing damages worth millions of dollars annually. Erosion is becoming a critical issue in renewable technologies as well such as concentrated solar thermal power (CSP) systems. In some CSP systems, solid particles can be used to absorb solar energy and enhance the heat storage. However, these particles may cause significant amount of wear to system components while falling down the power tower at high temperatures. This damage can be costly, and therefore, investigating solid particle erosion in CSP systems is of utmost importance. In collaboration with Sandia National Laboratories, the erosion durability of particle-based Generation 3 (GEN3) CSP system are being investigated both experimentally and numerically. In order to develop models to predict the life time of such systems, erosion under low temperature and low particle impact velocity conditions are investigated. Impact erosion and abrasion erosion experiments are conducted for low velocity and low temperature conditions for various candidate particles and containment materials. The impact erosion testing is conducted for three different containment material including Stainless Steel 316, special refractory material, and Inconel 740H with CARBOBEAD HSP 40/70 ceramic particles and UNIWEST 430 silica quartz erodent particles. All this data will enable us to better model the erosion behavior of these materials and provides a data base to investigate erosion at high temperatures experienced in CSP systems. At low temperatures and low velocities the softer refractory material exhibited greater erosion by an order-of-magnitude when compared to the harder Inconel 740H and Stainless Steel 316 materials. The overall erosion ratio for all the candidate materials was of the order of 10 -7 kg/kg. We also investigated wear in containment materials from sliding of particles over the surfaces at very low angles, also referred to as abrasion. For the velocities expected in a typical 1MW CSP plant, visible surface wear was noted, but the overall mass loss per unit surface area was found to be dependent on the hardness of the containment material tested. In this manuscript, we also present Computational Fluid Dynamics (CFD) simulations and erosion prediction of low velocity impact erosion. These results are compared with the experimental data to evaluate the ability of available erosion models for predicting erosion under these conditions.

14 SOLAR ENERGY↗
DOE OSTI2020

Tribal Renewable Energy: Bishop Paiute Tribe, Residential Solar Program Phase II (Final Report)

The project consisted of the design, installation, inspection, and interconnection of 35 grid-tied, solar electric systems, totaled 123 kW rated capacity, on qualified existing low-income single-family homes located within the Bishop Paiute Reservation, which provide at least 65-79% savings in displaced electricity. Tribal job trainees were hired for each installation, gaining valuable job experience. Additionally, each homeowner was educated on energy efficiency and renewable energy. The overall project goal was to deploy clean energy systems in order to achieve the Bishop Paiute Tribe’s long-term goals of energy self-sufficiency, environmental protection, and better lives for our Tribal members and community. The energy displaced was 82.4 percent of total electricity used (exceeding estimated 65-79%)or over 170,000 kWh/year generating approximately $1.29 million worth of power for low-income families over their lifespans, while eliminating an estimated 2,640 tons of greenhouse gas emissions. This reduction makes a significant difference on the reservation giving more families money to spend on other essential items, while reducing their carbon footprint in this beautiful mountain community. Also, implementing these 35 systems provided a approximately 132 hours of paid solar installation work for tribal members. Training and good paying jobs are scarce on the reservation and solar is the fastest growing industry in CA and this training offered our members a real chance to learn and then get paid. The program is very significant to the family who qualified, as most families fall below the federal poverty guidelines, and many are living paycheck to paycheck. Overall, the triple impact of the Bishop Paiute Tribe Residential Solar Program Phase II— affordable energy for low-income families, on-site clean energy production, and hands-on solar installation jobs for local workers—these all help build the Tribe’s energy, economic, environmental, and social self-sufficiency and sovereignty amongst the most needy on the Reservation

14 SOLAR ENERGY↗
DOE OSTI2020

RELAP5-3D Modeling of High Temperature Test Facility (HTTF) Test PG-26

The High Temperature Test Facility (HTTF) at Oregon State University (OSU) is a scaled integral effects experiment designed to investigate transient behavior in high-temperature gas-cooled nuclear reactors with prismatic fuel and reflector blocks. Several tests have been completed, and more are still planned to at the HTTF, including depressurized conduction cooldown (DCC) and pressurized conduction cooldown (PCC) transients. This report analyses test PG-26, a progression of the Double Ended Inlet-Outlet Crossover Duct Break transient that is referred to as a DCC. PG-26 has been performed at the HTTF between May 30 and June 30, 2019. Core initial conditions (i.e., before the DCC started) have been met using low power (<100 kW) and two of ten available electric heaters. The DCC transient was initiated during the 50 th hour of the test. The break valves were opened, and hot helium from the core and cold helium from the reactor cavity simulation tank (RCST) started mixing. The gases flowed in a countercurrent fashion, where the top half of the hot duct contained hot helium that flowed in one direction and cold helium that flowed in the other direction in the bottom half of the duct. After the pressure and density reached equilibrium, the event entered a diffusion mode. The onset of a reverse natural circulation was not observed during the DCC period of the test. Version 4.4.2ie of the RELAP5-3D computer code has been used to model the HTTF PG-26 test, and results have been compared to available high-quality measured data. The model used in this study is the quality-controlled HTTF RELAP5-3D model (HTTF base 2018-04-19 QA), originally developed by P. Bayless. The report includes RELAP5-3D results of the “base calculations” as well as some sensitivities to important uncertain model inputs, such as primary helium mass flow rate, core ceramic thermal properties, as well as heat evacuation and loop friction models. Using the base RELAP5-3D model predicts a countercurrent helium flow in the hot duct observed at the beginning of the DCC, but instead of going into a molecular diffusion mode, the model predicts the onset of natural convection. Increasing friction in the core and hot duct prevents the natural convection from happening in some of the simulations. Although some temperatures are well predicted (and even overpredicted), the general tendency is to underpredict the ceramic and helium temperatures and heat removal rates during the DCC, resulting in many of the assessment findings being in minimal or insufficient agreement with the data. It is worth noting that the described discrepancies between measured data and RELAP5-3D predictions are not RELAP5-3D code limitations. More so, they reflect limitations in boundary condition and thermal property knowledge. While the RELAP5-3D calculations of the test provide some insights into what happens during the transient, and point to missing or potentially uncertain data to which the experimenters can direct their attention, the principal conclusion is that the PG-26 test data are insufficient for a system code assessment.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2020

Fleet-wide Electrification Impacts Assessment for the Valley Transportation Authority

This report explores the long-term electrification opportunities for the Valley Transit Authority’s (VTA) transit bus fleet. The potential for transit bus electrification at VTA as well as the economic impacts of partial and complete electrification are explored. We use the Revenue Operation and Device Optimization model to determine the optimal charging, operation and lowest capital and operating cost solution to achieve different levels of electrification to meet their existing routes. This study finds that, relying on only depot charging, around 70% of the daily trips by VTA’s transit bus fleet can be replaced with battery electric buses (BEBs) today. The benefits and drawbacks of five methods for improving the electrification potential beyond that achievable with only depot charging are discussed including (1) increase charger power, (2) purchase of larger vehicle batteries, (3) en-route charging, (4) purchasing additional buses and swapping them to enable the existing routes/blocks1 to be met, and (5) route/block redesign. A strategy is developed to enable full fleet electrification by increasing charger power or allowing intraday charging as a proxy for the options mentioned above. This method allows us to develop an understanding of the impacts and trade-offs of full fleet electrification. Two charging strategies are examined. Immediate charging, when the bus is charged as soon as it arrives at a depot or en-route charging station, and smart charging, which uses a controller to determine the best times to charge to achieve the lowest charging cost, while maintaining the same trip schedules. Smart charging is effective at reducing the peak power consumption, which can be reduced by between 31% and 65% compared to immediate charging. This translates directly to lower electricity demand charges and lower costs for possible distribution system upgrades. The total lifetime net present value (NPV) costs for different scenarios are presented in Figure ES-1. Scenarios are separated into three sections. The first stacked bar on the left is the base case (business-as-usual) where all buses are diesel hybrids, the next four bars include partial and full fleet electrification utilizing only immediate charging, and the last four bars include partial and full fleet electrification utilizing smart charging. The results show that smart charging scenarios are within ±4% of the lifetime NPV cost of the diesel-hybrid only (business-as-usual) scenario. The scenarios with full fleet electrification (i.e., including intraday charging) are 4% lower cost and those with partial fleet electrification (i.e., without intraday charging) are 2%–3% higher. However, it is important to note that the intraday charging scenarios do not include any additional costs for the equipment necessary to achieve intraday charging (e.g., additional chargers, larger batteries, new route design). Additionally, it is worth noting that the Low Carbon Fuel Standard (LCFS) credit received for implementing electric buses is essential to achieving these results.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2020

Status Report on IES Plug-and-Play Framework

This report discusses the status of the flexible plug-and-play framework development currently ongoing that aims to integrate Modelica/Dymola with the Risk Analysis and Virtual ENviroment (RAVEN) software in terms of both Functional Mock-Up Interface (FMI)/Functional Mock-Up Unit (FMU) construction and repository structures that aim to ease the sharing and simulation of complex dynamic models. This report provides discusses the FMI/FMU adaptors that have been created within the HYBRID repository to allow users to quickly export models as FMUs. Several examples are shown that highlight the step-by-step process of converting an existing Modelica model into an FMU for use within the Dymola platform. Simulation results demonstrate that, while minor differences may occur, the overall control, trends, and solution integrity is maintained between standard Modelica simulation and FMU simulation results. However, it is worth noting that, for small systems, the FMU results have a slower simulation time than the Modelica only simulation. Using this process, a company can provide models that contain proprietary information to entities without disclosing any of the information about the model that could be considered business sensitive. Such an ability would allow institutions to bypass the necessity of “whitewashing” data. In addition to the investigative work being conducted on FMUs and FMIs, a series of updates to the hybrid repository has been completed. These updates include the addition of Modelica system-level regression tests and software quality assurance documentation that ensure that modifications to the Modelica models do not alter system-level model results. Overall, extensive work has been completed on developing FMUs and FMIs from existing models, understanding the requirements and limitations of FMUs, and opensourcing the HYBRID repository with an integrated regression system.

99 GENERAL AND MISCELLANEOUS↗
DOE OSTI2021

A Hierarchical Gibbs Sampler for Spatially Varying Multi-Regularization Image Reconstructions

This is a presentation for SIAM's (Society for Industrial and Applied Mathematics) conference on computational science and engineering. This presentation describes research on novel techniques to deblur images under a Bayesian framework. The title of the conference is SIAM Conference on Computational Science and Engineering (CSE21). This is a VIRTUAL conference; it was originally scheduled in Fort Worth, TX. The conference dates are March 1-5, 2021. The link to the conference's website is https://www.siam.org/conferences/cm/conference/cse21

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2020

Data-Driven Understanding of Low-to-Moderate Income Customers’ Adoption and Financial Qualification in Community Solar (Final Technical Report)

When Solstice began working in the community solar industry, it quickly became clear that there was a wide disparity along race and class lines in terms of what kind of household traditional solar offerings benefited. Solstice is an organization that aligns itself to the principles of a Just Transition, or the concept that a transition to a green economy should benefit and prioritize historically marginalized groups of people. Given that low-income communities are disproportionately burdened by our current polluting fossil fuel economy, Solstice set out to investigate the root causes of the exclusion of low to moderate income (LMI) households in the community solar market. As we worked more and more with financiers, developers, and LMI households, we recognized that significant barriers to entry in a developer-owned project were credit threshold requirements. A FICO score of 750 and higher discriminates against LMI households that are not financially stable enough to take on multiple lines of credit (or who may not have been deemed credit worthy enough to access a line of credit) yet who may have been reliable utility customers. As Solstice began looking further into preliminary data and speaking to community-based organizations (CBOs) that serve LMI households, we found our hypothesis to be worth investigating; there was indeed a subset of LMI households with poor FICO scores (or no FICO score at all) that had perfect bill payment history. Though initially Solstice was intent on gathering a body of data to prove or disprove this hypothesis, we were also concerned that all this proof of a financially stable and reliable customer was not being incorporated into FICO, and wondered if such a score would be possible. After preliminary research into the existence of alternative scores, Solstice realized that many mission-driven lending institutions rely on alternative metrics that are formulated for their specific industry. However, we also realized that community solar did not have an alternative credit underwriting mechanism, though there was great need from solar financiers for one. We anticipated that the creation of an EnergyScore would contribute to financiers’ need to qualify more people, as these entities are desperately looking for ways to lower the cost of customer acquisition. FICO turns away nearly 50% of potential customers (according to our own acquisition experience), and much of the community solar industry is realizing that FICO is not the perfect qualifying mechanism. Additionally, with a grounding in energy justice, just transitions, and climate justice, Solstice recognizes the need for a solution that addresses a more urgent need for LMI households to access renewable energy savings and relieve energy burdens. With funding from the Department of Energy, we gathered the data necessary to build the EnergyScore, reached out to mission-driven developers willing to test the metric, and secured several demonstration projects to pilot the EnergyScore. After acquiring customers for these demo projects using the EnergyScore, we will be continuously collecting customer payment behavior data. Though it goes beyond the scope of this project, we plan to disseminate this de-identified data with the wider community solar industry, which includes not only financiers and developers, but other mission-driven nonprofits, solar cooperatives, community-based organizations, environmental justice activists, and academics. While we intend to disprove the notion that LMI households cannot be included in projects without acutely increasing the risk to project finances, we also hope the data can be used to negotiate better pricing of systems and terms of ownership for community groups seeking to build inclusive projects.

14 SOLAR ENERGY↗
DOE OSTI2021

Classified library critical in Lab’s Annual Assessment of weapons to U.S. President. National Security Resource Center’s collections are the foundation to stockpile confidence

One of the most important accomplishments every year at LANL is a letter sent by the Laboratory Director that ultimately reaches the President of the United States. The subject is the current state of the weapons for which the Lab is responsible. Known as the Annual Assessment letter, it is a culmination of nearly 14 months’ worth of work and the contributions of more than 1,000 Lab staff members. Its classified contents come from the Lab’s Annual Assessment, which is an approximately 100-page document evaluating the safety, security and effectiveness of the stockpile.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2021

Be like Oppenheimer: Donate your weapons information for the next generation of LANL researchers

You can follow the Lab’s first physicists, J. Robert Oppenheimer, Richard Feynman, Hans Bethe, and so many others through the years, plus know your information is helping future researchers — just like our first scientists did for you. How? Donate your physical or digital classified weapons records to the Lab’s National Security Research Center (NSRC), said Riz Ali, NSRC Director. The NSRC houses 80 years’ worth of one-of-kind records, which total in the millions and include nearly every medium imaginable. It is the Laboratory’s largest collection of research materials and the largest classified library of any Department of Energy lab. It all started with Oppenheimer, our first Lab director, and his Technical Library that was established during the Manhattan Project, which was the U.S. government’s top-secret effort to create the first atomic bombs to help end World War II. “Few NSRC patrons are aware that most of its vital materials come from the Lab’s own workforce,” said Chris C’de Baca, the NSRC’s Group Leader. “A significant portion of our critical material — which today’s researchers access regularly — is a direct contribution from research scientists. If people don’t contribute, then we won’t have the information we need when people come to the NSRC for research.”

96 KNOWLEDGE MANAGEMENT AND PRESERVATION↗
DOE OSTI2021

Transportation Hub Infrastructure Expansion: Decision Support Under Uncertainty

The Athena project (www.athena-mobility.org) has worked to investigate the relationship between the Dallas-Fort Worth Airport (DFW) and the greater Dallas area in order to better understand and therefore better inform future decision-making regarding the critical infrastructure that influence mobility between the airport and the city. Through this work, infrastructure related to curbside pickup and drop-off, parking, public transit, and the road network congestion were identified as critical to the operation of the DFW transportation hub. The infrastructure analysis and expansion aspect of the Athena project is focused on the restructuring of the CTA curb as a hierarchical curb and the building or repurposing of parking infrastructure as the interplay between these two areas. Many sources of uncertainty exist that may impact future airport and transportation hub operations, such as passenger volume growth, population demographic changes over time, electric vehicle (EV) adoption rates, and autonomous vehicle (AV) adoption rates. Due to these sources of uncertainty, we have selected for our research a modeling framework that can capture various types of uncertainty and hedge against those uncertainties in the optimization process. We analyze road network and curb congestion, the rise of transportation networking companies, trends in parking usage, existing policies around this infrastructure, airport revenue streams, and other contributing factors to enable infrastructure decision making with less uncertainty. To accomplish this wholistic analysis, we have developed a novel multi-stage, multi-period stochastic optimization model which considers the airport's decisions from 2025-2045 under different possible future macro trajectories and day-to-day variations in operational conditions captured as "annual representation of operations" scenarios with respective probabilities. This model has also been designed to leverage the outputs of various efforts under the Athena project to create a combined decision framework for infrastructure decisions. These various efforts include the route optimization model, the ASPIRES simulation, the mode choice model, and the SUMO traffic simulation. Our computational experiments of this system at scale have resulted in a working version of our infrastructure model which enables the explicit representation and consideration of various sources of uncertainty in the decision process to enable robust, flexible decision-making. This model has been effectively run on NREL's HPC system, Eagle, with large numbers of stochastic scenarios and shows promise as a scalable tool for robust consideration of uncertainties in airport planning. We have tested our model using 30,240 operational circumstances in total, resulting in a problem with more 200 million variables. This model was solved in several different configurations, and a workflow to simulate the performance of the infrastructure model results was developed and deployed. In general, our results indicate that a combination of remote parking, remote curb infrastructure, and dynamic pricing can generate revenue, reduce emissions, accommodate emerging technologies such as AVs and EVs, and manage airport passenger growth over time. We note the success of the proposed strategy depends on the data collection and forecasting abilities of DFW. We have also seen that the AV adoption by TNCs might necessitate larger amounts of remote curb. The results of this work inform strategies for airport infrastructure decision making, as well as demonstrate the value of an adaptable model, but also indicate that there are avenues remaining where further research would be of value.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2021

Regal Beloit Final Technical Report

The original project proposal submitted from NovaTorque Inc (NovaTorque) in 2016 was to improve the existing motor with 95% efficiency by reducing the losses by 21% to achieve 96%. A few months after the proposal was submitted, NovaTorque lost funding and went out of business. The assets of NovaTorque were then acquired by Regal Beloit Corporation (“Regal Beloit” or “Regal”). When the NovaTorque proposal was selected, the project was transferred to Regal Beloit. Once we had production samples from the new Regal production line, they were tested at the Regal Beloit test lab in Wausau, WI. The original NovaTorque motor had an efficiency of 95%, but when the technology was transferred to Regal Beloit, there were multiple manufacturing improvements made, even though the basic electromagnetic design did not change. The test results in Wausau showed that the motors made at the Regal Beloit plant had an efficiency of 96%. Since the goal of the project was to reduce the losses by 21%, a new efficiency target of 96.8% became the project objective. In the first budget period, motors were tested to get the baseline performance. We then used FEA modeling with ANSYS Maxwell to model the existing motor to get correlation between the FEA simulations and the actual test results. Once the model was validated, we evaluated some changes that could be made to the stator to reduce the losses and improve efficiency without changing the rotor or stator housing, keeping the modifications easy to implement. The changes were primarily in the area of making the stator axially shorter and adding Soft Magnetic Composite (SMC) tooth tips. In the second budget period, we proceeded to design and build the new stator that was identified above and identified additional improvements in the process that included a stator machining modification and the use of rectangular wire. When we actually built the motor, the choice of rectangular wire turned out to be a problem. The wire was made by squishing round wire to get the rectangular shape, which caused work hardening, making the wire too stiff to make the desired coils. We shifted to annealed square wire which was better, but we still could not maintain the proper coil envelope. The result was that we had reduced cross section area for stator laminations. We also had to have a radial offset resulting in a radial misalignment between the stator and rotor because of the oversized coils. After the motor was completed, it was shipped to Texas A&M University for testing. With the loss of flux from these issues, the measured motor efficiency was only 96.3%. The primary focus of this motor was to make sure our FEA simulation model predicted the measured losses and overall efficiency, this we moved on to the FEA simulation. The FEA simulations of the motor “as built” with misalignments had good correlation with the test results, so the next step was to use that model to optimize the design of the motor for a final build. This time we considered changes to the stator and rotor and also minor changes to the housing diameter. In the third budget period, we did the detailed design and construction of the final prototypes. The final prototypes had a slight increase in the stator diameter to fit in a standard Regal Beloit housing. We shortened the stator and use more layers of wire in the coils. We also increased the cone angle of the rotor and stator from the original 110 degrees to 130 degrees to get some additional efficiency and optimized the stator cross section. The predicted efficiency from the FEA simulations was 96.9%. When completed, the motors were tested. We were a little short of reaching our target efficiency goal of 96.8%. We were only able to get to 96.7% efficiency. While it may be possible with additional iterations in designs and future builds to gain that additional 0.1%, we believe that we are close to the best we can achieve from a practical viewpoint, and additional iterations would be more work than the potential gains would be worth. No other motor in this class can even reach the 96% that we started with.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗