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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 289 records · Page 16
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Experimental Safe Extremum Seeking for Accelerators

Here, we demonstrate the recent designs of safe extremum seeking (Safe ES) on the 1-km-long charged particle accelerator at the Los Alamos Neutron Science Center (LANSCE). Safe ES is a modification of extremum seeking (ES) which, in addition to minimizing an analytically unknown cost, also employs a safety filter based on an analytically unknown control barrier function (CBF) safety metric. Tuning is necessitated by accelerators being large complex systems, with many drifting parameters due to thermal effects and degradation. At the same time, safe operation (the maintenance of state constraints) is crucial, as damage brings astronomical costs, both financially and in operation downtime. Our measured (but analytically unknown) safety metric is the beam current. We perform multivariable Safe ES on three accelerator applications, in which we adapt 4, 6, and 3 magnet strength parameters, respectively. Two of the three applications are for validated simulation models of beamlines at LANSCE: the first for the proton radiography (pRad) beamline of 800-MeV protons for spot size tuning; the second on a high-performance code, HPSim, for tuning the low-energy beam transport (LEBT) region that contains a beam of 750-keV protons. The third is an experimental tuning of the steering magnets in the LEBT at LANSCE.

43 PARTICLE ACCELERATORS↗
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 OSTI2023

Integrated solid-state rapid thermo-cycling system

Techniques, systems, and devices are disclosed for implementing a portable lab system for PCR testing. An example method for operating an integrated thermal cycling system includes depositing samples into the integrated thermal cycling system that includes a thermal cycling device and an electronic interface. The thermal cycling device includes multiple wells to receive the samples to be thermally cycled, a thermoelectric cooling (TEC) element connected to the multiple wells, a substrate on which the TEC element is positioned, and a controller coupled to the TEC element. The multiple wells are positioned within the substrate that includes a thermally conductive ground positioned between adjacent wells. Supplying power to the integrated thermal cycling system, via the electronic interface, allows the multiple wells to exchange heat with the substrate and for each well to operate independently from other wells.

Beer, N. Reginald↗
DOE OSTI2025

The SAS4A/SASSYS-1 Version 5.8 Safety Analysis Code System

SAS4A/SASSYS-1 is a software simulation tool used to perform deterministic analysis of anticipated events as well as design basis and beyond design basis accidents for advanced nuclear reactors. Detailed, mechanistic models of steady-state and transient thermal, hydraulic, kinetic, and mechanical phenomena are employed to describe the response of the reactor core, the reactor primary and secondary coolant loops, the reactor control and protection systems, and the balance-of-plant to accidents caused by changes in coolant flow, loss of heat rejection, or reactivity insertion. The consequences of single and double-fault accidents can be modeled, including fuel and coolant heating, fuel and cladding mechanical behavior, core reactivity feedbacks, coolant loop performance including natural circulation, and decay heat removal. Analyses are typically terminated upon demonstration of reactor and plant shutdown to permanently coolable conditions, or upon violation of design basis margins. The objective of the analysis is to quantify accident consequences as measured by the transient behavior of system performance parameters, such as fuel and cladding temperatures, reactivity, and cladding strain. Originally developed for analysis of sodium cooled reactors with oxide fuel clad by stainless steel, the models were subsequently extended and specialized to metallic fuel clad with advanced alloys and to several other coolant options, including lead, LBE, and water.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2025

HOLISTIC ENERGY EFFICIENCY ANALYSIS OF ELECTRIFIED OFF-HIGHWAY MATERIAL HANDLER: FROM DRIVE CYCLE CHARACTERIZATION TO POWERTRAIN, HYDRAULIC, AND THERMAL SYSTEM PERFORMANCE

Three complexities surrounding the operation and testing of hybrid electric, heavy-duty nonroad machines have been addressed experimentally and using 1D simulation. Their resolutions have been intertwined with the development of a prototype machine that was proven to reduce fuel consumption in excess of 20%. A real-world drive cycle that leveraged hydraulic cylinder position was developed and utilized to ensure accurate reproduction of hydraulic work between the baseline and hybrid machines, while simultaneously maintaining less than 5% RMS error in position for main load handling functions. The newly developed, machine-specific drive cycle also contributed towards making equivalent comparisons in energy consumption between machine types through composite performance metrics that were extrapolated over a typical shift duration. Lastly, this work addressed thermal management energy consumption, a topic of increasing popularity when discussing electrified vehicles, by proposing a 1.4% energy savings through special mechanization and control of cooling system components.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2023

Heat pump water heater enhanced with phase change materials thermal energy storage: Modeling study

A promising solution to improve the first hour rating (FHR) of a heat pump water heater (HPWH) involves employing a secondary tank which contains phase change material (PCM) capsules. To better understand the influence of PCM thermal storage on the HPWH operational performance, a dynamic model was developed to simulate and analyze the behavior of a newly developed HPWH technology that incorporates PCM storage into a standard HPWH to optimize key parameters such as the uniform energy factor and FHR. Mathematical models of several key components of the proposed HPWH-PCM integrated thermal energy storage (TES) system, e.g., water heater tank, PCM TES tank, evaporator, compressor, and expansion valve, have been elaborated. Also, a model-based control co-simulation platform was developed to integrate a embed PCM storage HPWH dynamic model with a control model for better supporting control design, analysis, verification, and validation. The model accuracy has been validated through comparing simulation results with lab test results, with a mean average percentage error of <5.5% for most of the selected performance variables. In addition, using the developed co-simulation platform, the demand response control strategy was studied to evaluate the load flexibility of the combined HPWH-PCM storage system by shifting system power usage to outside of the 3.5 h peak load period.

25 ENERGY STORAGE↗
DOE OSTI2021

Integrated Thermal Energy Storage System for Air-Conditioners with Phase-Change Composites

Thermal energy storage (TES) is a promising solution to store and dispatch energy and shave peak electric load, reducing the operational cost of HVAC systems. We present results of a TES system using phase-change materials (PCM) integrated with an air conditioner. The proposed system uses an organic PCM (tetradecane) encapsulated within compressed expanded natural graphite foams referred to as phase-change composite. The graphite foam encapsulates the PCM eliminating the need for expensive storage vessels, reduces installation costs, and provides higher thermal conductivity that can lead to faster charge/discharge rates. Two serpentines, multi-pass circuits, operating as a heat source and a sink, exchange heat to and from the phase-change composite. These two circuits are embedded in multiple slabs of this material. The "charge" circuit contains the refrigerant that is directly coupled to a vapor compression system, and the "discharge" circuit removes heat from an airstream and releases it into the PCM composite through a water-glycol liquid coupling. This configuration allows for multiple modes of operation depending on the state of charge of the thermal energy storage module, the building air-conditioning load, and the current electricity and demand charges. This flexible operation allows variable air volume capacity control without the need to have a variable capacity refrigeration system. We developed a 21 kW-hr (6 RT-hr) prototype TES system coupled with a commercial air-conditioner to characterize the component-and system-level performance.

air-conditioning↗
DOE OSTI2020

Design and analysis of optimal pre-cooling in residential buildings

Existing pre-cooling strategies provide a means of shifting or reducing the peak demand and/or energy cost in residential buildings. However, majority of them are rule-based and therefore may not be optimal in terms of cost saving, leaving room for improvement. In this paper, an integer linear programming problem that accounts for the thermal properties of a specific home, HVAC system capacity, utility rate structure, and weather conditions and makes use of a home thermal model is formulated. This problem determines the HVAC on/off control signal that minimizes the 24-h energy cost while maintaining thermal comfort and calculates the corresponding optimal indoor air temperature. The model is constructed using home thermal properties identified via data training in real-time. Through simulation, the energy performance of the proposed optimal pre-cooling strategy is investigated and compared with three rule-based operation strategies from the literature. It is found that the optimal strategy requires the least energy consumption without sacrificing thermal comfort. The superb energy performance of the optimal strategy is attributed to a longer runtime of the HVAC system in cool outdoor air conditions and to the elimination of deadband in HVAC operation, which is required by the rule-based strategies, to allow the indoor air temperature to stay near the thermal comfort upper bound as much as possible. In terms of energy cost, the rule-based operation strategies require 3.52, 1.90, and 2.79, respectively, while the optimal strategy only requires 1.52. These figures represent a saving of 56.82%, 20.00%, and 45.52%, respectively. The results suggest that the optimal strategy is indeed significantly more effective than the existing rule-based operation strategies.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2020

Optimized Highly Efficient SSCB Using Organic Substrate Packaging for Electric Vehicle Applications

Solid State Circuit Breakers (SSCBs) are an attractive protection solution for their arcless current interruption and fast actuation speeds over mechanical breakers. This paper proposes a Bidirectional SSCB (BSSCB) with a thermally defined and digitally controlled current time profile for fault protection in EV and other low-voltage DC systems. The paper proposes an organic packaging approach utilizing flex circuitry to develop a reliable, cost-effective power module for BSSCBs. The paper studies transient heat transfer in the power modules using finite element analysis (FEA). An RC themal ladder network is extracted to define a fusing curve. To demonstrate and verify the design, a 1kV/50 A SiC MOSFET BSSCB prototype is fabricated and tested, having a power density of 60 W/cm3 and 4x reduction in form factor over presently researched breakers. Also, given are results for 750 V/150 A operation showing interruption in 2.4 μs.

organic power packaging↗
DOE OSTI2024

High-Temperature Freeze & Leak-Resistant Advanced Molten Salt Valve (Final Project Report)

The overall goal of this investigation was to develop an innovative high-temperature chloride molten salt flow control valve capable of operation up to 750 °C. The team developed an integrated active and passive thermal management system to ensure robust design for freeze-thaw cycles, with either a bellows-sealed configuration, a high-temperature stuffing box, or combination of the two. The STM system is unique in the industry.

14 SOLAR ENERGY↗
DOE OSTI2022

The Robotic Multiobject Focal Plane System of the Dark Energy Spectroscopic Instrument (DESI)

Abstract A system of 5020 robotic fiber positioners was installed in 2019 on the Mayall Telescope, at Kitt Peak National Observatory. The robots automatically retarget their optical fibers every 10–20 minutes, each to a precision of several microns, with a reconfiguration time of fewer than 2 minutes. Over the next 5 yr, they will enable the newly constructed Dark Energy Spectroscopic Instrument (DESI) to measure the spectra of 35 million galaxies and quasars. DESI will produce the largest 3D map of the universe to date and measure the expansion history of the cosmos. In addition to the 5020 robotic positioners and optical fibers, DESI’s Focal Plane System includes six guide cameras, four wave front cameras, 123 fiducial point sources, and a metrology camera mounted at the primary mirror. The system also includes associated structural, thermal, and electrical systems. In all, it contains over 675,000 individual parts. We discuss the design, construction, quality control, and integration of all these components. We include a summary of the key requirements, the review and acceptance process, on-sky validations of requirements, and lessons learned for future multiobject, fiber-fed spectrographs.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2021

Quantum magnetism on small-world networks

While classical spin systems in random networks have been intensively studied, much less is known about quantum magnets in random graphs. In this work, we investigate interacting quantum spins on small-world networks, building on mean-field theory and extensive quantum Monte Carlo simulations. Starting from one-dimensional (1D) rings, we consider two situations: All-to-all interacting and long-range interactions randomly added. The effective infinite dimension of the lattice leads to a magnetic ordering at finite temperature Tc with mean-field criticality. Nevertheless, in contrast to the classical case, we find two distinct power-law behaviors for Tc versus the average strength of the extra couplings. This is controlled by a competition between a characteristic length scale of the random graph and the thermal correlation length of the underlying 1D system, thus challenging mean-field theories. We also investigate the fate of a gapped 1D spin chain against the small-world effect.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2024

Foreword: Special Section on Multiphysics Aspects of Power Electronics Packaging - Power Die, Power Module, and Converter Level - Part 1

Power electronics are increasingly being used to condition electricity for a wide array of applications, such as transportation (on land, air, and water), data centers, radio frequency, directed energy, wind, solar, and grid-tied applications. To increase power density, performance, efficiency, and reliability and reduce cost, innovations and developments are needed in the multiphysics packaging of power electronics at a die, module, and converter level. This includes fundamental research and development related to emerging high-voltage, high-temperature, and high-switching-frequency power electronics; packaging materials; thermal materials and interfaces; fluid-based thermal management technologies; reliability; condition monitoring; and prognostics. To address these important aspects, this Special Section on Multiphysics Aspects of Power Electronics Packaging includes several articles to be published in two parts. More details are given below on the articles included in the first part.

condition monitoring↗
DOE OSTI2022

Heavy Duty Natural Gas Single Cylinder Research Engine Installation, Commissioning, and Baseline Testing

Natural Gas (NG) Internal Combustion Engines (ICE) are a promising alternative to diesel engines for on-road heavy-duty applications to reduce greenhouse gas and harmful pollutant emissions. NG engines have not been widely adopted due to the lower thermal efficiency compared with diesel engine counterparts. To develop the base knowledge required to reach the desired efficiency, a Single Cylinder Engine (SCE) is the most effective platform to acquire reliable and repeatable data. A SCE test cell was developed using a Cummins 15-liter six-cylinder heavy-duty engine block modified to fire one cylinder (2.5-liter displacement). A Woodward Large Engine Control Module (LECM) is integrated to permit implementation of real-time advanced combustion control. Intake and exhaust characteristics, fuel composition, and exhaust gas recirculated substitution rate (EGR) are fully adjustable. A high-speed data acquisition system acquires in-cylinder, intake, and exhaust pressure for combustion analysis. The baseline testing shows reliable and consistent results for engine thermal efficiency, indicated mean effective pressure (IMEP), and coefficient of variance of the IMEP over a wide range of operating conditions while achieving effective control of all engine control and operation variables. This test cell will be used to conduct a research program to develop new and innovative control algorithms and CFD optimized combustion chamber designs, allowing ultra-high efficiency and low emissions for NG ICE heavy-duty on-road applications.

03 NATURAL GAS↗
DOE OSTI2024

Uncertainty Quantification and Sensitivity Analysis of Non-Nuclear Advanced Controls Testbed Reactor Mockup

The research presented in this report describes our progress in applying stochastic methods and uncertainty quantification, parametric study, and variance-based sensitivity analysis (also known as Sobol sensitivity analysis) to a full-core model of a nuclear thermal propulsion (NTP) system simulated with Griffin, with the goal of developing a reduced order (surrogate) model which can be rapidly sampled while perturbing multiple input parameters. In this NTP system, reactivity and power feedback affect the rotation of control drums, which are controlled by a hybrid proportional, integral and derivative (PID) controller, actuated by the power demand and reactivity feedback from the numerical model. This model uses reactor kinetic feedback (mean generation time and $\beta$ from a transient Griffin simulation executed with the improved quasi-static method to provide the kinetic parameters) as inputs to functions which control the CD rotation angle. Using a number of stochastic method approaches, we developed a dual purpose training-surrogate model of the NTP system using polynomial regression. The trained model can be rapidly sampled while simultaneously perturbing various input parameters of the model, such as coefficients on the PID control, or temperature (directly affect the neutron cross section). The surrogate model delivers accurate results orders-of-magnitude faster (minutes, not days) than the base model. Once the base model has been trained, distributions of the uncertain parameters can be changed at will to investigate the effects of perturbing multiple inputs and their effect on the output. For example, coefficients used in the PID control system may vary due to some physical interference, or there may be uncertainty in the temperature of the neutron cross sections in various regions of the reactor. A distribution can be placed on these parameters and operational boundaries can be determined. The goal of this work is to support development of an advanced control system to operate CDs in a functioning NTP system.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2019

Data-driven Identification of Occupant Thermostat-Behavior Dynamics

Building occupant behavior drives significant differences in building energy use, even in automated buildings. Users’ distrust in the automation causes them to override settings. This results in responses that fail to satisfy both the occupants’ and/or the building automation’s objectives. The transition toward grid-interactive efficient buildings will make this evermore important as complex building control systems optimize not only for comfort, but also changing electricity costs. This paper presents a data-driven approach to study thermal comfort behavior dynamics which are not captured by standard steady-state comfort models such as predicted mean vote. The proposed model captures the time it takes for a user to override a thermostat setpoint change as a function of the manual setpoint change magnitude. The model was trained with the ecobee Donate Your Data dataset of 5 min. resolution data from 27,764 smart thermostats and occupancy sensors. The resulting population-level model shows that, on average, a 2°F override will occur after ~30 mins. and an 8°F override will occur in only ~15 mins., indicating the magnitude of discomfort as a key driver to the swiftness of an override. Such models could improve demand response programs through personalized controls.

Kane, Michael↗
DOE OSTI2024

Performance evaluation of underground thermal storage integrated dual-source heat pump systems

The increasing demand for electricity stresses the existing electric grids. Buildings consume 73% of all U.S. electricity and are responsible for 30% of U.S. greenhouse gas emissions. Integrating thermal energy storage (TES) in building heating/cooling systems, which consume considerable electricity, can mitigate the challenges to electric grids. Here, this study reports on a novel thermal energy storage device integrated heat pump system to reshape the building electricity demand profile while maintaining thermal comfort. The annual performance of the proposed system has been evaluated through a dynamic system simulation with high fidelity in the Modelica platform. The dynamic model of the novel hybrid component named ‘dual purpose underground thermal battery’ was developed and validated. It was then incorporated into the system model. Given a time-of-use tariff, a rule-based control strategy was designed to shift the electric demand and switch the heat pump source for a typical single-family house in different climate zones of the United States. The system performance of the new TES-integrated dual-source heat pump was compared with that of a conventional air-source heat pump system. The results indicate that the proposed system can reduce the annual HVAC electricity cost by up to 52% while saving 45.2% on electricity consumption. In the Northern areas, the annual peak load of the HVAC system can be reduced by 64.9%. However, this reduction is less in the Southern areas as the system’s higher efficiency in winter dominates the overall energy-saving potential.

25 ENERGY STORAGE↗
DOE OSTI2020

Internal Insulation and Corrosion Control of Molten Chloride Storage Tanks

The U.S. Department of Energy Gen3 CSP program aims to develop integrated systems capable of delivering high temperature thermal energy to advanced power cycles [1]. The National Renewable Energy Laboratory (NREL) is leading a multi-national team to validate the potential of a chloride-based molten-salt system that uses a ternary blend of MgCl2/KCl/NaCl to provide higher temperature thermal energy storage capability (Fig. 1a). The economic viability of this concept is dependent on internally insulating the hot and cold storage tanks to enable the use of low-cost steel shells (Fig. 1b).

14 SOLAR ENERGY↗