SEARCH · Search NASA

Results for “cost model validation”

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.

SourceResearch connectionFrom yearThrough year

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 307 records · Page 17

All sources NASA NTRS DOE OSTI

DOE OSTI2021

Achieving 5,000-h and 8,000-h Low-PGM Electrode Durability on Automotive Drive Cycles

Whereas total Pt loading in anode and cathode catalysts below 0.125 mg cm −2 is required to meet the stringent cost target for automotive fuel cell systems (FCS) for light duty vehicles, low-loaded cathode catalysts are susceptible to unacceptable aging-related performance losses at high current densities. A framework model, validated by accelerated stress test data, has identified cell voltage, relative humidity (RH) and temperature as the key operating variables that affect degradation of a high-activity d-PtCo/C cathode catalyst with 0.1 mg cm −2 Pt loading. Drive cycle simulations indicate that these can be controlled by properly selecting the minimum FCS power, compressor-expander module (CEM) turndown, and stack coolant temperature. The optimum system parameters are 4-kW e minimum power for an 80-kW e FCS, CEM turndown of 12.5, and 66 °C average coolant exit temperature that combine to limit the maximum cell voltage to 850 mV and outlet RH to 90%–100%. Depending on Pt loading, the mismatch between actual and allowable degradation for 10% power loss over 5,000-h lifetime requires the stack to be oversized by 2.4%–5%, resulting in 8.4%–41% lower Pt utilization and 7.1%–20.5% penalty in stack cost. The corresponding results for 8,000-h lifetime are 10.3%-14% stack oversizing, 23%–51.8% lower Pt utilization, and 24.1%–35.4% stack cost penalty.

08 HYDROGEN↗

DOE OSTI2023

A Real-Time Degradation Estimation Approach for Batteries in PV and Battery Hybrid Plant Operation

Conventional cyclic degradation assessment for batteries is often limited in its ability to provide real-time degradation information during operation, because the estimation of degradation is commonly performed after a specific evaluation period. Modified methods can provide real-time evaluation but at the cost of high computation complexity. This paper proposes a novel estimation method that addresses these limitations. It efficiently determines the incremental degradation of any two consecutive state-of-charge (SOC) samples during battery operation, thus enabling real-time estimation. To validate the proposed method, measurement data from lithium-ion phosphate (LFP) battery testing was adopted, and the results were compared with the conventional model and the measured capacity. The results demonstrate accuracy over the evaluation period in terms of cumulative degradation, and a reduced computation cost compared with other methods. This approach has benefits in various applications, especially in cases where batteries experience irregular charging and discharging stress cycles such as PV and battery hybrid plants.

Wang, Shumeng↗

DOE OSTI2022

Estimating production cost for large-scale seaweed farms

Seaweed farming has the potential to produce feedstocks for many applications, including food, feeds, fertilizers, biostimulants, and biofuels. Seaweeds have advantages over land-based biomass in that they require no freshwater inputs and no allocation of arable land. To date, seaweed farming has not been practiced at scales relevant to meaningful biofuel production. Here we describe a techno-economic model of large-scale seaweed farms and its application to the cultivation of the cool temperate species Saccharina latissima (sugar kelp) and the tropical seaweed Eucheumatopsis isiformis. At farm scales of 1000 ha or more, our model suggests that farm gate production costs in waters up to 200 km from the onshore support base are likely to range between $\$$200 and $\$$300 per dry tonne. The model also suggests that production costs below $\$$100 per dry tonne may be achievable in some settings, which would make these seaweeds economically competitive with land-based biofuel feedstocks. While encouraging, these model results and some assumptions on which they are based require further field validation.

09 BIOMASS FUELS↗

DOE OSTI2020

Process-Based Balance-of-System Cost Modeling for Offshore Wind Power Plants in the United States: Preprint

This work describes the development of a process based and open source balance of system cost model which provides the capability to evaluate both existing and novel offshore wind technologies. Individual design and installation steps are represented with bottom-up engineering models that compute the times and costs associated with the process; furthermore, operational constraints are assigned to each process so that delays due to weather and presence of marine mammals may be accounted for in the overall project timeline. The model structure, assumptions, inputs, and results are vetted with industry partners and compared against actual projects for validation; installation times are shown to agree with real data with relative errors of less than 35\%. Case studies are presented to demonstrate the functionality of the model. First, individual vessel efficiencies are computed for varying numbers of installation vessels and weather time series to show the diminishing returns of more than two feeder barges. Then, array cable capital costs and installation times are determined for a representative project with different turbine sizes. This quantifies the cost benefit tradeoffs of decreasing number of turbines, increased turbine spacing, and fewer turbine terminations and shows a net cost savings. These results demonstrate that the BOS model features the accuracy, functionality, and accessibility to serve as the foundation for a wide range of analyses to identify cost reduction potentials for offshore wind energy in the United States.

17 WIND ENERGY↗

DOE OSTI2020

Joint Planning of EV Fast Charging Stations and Power Distribution Systems With Balanced Traffic Flow Assignment

To tackle the challenges introduced by the fast-growing charging demand of electric vehicles (EVs), the power distribution systems (PDSs) and fast charging stations (FCSs) of EVs should be planned and operated in a more coordinated fashion. However, existing planning approaches generally aim to minimize investment costs in PDSs while ignoring the risk of worsening traffic conditions. To overcome this research gap, this article integrates the interests of traffic networks into PDS and FCS joint planning model to mitigate negative impacts on traffic conditions caused by installing FCSs. First, a novel microscopic method that is different from traditional assignment methods is proposed to simulate the influences of FCSs on traffic flows and EV charging loads. Then, a multiobjective joint planning model is developed to minimize both the planning costs and unbalanced traffic flows. A new bilayer Benders decomposition algorithm is designed to solve the proposed joint planning model. Numerical results on two practical systems in China validate the feasibility of our microscopic method by comparing the simulated results with real data. Compared with existing approaches, it is also demonstrated that the proposed joint planning approach helps to balance traffic flow assignments and relieve traffic congestion.

bilayer expanded Benders decomposition↗

NASA NTRS2009

A Near-Term, High-Confidence Heavy Lift Launch Vehicle

The use of well understood, legacy elements of the Space Shuttle system could yield a near-term, high-confidence Heavy Lift Launch Vehicle that offers significant performance, reliability, schedule, risk, cost, and work force transition benefits. A side-mount Shuttle-Derived Vehicle (SDV) concept has been defined that has major improvements over previous Shuttle-C concepts. This SDV is shown to carry crew plus large logistics payloads to the ISS, support an operationally efficient and cost effective program of lunar exploration, and offer the potential to support commercial launch operations. This paper provides the latest data and estimates on the configurations, performance, concept of operations, reliability and safety, development schedule, risks, costs, and work force transition opportunities for this optimized side-mount SDV concept. The results presented in this paper have been based on established models and fully validated analysis tools used by the Space Shuttle Program, and are consistent with similar analysis tools commonly used throughout the aerospace industry. While these results serve as a factual basis for comparisons with other launch system architectures, no such comparisons are presented in this paper. The authors welcome comparisons between this optimized SDV and other Heavy Lift Launch Vehicle concepts.

Rothschild, William J.↗

DOE OSTI2024

Measurement of Wind Loading on Heliostats at the Crescent Dunes Power Plant: An Overview

The cost of solar collectors constitutes almost one third of the total cost of a CSP plant. One of the ongoing challenges in the design of these collectors is wind loading on mirrors, support structures, and drives. A particular challenge is dynamic wind loading, caused by the turbulent wind flow. To date, the design of solar collector structures has relied on wind tunnel experiments and numerical simulations that do not entirely capture the dynamic effects observed at scale. The CSP industry has shown increased interest in validating the idealized assumptions with measurements obtained in operational settings to improve wind load assumptions and increase reliability and cost-efficiency of the collector design. Further, performance models need realistic assumptions about wind loading and its impact on optical performance. In a parabolic trough field campaign, NREL successfully collected a wealth of long-term, high-resolution wind and loads data [2], that are publicly available and that can be used for the above-mentioned purposes. Heliostats are impacted differently by wind than parabolic troughs, due to their different shape, size, and field layout. To study the impact of wind and turbulence on heliostats, we initiated another field campaign in an operational power- tower plant, Crescent Dunes, in Nevada, USA. In this work, we present an overview of the measurements, first results, and potential implications of wind driven loads on Heliostats.

concentrated solar power↗

DOE OSTI2023

Evolution of dislocation substructures in metals via high-strain-rate nanoindentation

Deformation at high strain rates often results in high stresses on many engineering materials, potentially leading to catastrophic failure without proper design. High-strain-rate mechanical testing is thus needed to improve the design of future structural materials for a wide range of applications. Although several high-strain-rate mechanical testing techniques have been developed to provide a fundamental understanding of material responses and microstructural evolution under high-strain-rate deformation conditions, these tests are often very time consuming and costly. In this work, we utilize a high-strain-rate nanoindentation testing technique and system in combination with transmission electron microscopy to reveal the deformation mechanisms and dislocation substructures that evolve in pure metals from low (10 –2 s –1 ) to very high indentation strain rates (10 4 s –1 ), using face-centered cubic aluminum and body-centered cubic molybdenum as model materials. The results help to establish the conditions under which micro- and macro-scale tests can be compared with validity and also provide a promising pathway that could lead to accelerated high-strain-rate testing at substantially reduced costs.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Optimal management of electric hotel loads in mild hybrid heavy duty truck

Here, the problem of engine idling for heavy-duty trucks has been under study for decades with Auxiliary Power Units (APUs) and Truck Stop Electrification (TSE) as the most compelling solutions. With the electrification of trucks approaching feasibility in terms of cost-effective technology, hybridization offers another “degree of freedom” to tackle the problem. Here, this work aims at exploiting a battery pack of a 48 V mild-hybrid heavy-duty truck to store sufficient onboard energy for powering the auxiliary loads during the hoteling. This problem is not trivial, as the battery packs typically cannot recover the entire energy required through regeneration alone; hence an optimal energy management strategy needs to be employed to charge the battery through the engine during drive operation. This strategy optimizes powertrain performances among the four modes: (i) Engine of Coasting (EOC), (ii) Regeneration by braking, (iii) Regeneration by engine, and (iv) engine idling. This paper presents the development of a Dynamic Programming (DP) framework that employs a multi-objective cost function to minimize the fuel consumption and maximize the regeneration using the above-mentioned four modes. A typical heavy-duty truck drive cycle is used to represent the drive phase, with mandatory hoteling stops as per regulations. A comprehensive powertrain model is developed using validated components’ model. The DP employs two state variables: battery State-of-Charge (SOC) and engine mode, and three control inputs: (i) the engine ON–OFF state, (ii) clutch engagement state, and (iii) power request at the Electric Machine (EM) for calculating optimal SOC trajectory. The framework also tackles rapid engine ON–OFF scenarios to avoid the challenges associated with DP and the compromises in fuel cost with those approaches. Finally, the effectiveness of the proposed framework is tested for potential fuel savings on two different battery packs by performing the full cycle simulations. The results show 6.47% of fuel consumption reduction as compared to traditional APU-based heavy-duty truck.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2022

Enabling energy‐efficient manufacturing of pharmaceutical solid oral dosage forms via integrated techno‐economic analysis and advanced process modeling

Abstract The global pharmaceutical industry is a trillion‐dollar market. However, the pharmaceutical sector often lags in manufacturing innovation and automation which limits its potential to maximize energy efficiency. The integration of techno‐economic analysis (TEA) with advanced process models as part of an overarching smart manufacturing platform, can help industries create business models, which can be adapted for manufacturing to reduce energy consumption and operating costs while ensuring product quality which can further enable a more sustainable process operation. In this study, a rational design of experiment on three unit‐operations (wet granulation, drying, and milling) was performed on a batch (case 1) and continuous (case 2) pharmaceutical process to obtain experimental data. Process models for predicting product quality and energy efficiency of each of the three‐unit operations were developed. The experimental data were used to validate the models and good agreement was observed. The energy consumption of each unit operation was calculated using statistical models relating the power consumption and the process parameters. The developed process models and energy models were further integrated into a TEA framework, which quantified the energy and monetary cost of manufacturing for both batch and continuous manufacturing cases. With this integrated framework, energy costs savings of ~33% was obtained in the continuous manufacturing process (case 2) over the batch process (case 1).

Sampat, Chaitanya↗

NASA NTRS2018

Parametric Analysis of Aircraft WingWeight Using Low-Order Physics-Based Analysis

In the conceptual aircraft design phase, prediction of the empty weight typically relies on empirically-based regression equations which execute quickly and require little detailed information about the internal structural layout. Since they are based on existing aircraft, however, empirical methods can lose their validity for newer technologies and unconventional configurations. Designers can transition to higher-order, physics-based analysis methods to improve the accuracy of the weight prediction, but at the cost of complex model setup and increased computational time. This paper describes a methodology for low-order aero-structural analysis of conceptual aircraft configurations that increases the use of physics-based analysis in conceptual design, but is less complex and time-consuming than higher-order methods such as finite-element analysis. The methodology uses Vehicle Sketch Pad (OpenVSP) to model the aircraft geometry, and ASWING to perform the aero-structural analysis. The internal forces and moments from the ASWING analysis are post-processed to calculate the resulting direct and shear stresses in the structure, and the thickness distributions of the aircraft components are varied to match the maximum von Mises stress at each cross section to the material allowable. To offset the increased computational time relative to empirical weight equations, a process is studied which uses parametric variation to develop a regression equation relating the weight of the aircraft wing to major design variables. This new weight equation is similar to existing empirical equations, but is built using the more physics-based methodology; the new equation could be used to augment or replace portions of the empirical database to improve the validity of the wing weight prediction for unconventional configurations and advanced technologies.

Olson, Erik D.↗

DOE OSTI2021

Validation of the Community Land Model Version 5 over the Contiguous United States (CONUS) using in situ and remote sensing data sets

The Community Land Model (CLM) is an effective tool to simulate the biophysical and biogeochemical processes and their interactions with the atmosphere. Although CLM Version 5 (CLM5) constitutes various updates in these processes, its performance in simulating energy, water and carbon cycles over the Contiguous United States (CONUS) at scales which land surface changes and hydrometeorological and hydroclimatological applications are more locally relevant is yet to be assessed. In this study, we conducted three simulations at 0.125? during 1979-2018 over the CONUS using different configurations of CLM, namely CLM5-biogeochemistry (CLM5BGC), CLM4.5BGC, and CLM5-satellite phenology (CLM5SP). We validated and compared their simulations against multiple remote-sensed and in-situ datasets. Overall, the parametric and structural updates (e.g., carbon cost for nitrogen uptake, variable soil thickness, dry surface layer) in CLM5 improve its ability in capturing terrestrial biogeochemical dynamics. The low evapotranspiration in CLM5BGC is associated with biases in simulating vegetation phenological characteristics rather than soil water limitations. The mismatch between CLM5BGC-simulated peak leaf area index and reference data can be attributed to CLM5BGC's inability in simulating phenology of trees and grasses. The differences between CLM-simulated irrigation and reference estimates can be attributed to differences between processes represented in models and in reality, and uncertainties in input and validation datasets. Evaluation against observations at small catchments suggest that hydrologic parameters needed to be calibrated to improve simulations of runoff, especially subsurface runoff. Additional efforts are needed to incorporate spatially-distributed plant phenology and physiology parameters and regional-specific agricultural management practices (e.g., planting, harvest).

Cheng, Yanyan↗

DOE OSTI2022

Multi‐objective optimization for cost‐efficient and resilient machining under tool wear

Abstract With the onset and rapid growth of smart manufacturing, there is a constant increase in the demand for automation technologies to enhance productivity while providing uninterrupted, cost‐efficient, and resilient machining. Traditional manufacturing systems, however, suffer from several losses due to machine faults and degradation. Specifically, tool wear directly impacts the precision and quality of the milled parts, which causes an increase in the scrap production. Hence, more attempts are required to meet the desired quota of successful parts, which in turn results in wasted material, longer delays, further tool degradation, and higher energy, machining, and labor costs. As such, this paper develops a multi‐objective optimization framework to generate the optimal control set points (e.g., feed rate and width of cut) that minimize the total cost of machining operations resulting from multiple contradictory cost functions (e.g., material, energy, tardiness, machining, labor, and tool) in the presence of tool wear. Notably, we estimate the total expected cost in dollars, which provides automatic and intuitive weighting in this multi‐objective formulation. The optimization framework is tested on a high‐fidelity face milling model that has been validated on real data from industry. Results show significant dollar savings of up to as compared to the default control scheme.

Wilson, James P.↗

DOE OSTI2024

Oscillating surge wave energy converter using a novel above-water power takeoff with belt-arc speed amplification

We investigate the performance of a novel power takeoff (PTO) featuring belt-arc speed amplification for oscillating surge wave energy converters (OSWECs), aiming to address the challenges of extremely low rotary speed and large torque under the low-frequency ocean wave excitations. The belt-arc design significantly increases the rotary speed of the generator, enabling generator downsizing and decreasing the powertrain friction losses. The design also allows for placing the generator above water, eliminating the need for high Ingress Protection ratings for the generator and powertrain, and potentially leading to substantial reductions in capital and maintenance costs. Using the linear potential wave theory, the dynamics of the integrated system are analyzed, and key parameters are identified. To validate the numerical analysis, a 1:10 scale model is designed, fabricated, and tested in a wave tank. Performance evaluations are conducted under regular and irregular wave conditions, with quantified effects of parameter tuning. The results reveal an optimal wave-to-electric efficiency of 48% under regular wave excitation and 20% under irregular excitation. Furthermore, these findings underscore the effectiveness of the proposed novel PTO design in addressing the challenges of low rotation speed and large torque inherent in OSWECs, demonstrating its ability to efficiently convert wave power into electricity.

16 TIDAL AND WAVE POWER↗

DOE OSTI2024

Analytical Modeling of Metal Foam Composite Phase Change Materials (PCM) in Thermal Energy Storage Using Asymptotic Analysis

The use of phase change materials (PCMs) for thermal energy storage can release or absorb a significant amount of latent heat during the freezing or melting process, offering a higher energy storage density. One of the main drawbacks of PCMs is their low thermal conductivity, resulting in poor thermal performance. Recent research has attempted to enhance heat transfer and increase the thermal conductivity of PCMs, including the use of metal foams. However, modeling the metal foam composite PCM using conventional methods is computationally expensive. This paper proposes an asymptotic solution for a Stefan-like problem subject to a convective boundary for outward solidification in a hollow cylinder, capable of predicting the freeze-melt cycle of the metal foam composite PCM. Specifically, three temporal regimes and four spatial layers are considered in the asymptotic analysis for each phase change process. The thermal conductivity is calculated by a theoretical three-dimensional tetrakaidecahedron model, while other thermophysical properties are obtained using the method of volume averaging. The results are verified with numerical data and validated against experimental data in the literature. The presented analytical modeling framework could have the potential to be applied to other types of composite PCMs with considerably lower computational costs compared with conventional methods.

analytical model↗

DOE OSTI2021

Predictive Battery Lifetime Modeling at NREL [Slides]

Battery lifetime models are used to extrapolate data from accelerated aging tests to simulate degradation in real-world applications such as electric vehicles and battery energy storage systems. Methods developed at NREL utilize both expert domain-knowledge and machine-learning to identify models, using statistical methods such as cross-validation and bootstrap resampling to interrogate model performance and quantify uncertainty. These models can be utilized in systems level simulations to predict battery performance or technoeconomic models to estimate the lifetime cost of battery systems.

25 ENERGY STORAGE↗

NASA NTRS1994

Computational Methods for HSCT-Inlet Controls/CFD Interdisciplinary Research

A program aimed at facilitating the use of computational fluid dynamics (CFD) simulations by the controls discipline is presented. The objective is to reduce the development time and cost for propulsion system controls by using CFD simulations to obtain high-fidelity system models for control design and as numerical test beds for control system testing and validation. An interdisciplinary team has been formed to develop analytical and computational tools in three discipline areas: controls, CFD, and computational technology. The controls effort has focused on specifying requirements for an interface between the controls specialist and CFD simulations and a new method for extracting linear, reduced-order control models from CFD simulations. Existing CFD codes are being modified to permit time accurate execution and provide realistic boundary conditions for controls studies. Parallel processing and distributed computing techniques, along with existing system integration software, are being used to reduce CFD execution times and to support the development of an integrated analysis/design system. This paper describes: the initial application for the technology being developed, the high speed civil transport (HSCT) inlet control problem; activities being pursued in each discipline area; and a prototype analysis/design system in place for interactive operation and visualization of a time-accurate HSCT-inlet simulation.

Cole, Gary L.↗

NASA NTRS2011

Full-Scaled Advanced Systems Testbed: Ensuring Success of Adaptive Control Research Through Project Lifecycle Risk Mitigation

The National Aeronautics and Space Administration's Dryden Flight Research Center completed flight testing of adaptive controls research on the Full-Scale Advance Systems Testbed (FAST) in January of 2011. The research addressed technical challenges involved with reducing risk in an increasingly complex and dynamic national airspace. Specific challenges lie with the development of validated, multidisciplinary, integrated aircraft control design tools and techniques to enable safe flight in the presence of adverse conditions such as structural damage, control surface failures, or aerodynamic upsets. The testbed is an F-18 aircraft serving as a full-scale vehicle to test and validate adaptive flight control research and lends a significant confidence to the development, maturation, and acceptance process of incorporating adaptive control laws into follow-on research and the operational environment. The experimental systems integrated into FAST were designed to allow for flexible yet safe flight test evaluation and validation of modern adaptive control technologies and revolve around two major hardware upgrades: the modification of Production Support Flight Control Computers (PSFCC) and integration of two, fourth-generation Airborne Research Test Systems (ARTS). Post-hardware integration verification and validation provided the foundation for safe flight test of Nonlinear Dynamic Inversion and Model Reference Aircraft Control adaptive control law experiments. To ensure success of flight in terms of cost, schedule, and test results, emphasis on risk management was incorporated into early stages of design and flight test planning and continued through the execution of each flight test mission. Specific consideration was made to incorporate safety features within the hardware and software to alleviate user demands as well as into test processes and training to reduce human factor impacts to safe and successful flight test. This paper describes the research configuration, experiment functionality, overall risk mitigation, flight test approach and results, and lessons learned of adaptive controls research of the Full-Scale Advanced Systems Testbed.

Pavlock, Kate M.↗