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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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All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Convergence of Emerging Technologies - EAGL Test Information

The Emergency Automatic Gunshot Detection and Lockdown (EAGL) system provides automatic, autonomous, and timely gunshot detection in both indoor and outdoor environments. This system uses both wired and wireless devices. Self-contained wireless EAGL sensors passively “listen” for gunshot events. These devices also perform a single, daily supervisory heartbeat (HB) function to include a device self-check with reporting capability. Transmissions are received by an assigned EAGL Gateway, which translates the RF sensor data to a PoE network format solely for use by the EAGL system server. The server then performs additional processes after data receipt, which include but are not limited to: event validation and logging, GUI presentation, notifications, and other independent operations.

47 OTHER INSTRUMENTATION↗
DOE OSTI2025

Output Current Estimation and Control in Primary Side LCC Secondary Side Series Compensated Wireless Power Transfer System without Secondary Side Sensors

The estimation (and control) of the output variables is often challenging for wireless power transfer (WPT) systems. This paper presents a secondary side sensor-less closed loop estimation technique to estimate the output current in a primary side LCC and secondary side series compensated WPT system. Using information of primary side variables, the proposed estimation can estimate the output current over a wide range of load current variations. Results are presented to verify the efficacy of the proposed estimation.

Mukherjee, Subho [ORNL] (ORCID:0009000672297925)↗
DOE OSTI2025

xGFabric: Coupling Sensor Networks and HPC Facilities with Private 5G Wireless Networks for Real-Time Digital Agriculture

Advanced scientific applications require coupling distributed sensor networks with centralized high-performance computing facilities. Citrus Under Protective Screening (CUPS) exemplifies this need in digital agriculture, where citrus research facilities are instrumented with numerous sensors monitoring environmental conditions and detecting protective screening damage. CUPS demands access to computational fluid dynamics codes for modeling environmental conditions and guiding real-time interventions like water application or robotic repairs. These computing domains have contrasting properties: sensor networks provide low-performance, limited-capacity, unreliable data access, while high-performance facilities offer enormous computing power through high-latency batch processing. Private 5G networks present novel capabilities addressing this challenge by providing low latency, high throughput, and reliability necessary for near-real-time coupling of edge sensor networks with HPC simulations. This work presents xGFabric, an end-to-end system coupling sensor networks with HPC facilities through Private 5G networks. The prototype connects remote sensors via 5G network slicing to HPC systems, enabling real-time digital agriculture simulation.

Digital Agriculture↗
DOE OSTI2025

Enabling The Next Generation of Smart Sensors in Coal Fired Power Plants using Cellular 5G Technology

Ohio University (OHIO), West Virginia University (WVU), and American Electric Power (AEP) proposed to study and report on the benefits of 5G wireless cellular technologies for coal-fired power plants. The significant advantages, cost savings, and potential of 5G wireless data communications based sensors promised to usher in a new era of reliable, inexpensive, and powerful embedded systems that had not previously been available for coal-fired power plants. The team built upon existing experience with cellular-based systems, power plant water quality sensing, and high temperature sensors developed during past projects. Principal Investigator Wilhelm had been developing cellular-based sensor data systems with a commercial partner for 10 years, pioneering innovative solar-powered devices that began with 2G technology. The lessons and knowledge gained served as a foundation to demonstrate innovations and potential impacts specific to coal fired power plants enabled by 5G technology, along with integration with existing sensors and systems.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2025

Wireless Patch Antenna Characterization for Live Health Monitoring Using Machine Learning

Temperature monitoring in extreme environments, such as coal-fired power plants, was addressed by designing and testing wireless patch antennas for use in machine learning-aided temperature estimation. The sensors were designed to monitor the temperature and health of boiler systems. Wireless interrogation of the sensor was performed using a Vector Network Analyzer (VNA) and a pair of interrogation antennas to capture resonance behavior under varying thermal and spatial conditions with sensitivities ranging from 0.052 to 0.20 $\frac{𝑀𝐻𝑧}{°C}$. Sensor calibration was conducted using a Long Short-Term Memory (LSTM) model, which leveraged temporal patterns to account for hysteresis effects. The calibration method demonstrated improved performance when combined with an LSTM model, achieving up to a 76% improvement in temperature estimation error when compared with Linear Regression (LR). The experiments highlighted an innovative solution for patch antenna-based non-contact temperature measurement, which addresses limitations with conventional methods such as RFID-based systems, infrared, and thermocouples.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2025

Temperature and Strain Sensing Characteristics of a 128° YX-Cut LiNbO 3 Rayleigh-Mode SAW Sensor From Room to Cryogenic Temperatures

Accurate, passive, and wireless monitoring of cryogenic hardware is essential for high-energy physics, space propulsion, and biomedical instrumentation. Here, this study quantifies the coupled temperature-strain behavior of Rayleigh-mode surface acoustic-wave (SAW) delay-line sensors fabricated on 128° YX-cut LiNbO 3 . A nonlinear finite element (FE) model incorporating Varshni-based elastic constants, higher-order thermal expansion, and temperature-dependent piezo- and dielectric coefficients was developed and validated experimentally between 280K and 80K. Free-standing (first test condition) and bonded/wired (second test condition) devices exhibited indistinguishable thermal responses; the average temperature coefficient of delay (TCD) in the critical cryogenic range from 130K down to 80K differed by only 0.15 ppm/K (0.32%), confirming that bonding-induced stress is negligible. Over 280-80K the measured TCD was 61.77 ppm/K, while the FE model predicted an equivalent temperature coefficient of frequency (TCF) of −62.74 ppm/K with an overall coefficient of determination R2 = 0.998. In the critical cryogenic interval 130-80K the TCD fell to 47.66 ppm/K, indicating improved thermal stability at low temperature. Controlled loading (0-300 με) revealed a strain coefficient of delay (SCD) that rises from 0.53 ± 0.02 ppm/με at 300K to 1.05 ± 0.02 ppm/με at 80K. This modest sensitivity confirms that, for temperature sensing, strain is a second-order perturbation above 135K but must be compensated at deeper cryogenic levels. Overall, this work establishes a predictive multiphysics model together with repeatable wired measurements that confirm the suitability of SAW sensors for temperature and strain monitoring in extreme cryogenic environments, while also providing a baseline for future wireless implementations.

25 ENERGY STORAGE↗
DOE OSTI2024

Precision Agriculture using Networks of Degradable Analytical Sensors (PANDAS) (Final Technical Report)

Precision agriculture, where sensing of soil, environment and crop conditions are used to precisely synchronize inputs (such as water and fertilizer) to crop needs enhances input use efficiency. This can improve yields and farm profitability while mitigating environmental losses, improving soil carbon content and substantially decreasing energy use for food, feed and fuel crops. Unfortunately, farmers are not yet able to harness the full potential of these management technologies as there is a lack of available management information, and there is therefore a need for sensors that are able to economically measure spatio-temporal variability in soil and crop properties of extremely heterogeneous farm fields precisely at high resolution and at low cost. Real-time, in-situ monitoring of agricultural soil conditions is today carried out using devices that limit the total number of nodes that can be used economically to typically one per acre or less. Higher spatio-temporal resolution sensing would enable more precise agricultural input optimization, with significant benefits to the farmer and the environment. In order to address this issue, this project focused on developing additively manufactured, biodegradable, soil sensors with predicted costs of < $\$$1 per unit to monitor crop inputs (such as water and fertilizer) that predictably, harmlessly degrade away into the soil when no longer needed. These sensor nodes should be easy to place, accurately and continuously monitor soil and crop conditions for an entire season, be read remotely using existing farm equipment, require no ongoing maintenance, not impede farm operations and produce no persistent waste. This approach could enable a >100× increase in information density over current solutions for precision farming of row and other crops, and lead to significant reductions in input energy use and provide increased yield for biofuel crops. Over the course of this project the team at the University of Colorado Boulder, University of California Berkeley, and Colorado State University/Kansas State University investigated a wide range of printable biodegradable electronic materials and sensor designs for determining soil moisture and soil nitrate concentration. These efforts expanded the available materials set for printed soil degradable electronic materials, particularly for conductors, enabling high conductivity and stability. Printed soil moisture and nitrate sensors with suitable sensitivity and selectivity were developed and characterized. Low power and passive wireless electronic systems were integrated with the soil sensors, and testing was carried out with completed sensors to understand their functionality under agricultural conditions. Additionally, other sensor types enabled by the biodegradable materials set created during this project, such as soil microbial activity sensors, were also developed and demonstrated. Project outputs include 10 peer reviewed publications, 4 patent applications, 21 technical presentations, 3 PhD thesis, 10 media reports, 8 additional grants worth over $\$$6M, and the formation of 3 start-up companies.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2024

AOI [1] Advanced Manufacturing of Ceramic Anchors with Embedded Sensors for Process and Health Monitoring of Coal Boilers

Researchers at West Virginia University (WVU) developed methods to fabricate and test ceramic anchors with an embedded sensor technology for monitoring the health and processing conditions within pulverized coal (PC) and fluidized-bed combustion (FBC) boiler systems. The technology included the development of advanced manufacturing processes for 2D/3D printing electroceramic (conductive ceramic) sensor designs within the ceramic anchor microstructure during the manufacturing process. This advanced manufacturing process would allow for the precise control of local microstructure and composition in order to engineer layer-by-layer any protective and electrically active materials within the refractory anchor. This 3D printing technology would permit the rapid and controlled design of the refractory microstructure and embedded sensor design throughout the volume of the ceramic anchor. The work also included a method to interconnect the sensors to boiler shell through the anchor clamp, where the sensor signals will be processed by low-power electronics and transmitted wirelessly to a central processing hub. The end-goal of the program was to produce a ceramic anchor sensor system which would be ready for implementation within a coal boiler, and/or other similar refractory liner systems (such as that in the glass and metal manufacturing areas). The project objectives were to: 1) Define the chemical and microstructural stability, in addition to the electrical properties, of oxide and non-oxide ceramic composites to be embedded within the ceramic anchor compositions that may operate up to 1400ºC; 2) Develop and implement the 2D/3D printing technology to pattern and control the microstructure of the ceramic anchor and embedded sensor circuits; 3) Develop an interconnect technology which will permit easy installation of the ceramic anchors and signal collection at the boiler shell; 4) Develop low power analog electronics and wireless communication hardware to efficiently collect the sensor signal at each processing unit and transmit data to a central hub for data analysis; 5) Demonstrate the smart ceramic anchor system for temperature and liner fracture within a high-temperature processing unit, such as a boiler furnace or glass melting furnace floor/wall liner.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2024

Wireless Frequency‐Multiplexed Acoustic Array‐Based Acoustofluidics

Abstract Acoustofluidics has shown great potential in enabling on‐chip technologies for driving liquid flows and manipulating particles and cells for engineering, chemical, and biomedical applications. To introduce on‐demand liquid sample processing and micro/nano‐object manipulation functions to wearable and embeddable electronics, wireless acoustofluidic chips are highly desired. This paper presents wireless acoustofluidic chips to generate acoustic waves carrying sufficient energy and achieve key acoustofluidic functions, including arranging particles and cells, generating fluid streaming, and enriching in‐droplet particles. To enable these functions, the wireless acoustofluidic chips leverage mechanisms, including inductive coupling‐based wireless power transfer (WPT), frequency multiplexing‐based control of multiple acoustic waves, and the resultant acoustic radiation and drag forces. For validation, the wirelessly generated acoustic waves are measured using laser vibrometry when different materials (e.g., bone, tissue, and hand) are inserted between the WPT transmitter and receiver. Moreover, the wireless acoustofluidic chips successfully arrange nanoparticles into different patterns, align cells into parallel pearl chains, generate streaming, and enrich in‐droplet microparticles. This research is anticipated to facilitate the development of embeddable wireless on‐chip flow generators, wearable sensors with liquid sample processing functions, and implantable devices with flow generation and acoustic stimulation abilities for engineering, veterinary, and biomedical applications.

Li, Jiali↗
DOE OSTI2024

Enabling the Next Generation of Smart Sensors in Coal Fired Power Plants using Cellular 5G Technology

An important need for coal fired power plants is the ability to monitor multiple systems with ease and accuracy. Common implementations of these monitoring systems come with drawbacks due to the nature of coal fired power plants. Harsh environments, High Temperatures, and lots of RF (Radio Frequency) noise can create issues for accurately recording and transmitting data across wireless signals. In addition, as renewable energy sources come online, existing fossil fueled plants will need to operate more flexibly with their maintenance schedules outside of standard conditions. Therefore, additional sensing and control mechanisms need placed in existing plants to provide operators with more information such that maintenance decisions can be made well in advance of failures. A solution to this problem is the Next Generation of Smart Sensors, which leverages the power of 5G cellular signals and machine learning to overcome the myriad of problems with current implementations

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2026

Sap Velocity Data for Urban Trees in Chicago, Illinois (2024-2025)

This dataset contains uncorrected sap velocity measurements using the heat ratio method (HRM) collected using ICT International SFM1x sensors at five urban sites in Chicago, Illinois, as part of the DOE CROCUS project. The data includes continuous monitoring of sap velocity from various tree species, including Maples (Acer spp.): Sugar Maple (Acer saccharum), Silver Maple (Acer saccharinum), and Red Maple (Acer rubrum); Oaks (Quercus spp.): Swamp White Oak (Quercus bicolor); American Elm (Ulmus americana); Honey Locust (Gleditsia triacanthos); Cottonwood (Populus deltoides); and Tree of Heaven (Ailanthus altissima) across Chicago State University (CSU), Northeastern Illinois University (NEIU), Northwestern University (NU), University of Illinois Chicago (UIC), and West Woodlawn "Blacks in Green" (BIG). These include both street trees and those in urban park locations. Measurements were collected at 15-20 minute intervals, depending on the sensor, and transmitted via Long Range Wide Area Network (LoRaWAN) protocols. The wireless data was collected by Sage Network (https://sagecontinuum.org/) nodes. The dataset includes sensor ID, Global Positioning System (GPS) coordinates, tree species (common and scientific names), tree identification number, diameter at breast height (DBH in cm), uncorrected sap velocity measurements (cm/hr) from both inner and outer probes, and Sage Node identifiers so the data can be mapped to related variables such as air quality and wind speed that were collected on the Sage nodes. All timestamps are in local Chicago time (CDT/CST). Quality control flags are provided using a 3-bit binary system indicating physical range violations (< -10 or > 60 cm/hr), step spikes (absolute difference > 36 cm/hr), and stuck sensor conditions (> 10 consecutive identical values). These are raw data, not corrected for wood anatomy or species-specific characteristics. Data is provided in comma separated (CSV) format. This dataset is part of a larger collection of CROCUS environmental monitoring data, including linked datasets from Air Quality Transmitter (AQT) sensors, Weather Transmitter (WXT) sensors, and Multi-Function Research LoRaWAN (MFR) Nodes. DOIs for the supporting data are provided as part of this data package.

Chicago↗
DOE OSTI2024

Integrated energy harvesting transceivers and transmitters with dual-antenna architecture for miniaturized implants and electrochemical sensors

Systems and methods for utilizing a small form-factor, wirelessly powered transceiver are disclosed. In one embodiment, a wireless powered transceiver includes a receive antenna configured to receive a receive signal, a transmit antenna configured to transmit a transmit signal, a power harvesting system including a rectifier circuit configured convert radio frequency energy from the receive signal into DC (direct current) voltage, and a power management unit (PMU) configured to set the operating mode and biasing condition of the receive and transmit circuitry blocks and provide DC voltage from the receive circuitry block to the transmit circuitry block to maintain a minimum voltage, a receiver circuitry block configured to provide energy from the receive signal to the power harvesting system, and a transmitter circuitry block including a data modulator circuit, the data modulator circuit configured to generate the transmit signal using DC voltage received from the power management unit.

Babakhani, Aydin↗
DOE OSTI2025

Commercialization of the Transportation-Security, Tracking, and Reporting System (T-STAR)

The Transportation-Security, Tracking, and Reporting System (T-STAR) was developed by the National Nuclear Security Administration, NA-21, Office of Radiological Security (ORS) to provide a transportation security system for detection and tracking during transport of Category 1 and Category 2 radiological material. Few off-the-shelf systems for conveyance tracking offer detection of a cargo compartment breach or a removal of the cargo. Systems that do offer this capability often require permanent installation through modifying of the conveyance itself. This is not sustainable in many countries where ORS is building use, storage, and transport security capacity. The development of T-STAR has moved from fielding robust prototypes deployed in countries ranging from North America, Latin America and Central Asia to a commercially produced product that can now be deployed to provide enhanced security during transit. Each prototype deployment resulted in important lessons learned, which informed the requirements for the final commercial product. T-STAR uses both cellular and Iridium satellite modems to provide redundant communications to provide the configuration, status, and alerts to a server monitoring the shipment, which is accessible using a multilanguage browser-based user interface. A wireless security system employing using Z-wave sensors for intrusion detection located in the conveyance provide low cost but effective solution for a wide range of conveyance types. Additional capabilities include the ability to monitor a vehicles’ CANBUS (Controller Area Network) system, an ethernet port for high throughput sensor information such as video cameras, and the ability to power and use advanced external sensor payloads. These features make the T-STAR a capable and expandable security gateway that can be deployed on a variety of conveyances from box trucks to open trailers. The ability to provide tracking, monitoring, and detection provide a key component in overall best practices designed to protect shipments of radioactive material.

Schultze, Michael [ORNL] (ORCID:0000000283205671)↗
DOE OSTI2024

Practical Insights on Applying Simulation-Based Control Methods in Experimental Studies

Advanced nuclear reactors are crucial to the future of energy both in the United States and around the globe. In contrast to the current operating fleet, they are characterized as being deployable in remote locations and able to operate in semi-autonomous or autonomous fashion. This leap forward necessitates a new reactor control paradigm. Because advanced nuclear reactors are still under development in the United States, the creation of new control methods to achieve autonomous operations has been based on systems modeling and simulation. However, an important factor in successfully deploying these new control methods is the ability to seamlessly transition from simulation environments to real-world settings. Control methods tested in both simulation and experimental settings need to be investigated in the context of advanced reactor applications. This work developed a series of simple controllers for Idaho National Laboratory (INL)’s Microreactor Applications Research Validation and Evaluation (MARVEL) microreactor operating in load-following scenarios. These controllers were tested in both simulation and experimental settings, and a comparative performance analysis was performed. The simulation tests leveraged the Control and Optimization Modular Modeling Application for Nuclear Deployment (COMMAND) software developed in a previous stage of the current effort, along with the MARVEL Reactor Excursion and Leak Analysis Program (RELAP5-3D) and Monte Carlo N-Particle (MCNP) models. The experimental tests leveraged the COMMAND software, MARVEL models, and the U.S. Department of Energy Microreactor Program’s Microreactor Automated Control System (MACS). MACS was developed to serve as a control method testbed. It was customized to mirror the MARVEL microreactor, and COMMAND enabled MACS to emulate the physics of MARVEL. The load-following controller was developed using the simulation platform, with efforts to emulate real systems by introducing actuator saturation and noise. These factors were incrementally accounted for in the controller design. After finalizing the controller design, it was implemented with the experimental setup. The experimental conditions tested included an initial test under conditions similar to the final simulation test, and two additional scenarios. The first scenario introduced additional actuator saturation to account for equipment aging over time, which was unknown to the controller. The second scenario introduced sensor delay, a phenomenon anticipated with the use of remote operations or wireless communication in advanced reactors. These tests revealed several notable differences. While the controller performed well in simulation, it exhibited several limitations when transitioning to hardware. The main challenges involved maintaining the steady-state target power, as evidenced by larger error values between the true reactor power and setpoint power, as well as persistent oscillations in controlled reactor power. These issues could lead to unacceptable transient conditions in real reactor testing. Introducing actuator aging and stochastic delays in the experimental setup significantly impacted controller performance, resulting in increased overshoot and undershoot, and exacerbated error and oscillations previously mentioned. These findings underscore the importance of experimental testbeds for testing and validating control methods, as controllers developed using only theory and/or simulation may perform unexpectedly when applied to actual hardware. This research emphasizes the need for an experimental testbed for achieving such validation.

46 - INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AN↗
DOE OSTI2026

A network of soil moisture, soil temperature, air temperature, net radiation, ground heat flux and ground water for Chicago, Illinois

This dataset contains environmental monitoring data collected using solar-powered Multi-Function Research (MFR) Long Range Wide Area (LoRaWAN)-enabled nodes at 11 sites in Chicago, Illinois, as part of the DOE Urban Integrated Field Lab CROCUS project. The MFR node system consists of an Input/Output Digital Input Module (IB8) interface box (ICT International) providing wired connections for environmental sensors and an MFR-Node-L data logger that manages power, data processing, and LoRaWAN communication. The wireless data are ingested via Sage network (https://sagecontinuum.org/) nodes that contain LoRaWAN antennae. Measurements were collected from 11 MFR nodes deployed across Chicago State University (CSU), Northeastern Illinois University (NEIU), Northwestern University (NU), University of Illinois Chicago (UIC), West Woodlawn "Blacks in Green" (BIG), and Indian Boundary Prairies (IBP). Each MFR node supports a consistent suite of sensors measuring atmospheric, soil, and hydrological variables. Atmospheric measurements include 2m air temperature (°C), 2m vapor pressure deficit (kPa), and 2m shortwave/longwave radiation (incoming and outgoing, W/m²) measured using ATH-VPD and Apogee SN500 sensors. Soil measurements include volumetric water content (VWC, %) and temperature (°C) at four depths (15, 30, 45, and 60 cm below surface) using Meter Teros54 sensors, and heat flux (W/m²) at 10 cm depth using Huske HFP01-05 sensors. At selected locations, Meter Hydros21 sensors measure groundwater depth (mm), specific conductivity (dS/m), and temperature (°C). The dataset includes timestamps, site identifiers with location names, device IDs, Global Positioning System (GPS) coordinates, variable names with units, measurement depths, values, sensor names, and Sage node identifiers. All timestamps are in local Chicago time (CDT/CST). Quality control flags are provided using a 6-bit binary system indicating physical range violations, step spikes, 24-hour flat-line conditions, 6-hour jitter, 7-day ultra-low variance, and persistent high offset. Data is provided in CSV and CF-compliant NetCDF formats. This dataset is part of a larger collection of CROCUS environmental monitoring data, including linked datasets from Air Quality Transmitter (AQT) sensors, Weather Transmitter (WXT) sensors, and Sap Flow Meter (SFM1x) sensors.

Chicago↗
DOE OSTI2024

7-8 GHz Point-to-Point Testing

Wireless spectrum is a limiting resource for continued economic growth in the United States. As discussed in the recent National Spectrum Strategy (NSS), wireless spectrum underpins several aspects of the U.S. economy and the demand for additional spectrum is driving the need for realizing spectrum sharing to enable continued development. At the same time, wireless spectrum is an essential foundation of critical energy infrastructure, including electric, oil, and natural gas resources. In particular, wireless point-to-point (P2P) links are the backbone of vast infrastructure networks that enable the flow of sensor and control information needed to manage critical energy sector infrastructure in the United States. These links will only become more important as the energy sector incorporates more diverse sensing and more efficient control mechanisms, which increases system complexity and data volume requiring more resilient communications. Therefore, the continued economic development of the U.S. depends on determining novel approaches to spectrum management that balance both broad access for advanced wireless technologies and resilience for critical infrastructure.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2026

Correlation of Surface Acoustic Wave (SAW) force myography sensor output with elbow joint torque

Accurate assessment of skeletal muscle forces and net joint torque is essential for preventing fatigue-related injuries, optimizing physical training, and monitoring disease progression in neuromuscular conditions. However, existing joint torque evaluation techniques are hindered by limited portability and high operational costs, confining their use to controlled laboratory or clinical settings. Despite substantial advances in wearable joint torque estimation systems, ongoing challenges such as power constraints, bulky wired setups, and susceptibility to environmental or motion artifacts underscore the urgent need for truly batteryless, wireless solutions deployable in real-world settings. This paper proposes a novel surface acoustic wave (SAW)-based force myography (FMG) system for noninvasive measurement of joint torque, validated against a gold-standard electromechanical dynamometer. The approach uses a single SAW sensor embedded in an armband to detect volumetric biceps brachii changes, with a second-order polynomial mapping sensor output and elbow angle to torque. Seven participants were tested in both isometric (15°–90°) and isokinetic (10°/s and 20°/s) supinated elbow flexion tasks. Under isometric conditions, subject-specific calibration achieved a normalized root-mean-square error (NRMSE) of 13.6% ± 6.0% and R 2 = 0.834 ± 0.180, while a group-level model yielded 14.4% ± 6.8% and 0.808 ± 0.208, respectively. For isokinetic trials, the group model produced an NRMSE of 24.1% ± 6.6% at 10°/s and 24.9% ± 08.9% at 20°/s, highlighting the feasibility of using a single-sensor SAW-FMG setup across different speeds. Because SAW devices support wireless, battery-free operation, the proposed system offers a pathway to portable, real-time monitoring for sports medicine, rehabilitation, and clinical diagnostics.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Field validation of dynamic mechanical torque measurements using fiber-optic strain sensors for geared wind turbines

Abstract Accurate knowledge of the mechanical loads of wind turbine gearboxes has become essential in modern, highly loaded gearbox designs, as maintaining or even improving gearbox reliability with increasing torque density demands is proving to be challenging. Unfortunately, the traditional method of measuring dynamic mechanical torque using strain gauges placed on the outer surface of a rotating shaft and transmitting the resulting signal is unsuitable for serial deployment due to technical and economic constraints. An alternative method based on fiber-optic strain sensors placed on the stationary outer surface of the gearbox ring gear has been proposed. Like shaft torsion, the radial deformation of the ring gear is proportionate to the rotor torque. Placing the sensors on a stationary component is a cost-effective alternative for serial implementation because the need for complex and expensive data transfer via wireless transmission or a slip ring is eliminated. In this paper, we present the results of an extensive field experiment conducted to evaluate the torque measurement accuracy of this novel sensing solution installed on the gearbox of a Gamesa G97 2-MW wind turbine at the National Renewable Energy Laboratory’s Flatirons Campus. Torque measurements derived from fiber-optic strain sensors placed on the ring gear of the planetary stage are compared to conventional torque measurements from strain gauges placed on the main shaft. Two different torque estimation data processing methods were evaluated, with the method based on operational deflection shapes providing the most accurate results with an average normalized root mean square error below 0.7% for a load revolution distribution analysis. The effect of operating conditions on the torque estimate was also investigated, and the third planet-passing operational deflection shape was found to be the least sensitive to nontorque load-related effects. The fiber-optic strain sensors’ successful operation during the complete test campaign has demonstrated a robust and accurate solution for fleet-wide enhanced gearbox remaining useful life estimation.

17 WIND ENERGY↗