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DOE OSTI2020

Motion Control of Hydraulic Actuators In the Presence of Discrete Pressure Rail Switching

Conventional off-highway mobile machines are hydraulically actuated and have poor energy efficiencies. The goal to increase system efficiency and to reap the benefits of electrification have led to the creation of a novel Hybrid Hydraulic-Electric Architecture (HHEA) which could significantly increase efficiency, decrease the sizes and cost of electrical components, and maintain control performance. The key concept is to utilize a set of common pressure rails to provide the majority of power via the power dense hydraulics and to modulate that power by small electric components, which are less power dense, for precise control. The paper presents the motion control strategy for this architecture. The architecture presents a distinct challenge in that as the energy minimization algorithm selects different pressure rails, the system could experience large discrete jumps in pressures that impact control performance, especially when the electric components are torque limited. To meet this challenge, a passivity based back-stepping controller is used as the nominal controller between pressure rail switching events and a separate transition controller is used to deal with the pressure rail switching events. Two transition controllers are proposed, one uses the electric motor torque as the input, and the other also uses valve timing as a second input. For both transition controllers, a least norm control approach is used to steer the system states to the exact desired states at the end of the short transition period (~ 40 ms). The transition controllers are able to reduce the tracking error and the required electric motor torque, and hence achieve better control performance even with smaller electric components.

24 POWER TRANSMISSION AND DISTRIBUTION↗

NASA NTRS1971

Dynamic responses of railroad car models to vertical and lateral rail inputs

Simplified dynamic models were applied in a study of vibration in a high-speed railroad car. The mathematical models used were a four-degree-of-freedom model for vertical responses to vertical rail inputs and a ten-degree-of-freedom model for lateral response to lateral or rolling (cross-level) inputs from the rails. Elastic properties of the passenger car body were represented by bending and torsion of a uniform beam. Rail-to-car (truck) suspensions were modeled as spring-mass-dashpot oscillators. Lateral spring nonlinearities approximating certain complicated truck mechanisms were introduced. The models were excited by displacement and, in some cases, velocity inputs from the rails by both deterministic (including sinusoidal) and random input functions. Results were obtained both in the frequency and time domains. Solutions in the time domain for the lateral model were obtained for a wide variety of transient and random inputs generated on-line by an analog computer. Variations in one of the damping properties of the lateral car suspension gave large fluctuations in response over a range of car speeds for a given input. This damping coefficient was significant in reducing lateral car responses that were higher for nonlinear springs for three different inputs.

Sewall, J. L.↗

NASA NTRS1973

NASTRAN buckling study of a linear induction motor reaction rail

NASTRAN was used to study problems associated with the installation of a linear induction motor reaction rail test track. Specific problems studied include determination of the critical axial compressive buckling stress and establishment of the lateral stiffness of the reaction rail under combined loads. NASTRAN results were compared with experimentally obtained values and satisfactory agreement was obtained. The reaction rail was found to buckle at an axial compressive stress of 11,400 pounds per square inch. The results of this investigation were used to select procedures for installation of the reaction rail.

Williams, J. G.↗

NASA NTRS1977

Preliminary evaluation of fiber composite reinforcement of truck frame rails

The use of graphite fiber/resin matrix composite to effectively reinforce a standard steel truck frame rail is studied. A preliminary design was made and it was determined that the reinforcement weight could be reduced by a factor of 10 when compared to a steel reinforcement. A section of a 1/3 scale reinforced rail was fabricated to demonstrate low cost manufacturing techniques. The scale rail section was then tested and increased stiffness was confirmed. No evidence of composite fatigue was found after 500,000 cycles to a fiber stress of 34,000 psi. The test specimen failed in bending in a static test at a load 50 percent greater than that predicted for a non-reinforced rail.

Faddoul, J. R.↗

NASA NTRS1981

The electric rail gun for space propulsion

An analytic feasibility investigation of an electric propulsion concept for space application is described. In this concept, quasistatic thrust due to inertial reaction to repetitively accelerated pellets by an electric rail gun is used to propel a spacecraft. The study encompasses the major subsystems required in an electric rail gun propulsion system. The mass, performance, and configuration of each subsystem are described. Based on an analytic model of the system mass and performance, the electric rail gun mission performance as a reusable orbital transfer vehicle (OTV) is analyzed and compared to a 30 cm ion thruster system (BIMOD) and a chemical propulsion system (IUS) for payloads with masses of 1150 kg and 2300 kg. For system power levels in the range from 25 kW(e) to 100 kW(e) an electric rail gun OTV is more attractive than a BIMOD system for low Earth orbit to geosynchronous orbit transfer durations in the range from 20 to 120 days.

Bauer, D. P.↗

NASA NTRS1983

The LeRC rail accelerators: Test designs and diagnostic techniques

The feasibility of using rail accelerators for various in-space and to-space propulsion applications was investigated. A 1 meter, 24 sq mm bore accelerator was designed with the goal of demonstrating projectile velocities of 15 km/sec using a peak current of 200 kA. A second rail accelerator, 1 meter long with a 156.25 sq mm bore, was designed with clear polycarbonate sidewalls to permit visual observation of the plasma arc. A study of available diagnostic techniques and their application to the rail accelerator is presented. Specific topics of discussion include the use of interferometry and spectroscopy to examine the plasma armature as well as the use of optical sensors to measure rail displacement during acceleration. Standard diagnostics such as current and voltage measurements are also discussed.

Zana, L. M.↗

NASA NTRS1982

Electric rail gun projectile acceleration to high velocity

Electric rail accelerators are being investigated for application in electric propulsion systems. Several electric propulsion applications require that the rail accelerator be capable of launching projectiles at velocities above 10 km/s. An experimental program was conducted to develop rail accelerator technology for high velocity projectile launch. Several 6 mm bore, 3 m long rail accelerators were fabricated. Projectiles with a mass of 0.2 g were accelerated by plasmas, carrying currents up to 150 kA. Experimental design and results are described. Results indicate that the accelerator performed as predicted for a fraction of the total projectile acceleration. The disparity between predicted and measured results are discussed.

Bauer, D. P.↗

NASA NTRS1984

LeRC rail accelerators - Test designs and diagnostic techniques

Zana, L. M.↗

NASA NTRS1984

Energy partitioning in an inductively driven rail gun

The equations describing the performance of an inductively driven rail are analyzed numerically. Friction between the projectile and rails is included through an empirical formulation. The equations are applied to the experiment of Rashleigh and Marshall to obtain an estimate of energy distribution in rail guns as a function of time. It is found that only 15 percent of energy delivered by the inductor to the gun is transformed into the kinetic energy of the projectile. This study provides an insight into the nature of nonlinear coupling involved in the electromechanical interactions in a rail gun.

Sen, K. K.↗

NASA NTRS1984

Arc-driven rail gun research

The equations describing the performance of an inductively-driven rail gun are analyzed numerically. Friction between the projectile and rails is included through an empirical formulation. The equations are applied to the experiment of Rashleigh and Marshall to obtain an estimate of energy distribution in rail guns as a function of time. The effect of frictional heat dissipation on the bore of the gun is calculated. The mechanism of plasma and projectile acceleration in a dc rail gun is described from a microscopic point of view through the establishment of the Hall field. The plasma conductivity is shown to be a tensor indicating that there is a small component of current parallel to the direction of acceleration. The plasma characteristics are evaluated as a function of plasma mass through a simple fluid mechanical analysis of the plasma. By equating the energy dissipated in the plasma with the radiation heat loss, the properties of the plasma are determined.

Ray, P. K.↗

NASA NTRS2008

Fuel Savings and Aerodynamic Drag Reduction from Rail Car Covers

The potential for energy savings by reducing the aerodynamic drag of rail cars is significant. A previous study of aerodynamic drag of coal cars suggests that a 25% reduction in drag of empty cars would correspond to a 5% fuel savings for a round trip [1]. Rail statistics for the United States [2] report that approximately 5.7 billion liters of diesel fuel were consumed for coal transportation in 2002, so a 5% fuel savings would total 284 million liters. This corresponds to 2% of Class I railroad fuel consumption nationwide. As part of a DOE-sponsored study, the aerodynamic drag of scale rail cars was measured in a wind tunnel. The goal of the study was to measure the drag reduction of various rail-car cover designs. The cover designs tested yielded an average drag reduction of 43% relative to empty cars corresponding to an estimated round-trip fuel savings of 9%.

Storms, Bruce↗

DOE OSTI2021

Electromagnetic driver with helical rails to impart rotation

An EM driver for accelerating an object may be configured as an EM rifle for accelerating, rotating to spin-stabilize, and releasing a projectile. A core includes a stator coil, forward and reverse coils, a railed shaft, and a transfer shaft. The stator coil generates a first EM field, and the forward and reverse coils generate second and third EM fields which interact with the first EM field to accelerate the armature in forward and reverse directions, respectively. The railed shaft is elongated along a central axis through the armature and includes multiple rails arranged helically around a central shaft. The armature remains in contact with the rails during acceleration so as to impart a turning motion. The transfer shaft is physically coupled with and projects forwardly from the armature and transfers to the projectile the acceleration and the turning motion of the armature in the forward direction.

Timpson, Erik↗

DOE OSTI2022

Multi-Pressure Rail System Design with Variable Pressure Control Strategy

This paper presents the design and the control method of a Multiple Pressure Rail system (MPR) with a variable pressure control logic that allows minimization of throttling loss, therefore, increasing the overall fluid power actuation efficiency. An MPR system allows controlling hydraulic actuators with a pressure control logic, as opposed to traditional flow control logics which are well established in mobile applications. A proper setting of the number of pressure rails and the pressure level in each rail permits optimizing the system efficiency of an MPR solution. MPR systems have been recently proposed with different purposes, but seldom adopt variable pressure control strategies to manage the pressure variations in the rails. Moreover, the related past work attempts to maximize the energy recovery during overrunning load conditions. This paper, instead, addresses the case of an MPR system that handles a multitude of hydraulic functions without significant overrunning loads, as it occurs in many mobile applications such as in agriculture. The paper first presents the design alternatives considered for the MPR system, including the supply, the control valves, and the controller. Second, a dedicated test rig is developed to support experimental activities and validations of a lumped parameter model developed within this research to develop the MPR control strategy. The results describe the operating features of the proposed MPR solution. By considering the case of a traditional LS system, the paper results also show how system efficiency can be highly improved, with energy savings in the order of 49%

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2024

Abatement cost curve analysis of freight rail decarbonization alternatives

This paper investigates decarbonization alternatives for the freight rail industry, considering economic, environmental, and operational aspects. The study compares battery-electric and hydrogen fuel cell locomotives, drop-in fuels including biofuels and e-fuels, and overhead catenary electrification through abatement cost analyses. Scenario analysis identifies the cost-effectiveness of each of the technologies at different stages of decarbonization in the US Class 1 freight railroad network. We show that though battery locomotives offer a lower-cost decarbonization option in the considered scenarios, green hydrogen fuel-powered locomotives become more attractive when battery charging delays are considered. We introduce the concept of the technology margin to cater for uncertainties in battery charging operations and hydrogen fuel production for cases where carbon taxes are imposed on railroad operations. In conclusion, the study provides valuable insights for policymakers and rail operators, contributing to sustainable freight rail operations.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2022

A Variable Pressure Multi-Pressure Rail System Design for Agricultural Applications

This paper presents a solution for reducing energy loss in the hydraulic control system of agricultural tractors and their implements. The solution is referred to as a multi-pressure rail (MPR) and provides power to the hydraulic functions following a pressure control logic, as opposed to the traditional flow control logic typical of hydraulic systems used in off-road vehicles. The proposed hydraulic control system allows for elimination of redundant flow control valves in the state-of-the-art system, which cause excessive throttling losses leading to poor overall energy efficiency. Related work on MPR technology targets construction vehicles, where the MPR solution can allow energy recovery during overrunning loads and better engine management. This paper alternatively addresses the case of agricultural applications where functions mostly operate under resistive load conditions with slow dynamics, which offers an opportunity to target throttle losses. For this purpose, the paper introduces a variable pressure control strategy to handle the instantaneous pressure at each rail. To develop both the controller and the hydraulic system architecture, a stationary test rig is conceived and used to validate a numerical simulation model of the MPR system and its control strategy. Particular focus is given to the dynamic behavior of the system during the switches of a function between different pressure rails, which needs to ensure reduced oscillations of the flow provided to each hydraulic function. Once validated, the simulation model is used to predict the energy savings of the MPR solution in an actual application: a 435 hp hydraulic tractor powering a 16-row planter, for which operating features during typical drive cycles were available to the authors. The results show up to 59% total power reduction at the pump shaft, corresponding to 89.8% system efficiency gain.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Heralded Multiplexed High-Efficiency Cascaded Source of Dual-Rail Entangled Photon Pairs Using Spontaneous Parametric Down-Conversion

Deterministic sources of high-fidelity entangled qubit pairs encoded in the dual-rail photonic basis, i.e., presence of a single photon in one of two orthogonal modes, are a key enabling technology of many applications of quantum information processing, including high-rate, high-fidelity quantum communications over long distances. The most popular and mature sources of such photonic entanglement, e.g., those that leverage spontaneous parametric down-conversion (SPDC) or spontaneous four-wave mixing, generate an entangled (so-called continuous-variable) quantum state that contains contributions from high-order photon terms that lie outside the span of the dual-rail basis, which is detrimental to most applications. One often uses low pump power to mitigate the effects of those high-order terms. However, that reduces the pair generation rate, and the source becomes inherently probabilistic. We investigate a cascaded source that performs a linear-optical entanglement swap between two SPDC sources, to generate a heralded photonic entangled state that has a higher fidelity (to the ideal Bell state) compared to a free-running SPDC source. Furthermore, with the Bell swap providing a heralding trigger, we show how to build a multiplexed source, which despite reasonable switching losses and detector loss and noise, yields a fidelity versus success probability trade-off of a high-efficiency source of high-fidelity dual-rail photonic entanglement. We find, however, that there is a threshold of 1.5 dB of loss per switch, beyond which multiplexing hurts the fidelity versus success probability trade-off.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

DOE OSTI2021

Refueling Infrastructure Scoping and Feasibility Assessment for Hydrogen Rail Applications

The feasibility and component cost of hydrogen rail refueling infrastructure is examined. Example reference stations can inform future studies on components and systems specifically for hydrogen rail refueling facilities. All of the 5 designs considered assumed the bulk storage of liquid hydrogen on-site, from which either gaseous or liquid hydrogen would be dispensed. The first design was estimated to refuel 10 multiple unit trains per day, each train containing 260 kg of gaseous hydrogen at 350 bar on-board. The second base design targeted the refueling of 50 passenger locomotives, each with 400 kg of gaseous hydrogen on-board at 350 bar. Variations from this basic design were made to consider the effect of two different filling times, two different hydrogen compression methods, and two different station design approaches. For each design variation, components were sized, approximate costs were estimated for major components, and physical layouts were created. For both gaseous hydrogen-dispensing base designs, the design of direct-fill using a cryopump design was the lowest cost due to the high cost of the cascade storage system and gas compressor. The last three base designs all assumed that liquid hydrogen was dispensed into tender cars for freight locomotives that required 7,500 kg of liquid hydrogen, and the three different designs assumed that 5, 50, or 200 tender cars were refueled every day. The total component costs are very different for each design, because each design has a very different dispensing capacity. The total component cost for these three designs are driven by the cost of the liquid hydrogen tank; additionally, delivering that much liquid hydrogen to the refueling facility may not be practical. Many of the designs needed the use of multiple evaporators, compressors, and cryopumps operating in parallel to meet required flow rates. In the future, the components identified here can be improved and scaled-up to better fit the needs of heavy-duty refueling facilities. This study provides basic feasibility and first-order design guidance for hydrogen refueling facilities serving emerging rail applications.

08 HYDROGEN↗

DOE OSTI2026

Identification of Hydrogen Rail Maintenance Facility Hazards

Maintenance facilities for hydrogen rail, the activities conducted within such facilities, and how these activities differ from ordinary rail or hydrogen vehicle maintenance are currently being considered for the hazards specific to hydrogen. By performing a hazard and operability study (HAZOP) on numerous potential maintenance and repair scenarios, select low, medium, and high risk hazards relevant to hydrogen rail systems in such environments have been identified. The analysis resulted in 79 unique HAZOP scenarios: one scenario in the high risk category, 43 in the medium risk category, and 35 in the low risk category. Notably, large accidental releases of hydrogen due to tank rupture, aberrant defueling processes, or relief device opening within a facility are important low likelihood consequences that should nevertheless be appropriately prevented and mitigated.

08 HYDROGEN↗