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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 361 records · Page 20
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DOE OSTI2023

Automotive Silicon Carbide Power Module Cooling With A Novel Modular Manifold And Embedded Heat Sink

The next generation of integrated power electronics packages will implement wide-bandgap devices with ultrahigh device heat fluxes. Although jet impingement has received attention for power electronics thermal management, it is not used in commercial electric vehicles (EVs) because of the associated pressure drop and reliability concerns. Here, in this paper, we present a modular thermal management system designed for automotive power electronics. The system achieves superior thermal performance to benchmarked EVs, while adhering to reliability standards and with low pumping power. The system utilizes a low-cost and lightweight plastic manifold to generate jets over an optimized heat sink, which is embedded in the direct-bonded-copper (DBC) substrate. The embedded heat sink concept leverages additive manufacturing to add elliptical pin fins to the DBC substrate. The heat sink geometry is optimized for submerged jet impingement using a unit-cell model and an exhaustive search algorithm. The model predictions are validated using unit-cell experiments. A full-scale power module model is then used to compare the DBC-embedded heat sink against direct DBC cooling and baseplate-integrated heat sinks for single-sided (SS) and double-sided (DS) cooling concepts. Using the SS and DS DBC-embedded cooling concepts, the models predict a thermal resistance that represents a reduction of 75% and 85% compared to the 2015 BMW i3, respectively, for the same water-ethylene glycol inverter flow rate. We have shown that an inverter with a 100-kilo-Watt-per-liter power density is achievable with the proposed design.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2023

A Stochastic Charging Station Deployment Model for Electrified Taxi Fleets in Coupled Urban Transportation and Power Distribution Networks

Metropolitansworldwide are increasingly adopting electric taxis (ET) to address concerns about transportation-related emissions. However, the widespread deployment of electric taxis presents challenges in terms of increased electricity demand and changing demand profiles. This transition impacts both the urban transportation network (TN) and the electricity power distribution network (PDN), highlighting the interdependence between these two systems. Here, in this paper, we propose a two-stage stochastic programming planning model that aims to optimize both the TN and PDN, enabling efficient deployment of charging stations and grid upgrades. Our model seeks to strike a balance between meeting ET drivers' charging preferences, minimizing the costs associated with infrastructure deployment and grid expansion, and harmonizing the coordination between the TN and PDN. Additionally, we explore the potential benefits of utilizing an autonomous ET fleet to enhance overall system performance.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2021

Incorporating Valve Switching Losses Into a Static Optimal Control Algorithm for the Hybrid Hydraulic-Electric Architecture (HHEA)

The Hybrid Hydraulic-Electric Architecture (HHEA) has, in recent years, been proposed as an energy efficient alternative to conventional load-sensing architectures in mobile machines such as excavators and wheel-loaders. HHEA leverages the advantages of hydraulic power and electric power to eliminate throttling valves while also improving the energy and control performance of the system. The architecture utilizes a set of common pressure rails to provide a majority of power and and a small electric motor driven pump to modulate this power to meet the exact demand. Previous work has developed a computationally efficient Lagrange Multiplier approach for determining the optimal pressure rail selections that minimizes the energy losses in the system. The static model used considers only the energy use for each pressure rail selection but not the losses associated with the valves during the transition. This paper presents an approach to include the switching losses in the model and in the optimization procedure. To capture the switching losses, switching events between different rails and at various input and output flow rates were simulated with consideration of valve spool dynamics. A parameterized model that summarizes the losses is then obtained, allowing switching losses to be added to the previous energy analysis. The performance of the switching loss model was compared with reference data obtained from a high-fidelity simulation model. To incorporate the switching losses into optimal control algorithm, an efficient dynamic programming approach that prevents frequent switching is adopted in place of the Lagrange multiplier approach. The overall effect of switching losses on the energy consumption and optimal control decisions is presented. In general, switching losses contribute to about 9–10% of input energy.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2023

Summary of Expansions and Updates in R&D GREET ® 2023

The Greenhouse gases, Regulated Emissions, and Energy use in Technologies (GREET®) model was developed by Argonne National Laboratory (Argonne) with the support of the U.S. Department of Energy (DOE) and other federal agencies. R&D GREET is a life cycle analysis (LCA) model, structured to systematically examine the energy and environmental effects of a wide variety of transportation fuels and vehicle technologies in major transportation sectors (i.e., road, air, marine, and rail), other end-use sectors, and energy systems. Argonne has expanded and updated the model in various areas in R&D GREET 2023. This report provides a summary of the expansions and updates.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2021

Component Modeling, Co-Optimization, and Trade-Space Evaluation (FY2021 Annual Progress Report)

This project is intended to support the development of new traction drive systems that meet the targets of 100 kW/L for power electronics and 50 kW/L for electric machines with reliable operation to 300,000 miles. To meet these goals, new designs must be identified that make use of state-of-the-art and next-generation electronic materials and design methods. Designs must exploit synergies between components, for example converters designed for high-frequency switching using wide band gap devices and ceramic capacitors. This project includes: (1) a survey of available technologies; (2) the development of design tools that consider the converter volume and performance; (3) exercising the design software to evaluate performance gaps and predict the impact of certain technologies and design approaches, i.e. GaN semiconductors, ceramic capacitors, and select topologies; and (4) building and testing hardware prototypes to validate models and concepts. Early instantiations of the design tools enable co-optimization of the power module and passive elements and provide some design guidance; later instantiations will enable the co-optimization of inverter and machine. Prototype testing begins with evaluation of simpler conversion topologies (i.e. the half-bridge boost converter) and progresses with fabrication of prototype inverter drives.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2021

Highly Integrated Wide Bandgap Power Module for Next Generation Plug-In Vehicles (Final Report)

Wide bandgap devices are key enablers for high power density traction inverters. A highly integrated wide bandgap (WBG) power module enables higher temperature operation, higher inverter efficiency and overall smaller die area with the same power delivery. However, it requires careful design of the power module to take advantage of all the superior material properties that silicon carbide (SiC) provides over conventional silicon (Si) Insulated Gate Bipolar Transistor (IGBT) based design. This project developed an efficient and densely packed SiC power module for an automotive traction inverter application. Extensive study was performed to select the best performing SiC die considering a wide range of temperature variation, suitability to integrate into target packaging, robust body diode performance and overall high electrical efficiency. Multiple design ideas were explored to achieve lower stray inductance for both power loop and signal loop, uniform current distribution, compact form factor, and very high thermal performance. The final power module package includes all six inverter switches in the same module (six-pack) with die sintered at both bottom and top surfaces utilizing high performance substrate to achieve high electrical and thermal performance. Two power module variants were developed using 900 V and 1200 V devices for operating at two different high voltage levels (> 600 V HV battery). Both power modules were comprehensively characterized, and high efficiency operation of the inverter was confirmed through analysis. Finally, a complete functional inverter was built with the 1200V power modules using other essential components (HV capacitors, gate driver board, controller board, current sensor, connectors etc.) and tested using GM’s standard test procedure. There are several challenges associated with adopting WBG devices for high voltage operation. In order to assess and mitigate those challenges, GM and subrecipients of this project have conducted multiple detailed studies. This includes phase current reconstruction using integrated Rogowski coil, device junction temperature estimation using on-state gate resistance, modeling and testing the effect of high voltage and fast switching on motor insulation and bearings, partial discharge inception voltage measurement under different environmental conditions. Findings of all these studies are summarized in this report.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2023

Kinetics and extinction of non-premixed cool and warm flames of dimethyl ether at elevated pressure

Here, the growing demand of clean and efficient propulsion and energy systems has sparked an interest in understanding low-temperature combustion at high pressure. Cool flame transition and extinction limits as well as oxygen concentration dependence at elevated pressures provide insights of the low-temperature and high-pressure fuel reactivity. A new experimental high-pressure counterflow burner platform was designed and developed to achieve the studies of high-pressure cool flames. Dimethyl ether (DME) was chosen to study its non-premixed cool flame in high-pressure counterflow burner at pressure up to 5 atm, perhaps for the first time. This paper investigates the effects of pressure on cool flame structure, extinction and transition limits, and oxygen concentration dependence as well as ozone assisted warm flames of DME in experiments and numerical simulations. The results show that the reignition transition from cool flame to hot flame occurs either with the decrease of the strain rate at a given fuel concentration and pressure or with the increase of fuel mole fraction or pressure at a given strain rate. Furthermore, it is shown that the higher pressure shifts the cool flame to higher strain rates and results in higher cool flame extinction strain rates. However, the existing kinetic model of DME fails in predicting the cool flame extinction limit at elevated pressures. Besides, the cool flame extinction limits are proportional to nth power of the oxygen concentration, [O 2 ] n , and the increase of pressure leads to stronger extinction limit dependence (larger n) on oxygen concentration. The present experiment and detailed kinetic analysis show clearly that increasing pressure promotes the low-temperature chemistry including the oxygen addition reactions. In addition, stable warm flame was first experimentally observed by using DME at elevated pressure with ozone sensitization.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2021

POINT: Partially Observable Imitation Network for Traffic Signal Control

Smart traffic signals bring together transportation infrastructure and advance technologies to improve the mobility and efficiency of urban transportation network. Adaptive traffic signal control studies can be categorized into modeling-based approaches and learning-based approaches. In order to take advantages of these two systems, this study developed an offline-online combined Partial Observable Imitation Network for Traffic signal control (POINT). In the offline system, the traffic signal timing optimization problem was formulated as a Mixed Integer Nonlinear Programming (MINLP) given complete traffic information, i.e., second-by-second speeds and locations of all vehicles. Furthermore, the objective of MINLP is to minimize total travel delays considering individual vehicle trajectories under Connected Vehicle (CV) environment. The calculated optimal solutions under various traffic conditions were considered as the ”expert” decisions. In the online system, an imitation neural network model was developed to learn the ”expert” signal plans generated from offline system. Given partial observable traffic conditions in real time, e.g., the aggregate-level of traffic volume, the POINT model can compute the signal timing parameters in the online system. The numerical results demonstrated that the proposed method outperformed other state-of-the-art signal control method under high and unbalanced traffic demand levels in terms of reducing travel delays and queue length.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2022

Multimodal Freight Energy Model for Emerging Freight Technology Analysis

While freight movement represents a small portion of the volume in the transportation sector, they are a critical contributor for energy consumed in that sector. To reduce logistics costs, energy consumption and negative environmental impact, emerging technologies, such as digitalization of logistics and alternative powertrain, have been developed and extended applications in freight. These trends are expected to grow and provide opportunities for greater efficiencies in freight movement and corresponding energy use. Still, the complexity of freight systems present challenges in evaluating these benefits, especially in the multimodal inter-city freight. Addressing the research need, this paper develops a multimodal freight energy modeling framework for the analysis of emerging freight technology scenarios. The framework is a bi-level optimization problem: network cost minimization problem (lower-level) and energy minimization problem (upper-level). The lower-level problem is a mode-path assignment problem in multimodal inter-city freight networks, where commodity-specific congestion effects on trans-shipment links are considered. For this model, an inverse modeling approach is applied to infer parameters of the lower-level model. The upper-level problem is designed to search for an optimal scenario that has the lowest energy consumption among different levels of technology applications. The proposed model is empirically tested to analyze truck load-pooling and multimodal load-pooling scenarios through stand-alone and mixed applications using freight shipments originating from or destined to the Chicago region. This framework can be used to explore the impact of emerging freight technologies on mode-path freight flow and energy consumption in the national multimodal freight network.

ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2024

What’s stopping electric vehicle batteries from having a second life?

We face the grand challenge of a growing number of end-of-life lithium-ion batteries over the upcoming years. A recent Cell Reports Sustainability article presents a model for effective end-of-life battery management in China for rural electrification. Here, we emphasize the need for incorporating various stakeholders early in the design phase to remove the barriers to the reuse of retired batteries.

25 ENERGY STORAGE↗
DOE OSTI2019

Understanding Transient Combustion Phenomena in Low-NO x Gas Turbines

The goal of this work was to understand, quantify, and eventually predict combustion instability during operational transients in low-NO x gas turbine combustors. Transient operation is defined as a mode where one or more key operating parameters, including equivalence ratio, fuel composition, or fuel splitting between nozzles in a combustor, are varying in time. The timescale over which this variation occurs will be referred to as the transient timescale, the magnitude of the change in the transient parameter will be referred to as the transient amplitude, and the direction of the variation will be referred to as the transient direction. Transients occur regularly in power generation gas turbine operation. For example, load-following gas turbines vary load to meet power demands while accounting for variation in unsteady grid contributors like wind and solar power. Operators achieve this by varying equivalence ratio and fuel splitting inside the combustors to produce more or less power. Another example of transient operation is during fuel-switching operations, a particular issue for turbines operating with syngas fuels in a co-generation facility. In this case, the composition of the fuel stream may vary in time either as a result of fluctuations in the pipeline, or in the case of a co-generation plant, variations in feedstock or gasification processes. This fluctuation in fuel composition can have significant implications for combustion processes, particularly with high-hydrogen fuels. A small number of studies have investigated transient behavior in gas turbine combustors, particularly in the context of flame blow-off; here, investigators have typically focused on issues of transient amplitude, though without the depth and physics-based experimental design that is proposed in this program. To our knowledge, there have been no studies that have quantified the impact of the transient timescale on combustion. The work helped us understand the impact of several types of transients on combustion stability. Both static and dynamic combustion stability will be considered. The transients will be quantified using their amplitude, direction, and timescale, and we will consider transients in equivalence ratio, fuel composition, and fuel splitting. There were two main objectives of this work: 1. Provide a fundamental understanding of combustion stability during transient operation using data obtained from a number of high-speed diagnostic techniques on experimental configurations that capture important gas turbine combustor features and operating conditions. This goal was met in conjunction with our industrial partner, GE Global Research, with whom we worked closely throughout the program. 2. Develop a stability prediction framework that will allow for the prediction, and possible control, of instabilities as a function of the transient amplitude, direction, and timescale. This input/output model should be physics-based and allow for screening of operating conditions and prediction of unstable behavior at the end of a transient by monitoring combustor health and precursor signals during operation.

03 NATURAL GAS↗
DOE OSTI2020

An Alfvenic reconnecting plasmoid thruster

A new concept for the generation of thrust for space propulsion is introduced. Energetic thrust is generated in the form of plasmoids (confined plasma in closed magnetic loops) when magnetic helicity (linked magnetic field lines) is injected into an annular channel. Using a novel configuration of static electric and magnetic fields, the concept utilizes a current-sheet instability to spontaneously and continuously create plasmoids via magnetic reconnection. Here, the generated low-temperature plasma is simulated in a global annular geometry using the extended magnetohydrodynamic model. Because the system-size plasmoid is an Alfvenic outflow from the reconnection site, its thrust is proportional to the square of the magnetic field strength and does not ideally depend on the mass of the ion species of the plasma. Exhaust velocities in the range of 20 to $500\ \textrm {km}\ \textrm {s}^{-1}$ , controllable by the coil currents, are observed in the simulations.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2022

Hydrogen Plus Other Alternative Fuels Risk Assessment Models (HyRAM+) Version 4.1 Technical Reference Manual

The HyRAM+ software toolkit provides a basis for conducting quantitative risk assessment and consequence modeling for hydrogen, methane, and propane systems. HyRAM+ is designed to facilitate the use of state-of-the-art models to conduct robust, repeatable assessments of safety, hazards, and risk. HyRAM+ integrates deterministic and probabilistic models for quantifying accident scenarios, predicting physical effects, characterizing hazards (thermal effects from jet fires, overpressure effects from delayed ignition), and assessing impacts on people. HyRAM+ is developed at Sandia National Laboratories to support the development and revision of national and international codes and standards, and to provide developed models in a publicly-accessible toolkit usable by all stakeholders. This document provides a description of the methodology and models contained in HyRAM+ version 4.1. The two most significant changes for HyRAM+ version 4.1 from HyRAM+ version 4.0 are direct incorporation of unconfined overpressure into the QRA calculations and modification of the models for cryogenic liquid flow through an orifice. In QRA mode, the user no longer needs to input peak overpressure and impulse values that were calculated separately; rather, the unconfined overpressure is estimated for the given system inputs, leak size, and occupant location. The orifice flow model now solves for the maximum mass flux through the orifice at constant entropy while conserving energy, which does not require a direct speed of sound calculation. This does not affect the mass flow for all-gaseous releases; the method results in the same speed of sound for choked flow. However, this method does result in a higher (and more realistic) mass flow rate for a given leak size for liquid releases than was previously calculated.

08 HYDROGEN↗
DOE OSTI2021

Summary of Expansions and Updates in GREET ® 2021

The GREET® (Greenhouse gases, Regulated Emissions, and Energy use in Technologies) model has been developed by Argonne National Laboratory (Argonne) with the support of the U.S. Department of Energy (DOE). GREET is a life-cycle analysis (LCA) tool, structured to systematically examine the energy and environmental effects of a wide variety of transportation fuels and vehicle technologies in major transportation sectors (i.e., road, air, marine, and rail) and other end-use sectors, and energy systems. Within the transportation sector, GREET covers road, air, water, and rail transportation sub-sectors. Recently, GREET was expanded to cover the building sector. Historically, GREET includes LCA of various materials such as steel, aluminum, cement, and different plastic types. Argonne has expanded and updated the model in various sectors in GREET 2021, and this report provides a summary of the release.

09 BIOMASS FUELS↗
DOE OSTI2022

NO x Control and Measurement Technology for Heavy-Duty Diesel Engines (CRADA Final Report)

The Catalyst CRADA focused on lean-NO x trap (LNT) and selective catalytic reduction (SCR) automotive emission control catalyst technology. It particularly had the goal of developing and applying advanced diagnostics capable of elucidating the network and sequence of catalyst reactions, as well as how they are affected by real-world operation and aging. Another overarching goal and action of this CRADA section was to develop methods to quantify and monitor catalyst states and support the development of full and reduced models for design and in-use control applications. William Partridge was the ORNL principal investigator (PI) throughout the Catalyst CRADA; Neal Currier was the Cummins PI through circa 2017, and Saurabh Joshi was the subsequent Cummins PI.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2026

Livewire: A Model Platform for Data Quality Assessment and AI Readiness Across DOE Missions

High-quality, well-governed data is essential for accelerating discovery and achieving operational excellence across DOE and national laboratory missions. The Livewire Data Platform is a DOE-supported platform that offers automated assessments of data quality, standardization, provenance, and Artificial Intelligence (AI) readiness. It allows researchers and data practitioners to systematically and easily evaluate datasets against established governance criteria and prepare them for advanced analytics. Livewire addresses critical challenges in DOE's data ecosystem with integrated capabilities for metadata validation, provenance tracking, and schema alignment. This platform's automated workflows assist users in identifying data quality gaps, enhancing interoperability between datasets collected from various stakeholders, and ensuring compliance with DOE data standards, all while reducing manual curation efforts. Additionally, we will discuss its AI readiness framework, which is being developed to prepare datasets for training models, developing advanced analytic tools, and machine learning applications. Using some of the more than one hundred tabular datasets on Livewire, processed with this open-source methodology, we will demonstrate how Livewire can serve as a model for scalable, standards-driven data management. This approach provides a pathway to leverage existing and future datasets within the DOE, boosting innovation and efficiency across national laboratories.

33 - ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2026

Two-Phase Cooling for High Packaging Density Planar Inverter: Cooperative Research and Development Final Report, CRADA Number CRD-15-00592

The project objective was to utilize two-phase heat transfer to enable compact and power-dense inverters. The high heat transfer capacity and near isothermal characteristics of two-phase cooling can enable higher power densities, reducing the size and cost of the power electronics system. This project focused on developing efficient, passive (no pump or compressor) two-phase cooling strategies that consist of an air-cooled condenser and evaporator. This report describes the modeling work conducted to design the evaporator and air-cooled condenser for a prototype inverter development work underway in the John Deere. Prototypes of the final evaporator and condenser designs were then fabricated via 3D printing for testing. Experiments on the evaporator confirmed that this component can meet the heat load and junction temperatures requirements for Si IGBT (insulated-gate bipolar transistor) inverter. Experiments with the air-cooled condenser were not possible due to leaks through the condenser walls.

33 ADVANCED PROPULSION SYSTEMS↗