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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 379 records · Page 21

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DOE OSTI2022

Connected and automated vehicles, driving systems, and control logic for info-rich eco-autonomous driving

A method for controlling automated driving operations of a vehicle includes determining vehicle origin and destination data, and generating a graphical representation of a road network with multiple candidate routes between the vehicle's origin and destination. Road-level data, including speed, turn angle, and/or gradient data, is received for each candidate route, and respective total energy uses are estimated for the vehicle to traverse across the candidate routes. Multiple candidate driving strategies, each having respective speed and acceleration profiles, are determined for the candidate route with the lowest estimated total energy use. An optimal candidate driving strategy is selected through a cost evaluation of the associated speed and acceleration profiles and forward movement simulations of the vehicle over a prediction horizon. Command signals are transmitted to the vehicle's steering and/or powertrain systems to execute control operations based on the optimal driving strategy and the candidate route with the lowest energy use.

Zhao, Junfeng↗

DOE OSTI2022

Automotive Power Electronics Cooling Technology Research at NREL

This presentation describes power electronics thermal management technologies used for on-road EVs. Examples are provided and heat exchangers are described. Advanced cooling technologies developed are NREL to enable increased power density and enable high WBG temperature operation are then presented. The performance (e.g., thermal resistance, pumping power) of the advanced power electronics cooling technologies are compared to the performance of current, on-road technology.

ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2023

Power Electronics Thermal Management

The 2017 Electrical and Electronics Technical Team Roadmap [1] proposes aggressive research and development targets aimed at improving power electronics technology to enable the mass-market penetration of electric-drive vehicles. Achieving these aggressive targets will require a decrease in cost (year 2025 cost target: $2.70/kW) and an increase in power density (year 2025 power density target: 100 kW/L) as compared with current on-road technology. Replacing traditional silicon device-based components with more efficient and higher-temperature wide-bandgap (WBG) semiconductor device-based components will enable increased power density. However, meeting the power density target will also require innovative thermal management solutions to increase the heat fluxes dissipated and allow for compact electronics packaging. This project conducts research to develop new power electronics thermal management technologies to increase power density, enable high WBG temperature operation, and decrease cost. The performance (e.g., thermal resistance, pumping power) of the power electronics cooling technologies developed in this project are compared to the performance of current, on-road technology. One of the main challenges to achieving high power densities is associated with packaging high-temperature (up to 250 degrees C) WBG devices near lower-temperature-rated components (e.g., electrical boards and capacitors).

ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2023

Power Electronics Cooling Technology Research at NREL

DIRECT ENERGY CONVERSION↗

DOE OSTI2023

The 2030 National Charging Network: Estimating U.S. Light-Duty Demand for Electric Vehicle Charging Infrastructure; A Nationwide Assessment

Ambitious federal clean goals, along with historic investment in American manufacturing, have put the United States on track to see 30-42 million light-duty electric vehicles (EVs) on the road by 2030. Now, a groundbreaking study from the National Renewable Energy Laboratory (NREL) has estimated the EV charging infrastructure needed nationwide to support a sweeping transition to electrified transportation. The study, titled "The 2030 National Charging Network: Estimating U.S. Light-Duty Demand for Electric Vehicle Charging Infrastructure," estimates the number, type, and location of the chargers needed to create a comprehensive network of EV charging infrastructure. Its use of proprietary NREL software tools and sophisticated analysis have resulted in a nationwide infrastructure needs assessment with a never-before-seen level of detail - one that takes into account the different ways Americans travel, from running errands to taking road trips, and can adjust to changing circumstances as EV adoption rates change over time.

ADVANCED PROPULSION SYSTEMS,ENERGY PLANNING, POLIC↗

DOE OSTI2023

A comparison of mechanical properties from natural and process-induced interfaces in filament extrusion AM of polymer blends

Polymer blends are commonly tuned for specific applications to achieve desired properties otherwise inaccessible or prohibitively expensive to obtain via homopolymers. The interfacial characteristics of the polymer A-polymer B interface and resultant domain sizes govern key performance properties. Micro- and meso-scale morphology forms through the interplay of surface forces between the polymers and between each polymer and the surrounding atmosphere. Analogously, the layer-layer and road-road interfaces of material extrusion (MEX) additive manufacturing (AM) govern key performance properties of printed parts. This work explores the effect of layer height on the thermomechanical performance of polystyrene (PS)-polycarbonate (PC) blends. Filament is prepared from a 50/50 weight ratio of the two polymers and compared against dual-nozzle printing where every layer alternates between PS or PC homopolymer forming a part with an overall 50/50 polymer ratio. Typical indicators of polymer blend compatibility are also studied.

Chatham, Camden A.↗

DOE OSTI2025

Enhanced Lighting Signals for Safety and Efficiency - Experiments with Addressable LEDs

For enhanced roadway safety, clear and immediate visual cues are essential for preventing accidents between drivers and pedestrians. At intersections, however, the line of sight to other roadway users may be obstructed by vehicles and infrastructure. Additionally, adverse conditions, including low visibility, poor weather, or inadequate lighting can increase the potential for collisions. Distracted drivers and pedestrians can further exacerbate the risk of accidents, particularly when using a smartphone, rather than focusing on roadway surroundings. These issues demonstrate the need for infrastructure upgrades that enhance visibility and awareness at crosswalks. A potential solution is through enhanced lighting signals integrated into the roadway infrastructure. One such example is the use of addressable LEDs, individually controllable lights that can change color and brightness instantaneously through programmable microcontrollers. They can be installed and integrated into crosswalks to maintain visibility in conditions where pedestrians may be difficult to see, while also offering peripheral cues to pedestrians who may be distracted by their phones or other objects rather than the road. Such a system (as one example) that is integrated into a traffic intersection digital twin that tracks all roadway users accurately, has the potential to enhance visibility of vulnerable road users, and thus enhance safety. This paper examines the potential implementation and feasibility of this technology, as well as the safety benefits it could provide. Laboratory experiments with addressable LEDs reveal the capabilities and challenges of this technology for roadway infrastructure safety. These findings could pave the way for more integrated lighting in infrastructure for vehicles and pedestrians at intersections, merge and diverge locations, and other areas where complex interactions present safety hazards. Such lighting solutions, enabled by modern computation and communications, could enhance safety and efficiency in our transportation system and improve overall mobility.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2025

Transforming Aeration Energy in Water Resource Recovery Facilities (WRRFs) through Suboxic Nitrogen Removal (Final Report)

The objective of this project was to advance two key technological components—aeration control strategies and process design methodologies—to support the development and broader adoption of suboxic biological nitrogen removal (SBNR). The project focused on achieving the following three goals: • Enhance Model Predictive Control (MPC) Technology: Advance the DO/Nmaster MPC platform from its initial 2018 pilot deployment at the Chico Water Resource Recovery Facility in California to full-scale integration. This included partnering with a blower technology commercialization partner and incorporating machine learning (ML) capabilities to enable nationwide deployment. • Bridge Knowledge Gaps in SBNR Process Design: Address fundamental gaps in SBNR process understanding through controlled pilot-scale testing at a dedicated pilot facility. These efforts supported the development of robust kinetic models to inform reliable SBNR control, operational strategies, and design frameworks. • Demonstrate Full-Scale Implementation of Low DO/SBNR with ML: Transition low dissolved oxygen (DO)/SBNR coupled with ML from pilot-scale trials to full-scale demonstration in flow-through biological nutrient removal (BNR) systems, with the goal of enabling scalable, nationwide adoption in activated sludge treatment processes. The project included demonstration of SBNR at the pilot scale as performed by Hampton Roads Sanitation District (HRSD) and at the full-scale as performed by the Los Angeles County Sanitation Districts' (LACSD) Pomona Water Reclamation Plant (POWRP).

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2023

Control oriented model order reduction for the hydraulic system of an autonomous wheel loader

Control design for an autonomous wheel loader requires a high-fidelity and low-order dynamics model. The objective of order reduction is to decrease the number of states in the model while maintaining performance comparable to the original model. Of all the power components in a wheel loader, the model order reduction for steering and working hydraulic systems is most demanding due to its nonlinear and stiff dynamical nature. This paper describes a physics-inspired model order reduction method that can reduce the model order by close to thirty percent. It is achieved by discarding orders with fast dynamics and consolidating multiple states into less new states. Furthermore, this method can also be extended to other types of off-road vehicles such as excavators, bulldozers, etc. Simulation results demonstrate that the reduced-order model exhibits very similar performance to the full-order model under typical operating conditions of wheel loaders, with an output error of less than six percent.

42 ENGINEERING↗

DOE OSTI2023

An electrified boom actuation system with energy regeneration capability driven by a novel electro-hydraulic unit

This paper presents a novel electrified solution for linear actuation systems, which has undergone a successful in-vehicle demonstration, marking a significant advancement in this field. Aligned with the growing trend towards electrification, this solution holds promise for a wide range of off-road applications. The showcased electrohydraulic actuation architecture enables efficient four-quadrant operation and incorporates energy recovery capabilities. At the core of the system lies a distinctive electro-hydraulic unit, integrating a fixed hydraulic pump and a variable-speed electric motor into a compact and powerful entity. A specialized hydraulic system is designed to efficiently transform electrical energy from the electro-hydraulic unit into boom cylinder actuation. The sizing of the system is determined by the boom operation of a commercial compact loader. The maximum power output of the electro-hydraulic system is approximately 15 kW. The components of the proposed system are integrated into the reference vehicle, and comprehensive performance tests are conducted. The results of the tests performed on the vehicle with the boom lifting and lowering cycle indicate an overall system efficiency of 60%. The electrified solution consumes only about one-third of the energy used by the conventional boom actuation system on the reference machine, while exhibiting energy savings exceeding 75% during specific work phases. The energy savings come mainly from energy regeneration and minimal loss from throttling through the specialized hydraulic circuit design. Finally, the successful demonstration on the reference vehicle underscores the practicality and effectiveness of the proposed electrified solution in current mobile hydraulic applications

42 ENGINEERING↗

DOE OSTI2021

Development of heavy-duty vehicle representative driving cycles via decision tree regression

Previously, researchers who developed representative driving cycles mainly focused on light-duty vehicles and only considered vehicle speed and related derivations. In this paper, we propose a novel approach to develop representative cycles for heavy-duty vehicles. By implementing decision tree regression (DTR) to the Fleet DNA on-road vehicle data, a broader set of metrics, such as engine power and fuel consumption, can be used for more robust cycle development. Additionally, the influence of each metric on the regression target is also accounted for by a weighted number derived through the DTR to enhance the representativenss of the developed cycle. As case studies, we applied the proposed method to five heavy-duty vocations (drayage, long haul, regional haul, local delivery, and transit bus) and derived the most representative cycle, as well as four extreme cycles (maximal energy consumption, maximal power-weighted work, maximal fraction of high speed, and minimal fuel economy) to advance the related alternative powertrain design.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2020

Optimal Eco-Driving Control of Connected and Autonomous Vehicles Through Signalized Intersections

This article focuses on the speed planning problem for connected and automated vehicles (CAVs) communicating to traffic lights. The uncertainty of traffic signal timing for signalized intersections on the road is considered. The eco-driving problem is formulated as a data-driven chance-constrained robust optimization problem. Effective red-light duration (ERD) is defined as a random variable, and describes the feasible passing time through the signalized intersections. Usually, the true probability distribution for ERD is unknown. Consequently, a data-driven approach is adopted to formulate chance constraints based on empirical sample data. This incorporates robustness into the eco-driving control problem with respect to uncertain signal timing. Dynamic programming (DP) is employed to solve the optimization problem. The simulation results demonstrate that the proposed method can generate optimal speed reference trajectories with 40% less vehicle fuel consumption, while maintaining the arrival time at a similar level compared to a modified intelligent driver model (IDM). The proposed control approach significantly improves the controller's robustness in the face of uncertain signal timing, without requiring to know the distribution of the random variable a priori.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2023

On-Line Prediction of Resistant Force During Soil–Tool Interaction

For off-road vehicles such as excavators and wheel loaders, a large portion of energy is consumed to overcome the soil resistant force in the digging process. For optimal control of the digging tool, a high-fidelity model of the soil–tool interaction force is important to reduce energy consumption. Here, in this paper, an on-line soil resistant force prediction method is proposed. In this method, a hybrid model, which combines a physical model and a data-driven model, is used for the force prediction. In addition, the parameters of the hybrid model can be updated on-line based on real-time data. Comparisons with experimental data demonstrate that the proposed prediction method has an average error of around 12.7%.

42 ENGINEERING↗

DOE OSTI2025

Cooperative On-Ramp Merging with Time-Varying Vehicle-to-Vehicle Communication Delay Compensation via a Model-Free Approach

Cooperative merging strategies enabled by vehicle-to-vehicle (V2V) communication have shown promise in addressing congestion, fuel inefficiency, and collision risks. However, their performance can be severely degraded by time-varying and uncertain communication delays-an issue often overlooked in existing research, which primarily focuses on merging sequence determination and trajectory planning. Furthermore, practical considerations such as heterogeneous vehicle dynamics, varying road conditions, and real-time implementation complexities are frequently neglected. This paper presents a model-free, online planning framework for cooperative on-ramp merging of connected and automated vehicles (CAVs), explicitly accounting for time-varying V2V communication delays. Without relying on detailed vehicle dynamics, the proposed method introduces a data-driven delay compensation scheme. A co-simulation platform integrating high-fidelity vehicle dynamics, traffic simulation (SUMO), and V2V communication within MATLAB/Simulink is developed to evaluate the proposed method. Simulation results demonstrate that unaddressed V2V communication delays significantly impair merging performance. In contrast, the proposed framework enhances intervehicle distance tracking and maintains low CO2 emissions and fuel consumption, under communication delay across different communication frequencies. In conclusion, its lightweight design also facilitates real-time implementation, making it well-suited for deployment in practical CAV systems.

Accounting↗

DOE OSTI2021

Development of in-use engine speed/torque heat maps across multiple heavy-duty commercial vehicle vocations

The U.S. Department of Energy (DOE) established the SuperTruck program with the goal of achieving brake thermal efficiency (BTE) greater than or equal to 55% as demonstrated in an operational heavy-duty (HD) diesel engine at a 65-miles-per-hour (mph) cruise point. Beyond the line-haul application, HD engines operate in a wide range of speed and torque conditions that are unlikely to yield the same efficiency under real-world operation. Thereby, the in-use engine heat maps described in this paper are a valuable tool to illustrate whether the engine-efficiency “sweet spot” matches the most frequent operating conditions. In this study, NREL developed engine heat maps to quantify the important operating points for various vocations using our Fleet DNA database of commercial fleet vehicle operations data. These heat maps clearly show that high-frequency operating points vary significantly according to vehicle vocation, while only a few of them match the sweet spot. Beyond the illustration, engine in-use heat maps can also be leveraged to build up reduced-order engine-efficiency models, needed by many rapid powertrain simulations. As case studies, nine reduced-order models – including line-haul truck, transfer truck, transit bus, transit bus with compressed natural gas (CNG) engine, drayage, refuse pickup, local delivery, utility truck, and school bus with CNG engine – using a trust-region reflective algorithm to fit the on-road data extracted based on the engine in-use heat maps.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2022

Heavy-Duty Vehicle Activity Updates for MOVES Using NREL Fleet DNA and CE-CERT Data

The U.S. Environmental Protection Agency's (EPA's) Motor Vehicle Emission Simulator (MOVES) is a publicly available tool used by researchers and policymakers to help understand motor vehicle emission sources at a national, county, and project level. Estimates of heavy-duty activity in the most recent version of the model at the time this work was conducted, MOVES2014, was identified as an area in need of improvement. The start activity in MOVES2014 is based on a limited and dated data set. In addition, MOVES2014 relies on drive cycles that represent on-network activity but do not account for idling activity that occurs on off-network roads, such as at a distribution center, while the truck is queuing or during loading and unloading. As a result, MOVES2014 may currently underestimate the number of starts and idle and soak time for heavy-duty trucks in real-world operation. The National Renewable Energy Laboratory (NREL) has previously leveraged its expansive Fleet DNA database of heavy-duty vehicles to idle and start activity for six of the nine heavy-duty vehicle source types of classes in the MOVES model. The data available in Fleet DNA from 416 conventional, diesel-powered vehicles provided activity estimates from more than 120,000 hours of operation throughout 14,682 vehicle days between October 2006 and January 2016. NREL calculated start fraction, starts per day, soak fraction, and idle fraction by hour of the day for each vehicle type, state, and vocation, and provided results in .CSV files that can be translated to MOVES table inputs. The idle and start activity from this initial analysis of Fleet DNA data was used to develop default idle and start data for heavy-duty vehicles in MOVES3. Satisfied with the results from the Fleet DNA data used for MOVES3, the EPA asked NREL to extend this start/soak/idle analysis using additional data from a larger number of vehicles for a potential future update to the MOVES model. Such a data set was achieved from a project led by the University of California at Riverside, College of Engineering, Center for Environmental Research & Technology (CE-CERT) and funded by California Air Resources Board. Specifically, this data set consists of 90 heavy-duty vehicles operated mainly in California, which can be separated into five of the nine heavy-duty vehicle classes in the MOVES model. In addition, the heavy-duty activity database collected by CE-CERT provided activity estimates from more than 44,000 hours of operation throughout 4,724 vehicle days between November 2014 and September 2016. This report details the analysis of the heavy-duty activity database collected from the University of California at Riverside by providing graphical analysis and context for the start, soak, and idle distributions. The comparison of the related results from both the Fleet DNA and CE-CERT data sets are documented as well.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2022

Code of Record: DOE Standard Canister (DOESC)

The United States Department of Energy (DOE) Spent Nuclear Fuel (SNF) Packaging Demonstration seeks to develop and demonstrate the designs, technology, processes, and regulatory framework for packaging DOE SNF for road-ready dry storage (RRDS); and establish the processes that will be used in a future production facility. The Packaging Demonstration will utilize the DOE Standard Canister (DOESC) for packaging select DOE-managed SNF types for interim storage, transportation and disposal as part of RRDS. Placing DOE-managed SNF into RRDS is part of the strategic framework for SNF on the Idaho National Laboratory (INL) site. To comply with DOE, INL and Nuclear Regulatory Commission (NRC) requirements, this Code of Record establishes the American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel Code (BPVC), Section III, Division 3 as the Code that will govern DOESC and internal support structure constructioni, with certain clarifications. This Code of Record establishes a rationale for proceeding without construction certification of the DOESC (i.e., “N-stamping) and the extent to which a Registered Professional Engineer is required for the DOE Spent Fuel Packaging Demonstration. Given the (i) standard industry practice to pursue independent licensure of commercial storage casks and transportation packages by the NRC in lieu of ASME certification and (ii) guidance provided by 10 CFR 830, DOESC construction activities need not be certified (i.e., “stamped”) to the ASME BPVC. However, additional quality assurance requirements will apply as outlined in this Code of Record.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2021

Optimal Control and Architecture Design Optimization for Hydraulic Drive Train of a Compact Track Loader

Hydrostatic transmission (HST) is a common hydraulic drive train transmission used in track loaders and other high power off-road vehicles. While reliable, traditional HST with fixed-displacement motors has relatively poor efficiencies. In this paper, alternative HST and series hybrid drive train architectures are proposed to replace the traditional HST to allow the implementation of optimal control and optimization methods for better vehicle fuel efficiency. Besides the optimal control methods applied to minimize fuel consumption, the proposed architectures are also optimized for the best configuration in terms of component sizing. Backward-facing (acausal) simulation models were developed to estimate the fuel efficiency of each architecture. Finally, each architecture is compared for optimized performance and fuel saving relative to the traditional HST as baseline.

33 ADVANCED PROPULSION SYSTEMS↗