SEARCH · Search NASA

Results for “Design and Prototype”

Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

SourceResearch connectionFrom yearThrough year

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

At least 487 records · Page 27

All sources NASA NTRS DOE OSTI

DOE OSTI2020

Full-Set Transformer Protection Barrier Manufacturing and Technology

This Technology Commercialization Fund (TCF) project provided the design, fabrication, and testing a full-scale prototype “Corner Unit” protective barrier to provide seamless 360° perimetrical protection for highly expensive power generation or transmission infrastructure. The Corner Unit will seamlessly match up to the existing A-Frame design to form the 360° protection desired from industry. This TCF project also demonstrated how commercial industry could fabricate and deliver the full-scale barriers to remote locations.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2020

Level set topology optimization in Firedrake

Lestofire is an academic software for the automated design of engineering components. It finds the optimal geometry of a system to minimize a given cost function while constrained by a given set of physics equations. Using a level set function to describe the geometry, lestofire uses shapes derivative to evolve the system until its optimal shape. It leverages the compilation of variational forms in Firedrake (https://www.firedrakeproject.org/) and the automated calculation of shape derivatives via pyadjoint (http://www.dolfin-adjoint.or/en/latest/) to allow fast prototyping of different physics, cost functions and design parametrizations.

Salazar De Troya, Miguel↗

DOE OSTI2025

SCR-based Medium Voltage DC Solid-State Circuit Breaker

This paper describes a medium voltage solid-state circuit breaker (SSCB) based on SCR technology, featuring short fault-interruption time and a minimal turn-off auxiliary circuit. The SSCB design incorporates a specialized SCR and a commutation circuit designed with an objective to reduce the required SCR hold-off/turn-off time, tq, which primarily determines the fault interruption duration. To validate the design, simulation analysis is presented, and a 1.5 kV 300 A SSCB prototype has been built and tested. The results confirm the effectiveness of the proposed design philosophy demonstrating the SSCB's ability to interrupt a 200 A load current in less than 50 μs. The proposed SCR-based SSCB has been developed for DC applications but is equally applicable to AC applications.

Kandula, Prasad [ORNL] (ORCID:0000000174017284)↗

DOE OSTI2026

Lab-Scale Cable-Driven Parallel Robot Prototype for Automated Prefabricated Component Manipulation

This paper presents the design and evaluation of a lab-scale cable-driven parallel robot (CDPR) developed as a flexible platform for automated installation of prefabricated components onto exterior building envelopes. Traditional manual installation methods for prefabricated components, which depend on scaffolding, cranes, cherry pickers, and verbal coordination, are not only labor-intensive and error-prone but also face significant limitations in dense urban environments due to site access constraints. To address these challenges, we developed a lab-scale CDPR platform capable of autonomously transporting building envelope components from a designated pickup zone to their target installation location, minimizing the need for human intervention. This study describes the system’s mechanical design, actuation architecture, real-time feedback system, and control strategy of the CDPR, and evaluates its performance in a laboratory environment. The robot’s actuation system uses torque control for end-effector manipulation. The robot’s real-time pose feedback comes from a construction-grade total station and a wireless inertial measurement unit (IMU), which together support precise end-effector control. Experimental results demonstrate the successful integration of the hardware, sensing, state estimation, and control subsystems. Preliminary tests showed that our lab-scale prototype can position the end effector with an error of less than 3 mm, which is a level of precision not previously achieved by existing CDPRs in construction applications. The key findings are twofold: (1) torque-only control is necessary but not sufficient for minimizing final pose error, and (2) incorporating real-time pose feedback can achieve the desired placement accuracy.

Liu, Yifang [Oak Ridge National Laboratory (ORNL),↗

DOE OSTI2021

Report on the Second MPEX User Research Forum

The Material Plasma Exposure eXperiment (MPEX) User Research Forum (MURF), a 2 day workshop, was held virtually on September 13–14, 2021, to seek community input for MPEX, a new high-power linear plasma device that is currently being built at Oak Ridge National Laboratory (ORNL). This was the second MURF workshop. The first MURF workshop was held in October 2019 in La Jolla, California, and focused exclusively on the definition of the surface analysis station for MPEX. MPEX is designed to address crucial R&D gaps in plasma material interactions (PMI) for future fusion reactors. The MPEX plasma source and heating systems will allow plasma exposures of plasma-facing materials and components to prototype fusion reactor divertor plasma conditions. The MPEX design accommodates the introduction of previously neutron-irradiated materials for fusion reactor-relevant plasma exposures. This capability will be unique worldwide. The US fusion program has advocated for such a device in numerous community reports in recent years, and now ORNL is building this new device. MPEX is a Major Item of Equipment project executed by the US Department of Energy’s Office of Science Fusion Energy Sciences.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2025

Design and Analysis of Short Period 2G-HTS Undulators

Recent advancements in second-generation high-temperature superconducting (2G-HTS) materials have opened new possibilities for superconducting undulator (SCU) technology, particularly in achieving shorter periods and higher magnetic fields. Here, this paper presents the design and analysis of a short-period, as small as 10 mm, 2G-HTS undulator, focusing on magnetic performance, mechanical force minimization, and quench protection. A force-balanced coil pack design is introduced to significantly reduce mechanical stresses on the conductors, eliminating the need for heavy support structures. Rapid prototyping techniques such as3D printing is employed to refine the design for scalability and manufacturability. Correction schemes for end-field effects are developed using a combination of 2G-HTS tapes and NbTi conductors to optimize field integrals. Simulation results demonstrated that optimized magnetic performance and enhanced mechanical stability, positioning 2G-HTS undulators as promising candidates for storage ring and free-electron based light sources.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

DOE OSTI2026

Quantum Computing for AI-based Design and Optimization of Electric Motors

Knowledge-based artificial intelligence and hierarchical fuzzy logic offer an interpretable framework for electricvehicle motor preliminary design, but their computational burden grows with linguistic granularity and coupled design-space size. This paper presents a reduced quantum reformulation of the hierarchical fuzzy inference of air-gap flux density, a representative level-one motor-design parameter. Starting from the published electric-vehicle motor-design framework, a three-term fuzzy prototype is constructed from the original inference structure. The reduced model is then reformulated as a modular quantum register-oracle system, in which each hierarchical subrelation is encoded as a block oracle and evaluated through superpositionbased candidate-label testing. The proposed modular quantum formulation reproduces the reduced classical prototype after block fusion. A resource analysis shows that the reduced modular system requires seven qubits per block and twenty-two qubits in a straightforward four-block implementation. Finally, a crossovercomplexity model is derived to identify the regime in which quantum candidate search may become favorable relative to hierarchical fuzzy inference. The results show that no quantum advantage should be claimed for the present one-output reduced benchmark, but that a plausible crossover emerges for larger joint candidate spaces and higher linguistic granularity. The work therefore establishes a technically consistent starting point for future quantum-assisted electric-vehicle motor-design optimization.

Kumar, Praveen [ORNL] (ORCID:0000000291877857)↗

DOE OSTI2023

From Atoms to Wheels: The Role of Multi-Scale Modeling in the Future of Transportation Electrification

Traditionally, prototype hardware is built for validation testing to ensure battery systems design changes meet vehicle-level requirements, which is expensive both in cost and time. Virtual engineering (VE) of battery systems for electric vehicle (EV) propulsion offers a reduced-cost alternative to the traditional development process and uses multi-scale modeling to virtually probe the impact of design changes in a particular part on the overall performance of the system. This allows for rapid iteration over multiple design spaces, without committing to build hardware. This perspective article discusses current trends in VE for EV applications and proposes improvements to accelerate EV adoption.

Garrick, Taylor R. (ORCID:0000000322518129)↗

DOE OSTI2024

Control-inspired design and power optimization of an active mechanical motion rectifier based power takeoff for wave energy converters

Ocean waves have high energy density and are persistent and predictable. Yet, converting wave energy to a useable form remains challenging. A significant hurdle is the oscillatory nature of waves resulting in the alternating loads, which necessitate the use of rectification at some stage of the energy conversion. This research effort presents a novel design of active mechanical motion rectifier (AMMR) for the power takeoff (PTO), which provides enhanced controllability and better power performance when compared to passive mechanical motion rectifiers (MMR). Inspired by transistors used in synchronous electrical rectifiers, the proposed design uses controllable electromagnetic clutches in the mechanical transmission to allow active engagement-disengagement control; thus, rectifying the oscillatory motion into a unidirectional rotation for high energy conversion efficiency and allowing the generator in unidirectional rotation to control the bidirectional wave capture structure for maximizing the power output. A semi-analytical computational approach is developed to efficiently evaluate the optimal power achieved using the proposed AMMR-based PTO and active control. It is found that the AMMR-based PTO design yields a higher optimal power than the previous passive MMR design across the wave spectrum. The influences of generator inertia and reactive power are discussed. Furthermore, the effects of control parameters on the power output and the optimal trajectories are analyzed. Wave tank tests with the AMMR prototype demonstrated the effectiveness of AMMR based PTO design and validated the numerical analysis.

16 TIDAL AND WAVE POWER↗

DOE OSTI2020

First measurements with the CMS DAQ and Timing Hub prototype-1

The DAQ and Timing Hub is an ATCA hub board designed for the Phase-2 upgrade of the CMS experiment. In addition to providing high-speed Ethernet connectivity to all back-end boards, it forms the bridge between the sub-detector electronics and the central DAQ, timing, and trigger control systems. One important requirement is the distribution of several high-precision, phase-stable, and LHC synchronous clock signals for use by the timing detectors. The current paper presents first measurements performed on the initial prototype, with a focus on clock quality. It is demonstrated that the current design provides adequate clock quality to satisfy the requirements of the Phase-2 CMS timing detectors.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

DOE OSTI2022

Developments and Challenges in the Design of the ITER DRGA

We report the ITER Diagnostic Residual Gas Analyzer (DRGA) will measure the distribution of gas species, i.e., deuterium (D), tritium (T), and impurities, in the divertor exhaust stream and in the plasma periphery, with time resolution relevant to fusion plasma–wall particle dynamics. The uniqueness of the DRGA, over previous implementations of plasma dynamics residual gas analysis, is an integrated approach, combining mass and low-temperature plasma-activated optical spectroscopy, in a differentially pumped analysis station. A further unique feature of the ITER divertor-specific DRGA is an ~8-m separation of the analysis station from the sampled pumping duct, while still maintaining a ~1-s response time for hydrogen isotopic concentrations. ITER DRGA final design activities are strongly benefiting from testing of prototypical DRGA components and methods on present fusion devices, most currently on JET and W7-X. DRGA systems are implemented on both these devices and include sensors (and pumping methods) that are directly relevant to the ITER DRGA design. The recent JET-DTE2 campaign has provided the first experience on operating the combined ITER DRGA sensors with D-T plasmas. While enhancing system design for ITER, this experience on operating devices has also revealed additional engineering challenges, which further guide the continuing final design project. Meanwhile, the recent determination that the ITER DRGA, with slight optimization, will resolve the helium isotopes well enough to support an ITER pre-DT, He-3-based heating scheme, has greatly increased ITER Research Program interest in the DRGA and its implementation well ahead of the DT phase.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2024

Feasibility study for test rig assessments of fish passage conditions in a Kaplan turbine

The assessment of fish passage conditions in hydroelectric turbines consists of identifying and quantifying physical magnitudes leading to increased risks of injury of fish passing through turbines in operation. Such assessments are usually carried out either with the use of computer-based methods during design or with field testing of live fish and sensors passing through prototypes. A method in between consists of test rig experimentation, which is critical for testing fish-focused design concepts and offers the opportunity for implementing the most effective design measures for improved fish survivability. However, fish-related assessments in test rigs are not sufficiently documented for industrial applications. This work presents the main findings of an experimental campaign to quantify fish-related hydraulic magnitudes in a physical model of a Kaplan turbine in a commercial test rig. Two operating conditions were tested by releasing miniaturized autonomous sensor devices (termed Sensor Fish Mini) at the turbine intake flow, passing them through the runner in motion and recovering them at the draft tube exit. During passage, time series of acceleration, absolute pressure and rotational velocity were recorded. The recordings were then interpreted to determine the magnitude and likely location of hydraulic stressors hazardous to fish. The statistical tests on the reported measurements indicated that low pressure, collisions on the runner and rotations in the draft tube were not different between the two tested operating points. On the other hand, pressure drop and collision rates on the distributor differed considerably as a function of net head. The outcomes of this investigation showed that test rig evaluations of fish-related properties with Sensor Fish Mini can contribute to an evidence-based development of turbine geometries designed for providing safer passage conditions. Future work will investigate the scaling of test rig measurements to hydraulically equivalent magnitudes in the prototype and their biological consequences.

13 HYDRO ENERGY↗

DOE OSTI2020

Development of Mockups and Instrumentation for Spent Fuel Drying Tests

The purpose of this report is to provide updates on the experimental components, methodology, and instrumentation under development for use in advanced studies of realistic drying operations conducted on surrogate spent nuclear fuel. Validation of the extent of water removal in a dry spent nuclear fuel storage system based on drying procedures used at nuclear power plants is needed to close existing technical gaps. Operational conditions leading to incomplete drying may have potential impacts on the fuel, cladding, and other components in the system. Water remaining in canisters upon completion of drying procedures can lead to cladding corrosion, embrittlement, and breaching, as well as fuel degradation. Additional information is needed on the drying process efficacy to help evaluate the potential impacts of water retention on extended longterm dry storage. A general lack of data suitable for model validation of commercial nuclear canister drying processes necessitates additional, well-designed investigations. Smaller-scale tests that incorporate relevant physics and well-controlled boundary conditions are essential to provide insight and guidance to the simulation of prototypic systems undergoing drying processes. This report describes the implementation of moisture monitoring equipment on a pressurized, submersible system employing a single waterproof, electrically heated spent fuel rod simulator as a demonstration of analytical capabilities during a drying process. A mass spectrometer with specially designed inlets was used to monitor moisture and other gases at 150 kPa to 800 kPa for a test simulating a forced helium dehydration procedure and below 1 torr for tests mimicking a vacuum drying process. The dew point data from the mass spectrometer was found to be in good agreement with a solid-state moisture probe. A distinct advantage of the mass spectrometer system was the capability to directly sample from the hightemperature (>200 °C) head space expected in a prototypic scale experiment where a solid-state moisture probe would suffer considerable loss of accuracy or fail altogether. The operational and analytical experiences gained from this test series are poised to support an expansion to assembly-scale tests at prototypic length. These assemblies are designed to feature prototypic assembly hardware, advanced diagnostics for in situ internal rod pressure monitoring, and failed fuel rod simulators with engineered cladding defects to challenge the drying system with waterlogged fuel.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2020

Design Optimization of Medium-Frequency Transformer for DAB Converters With DC Bias Capacity

Medium-frequency transformer (MFT) dc bias is critical for the safe operation of dual-active-bridge (DAB) converters. To analyze the dc bias, expressions of dc bias are derived for SiC MOSFET DAB converters. It shows that the dc bias is a current source in steady state; thus, a dc bias current capacity is defined and used as a design constraint in the optimization of MFT. The dc bias current capacity is related to core materials, geometric parameters, and flux density, which is analyzed with analytical expression. Optimization equations with geometric variables are derived, which can be solved theoretically or numerically for both interleaved winding (IW) and separated winding (SW) MFT without and/or with leakage inductance design. Based on the optimization equations, different MFT designs for a 150-kW SiC MOSFET DAB converter are compared on the aspects of core materials, winding structures, and without/with leakage inductance design. The combination of IW structure MFT with auxiliary phase shift inductors is chosen, and the assembled prototype is tested with the 150-kW DAB converter. Here, the designed dc bias capacity, temperature rise, and efficiency are verified.

42 ENGINEERING↗

DOE OSTI2025

28nm front end ASIC and 12” LGADs for 3D integration

The 3DIntSenS Collaboration—a joint effort between SLAC, Fermilab, and LLNL—is developing enabling technologies for next-generation radiation imaging detectors that combine ultra-fine spatial resolution (≈10 μm) with precision timing (<20 ps), while maintaining low power <1 W/cm2 and high data throughput. The approach leverages 3D integration between advanced CMOS readout ASICs and finely pixelated LGAD sensors to achieve the performance and scalability required for large-area, high-rate applications. High-granularity, precision-timing detectors are essential for scientific advances in HEP, NP, BES, and FES, but widespread adoption is limited by the cost and complexity of 3D integration. To close this gap, the collaboration is developing LGAD sensors compatible with 12-inch commercial CMOS processes, enabling cost-effective integration with high-performance ASICs under development. We present the design and results from a 28 nm CMOS ASIC prototype, including a low-jitter front end, and in-pixel TDC demonstrating sub-10 ps timing resolution. We also report on the co-design and characterization of reticle-scale LGAD sensors with 50 μm and 100 μm pixels and introduce the next 10k-pixel ASIC designed for full 3D integration. These advances represent a critical step toward scalable, high-resolution radiation imaging systems for future scientific instrumentation.

England, Troy [Fermilab] (ORCID:0000000154405255)↗

DOE OSTI2026

Design of a 915 MHz conduction-cooled cryomodule

High-power, compact, continuous-wave (CW) linear electron accelerators with beam energies of up to 10 MeV are being considered for possible industrial applications. Conduction-cooled, superconducting radio-frequency (SRF) technology allows operating such machines at high electrical efficiency, thereby reducing the operating cost significantly. A prototype conduction-cooled SRF cryomodule has been designed and components are currently being manufactured. The cryomodule features a two-cell, 915 MHz SRF cavity, two cryocoolers, a fundamental power coupler, two magnetic shields, a thermal shield and warm-to-cold transitions. The cryomodule has been designed to be able to provide an energy gain of 3.5 MeV to a CW electron beam with a current of 5 mA. This contribution focusses on thermal and mechanical design aspects of the cryomodule.

Ciovati, G. [Old Dominion Univ., Norfolk, VA (Unit↗

DOE OSTI2025

Design of a 915 MHz conduction-cooled cryomodule

Ciovati, G. [Old Dominion Univ., Norfolk, VA (Unit↗

DOE OSTI2021

Experimental Validation of Subsystem Models for a Novel Variable Displacement Hydraulic Motor

A novel, variable displacement, low-speed high-torque hydraulic motor is being developed that is expected to be highly efficient across a broad operating range. To ensure the final hardware achieves the expected performance, the models used in the development of the motor must be experimentally validated and revised, as necessary. The specific focus in this work is on mechanical energy loss models that were used to guide the design of a single-cylinder motor prototype and on experimental tests used for model validation. Ideally each model, whether friction loss in a piston/cylinder interface or energy loss due to leakage in a valve , would be individually validated by an independent test. This granular approach would remove any question of where the error lies and result in highly accurate models. However, many motor components have multiple forms of energy loss, creating difficulty in validating individual losses. Additionally, it is not physically realizable to divide many components into an individual model equivalent test. Testing the motor as a full assembly is possible, but pinpointing the source of discrepancies between the model and the hardware becomes difficult with dozens of models potentially being partially responsible. A compromise was found by separating the motor into functional component groups that are characterized by the type of loss and ability to test each subcomponent independently. By checking for correlation between test observations and model predictions, revisions could be implemented into the models. This allows future solutions to be more accurately predicted in the design phase to drive the design of better machines.

24 POWER TRANSMISSION AND DISTRIBUTION↗