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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 55 records · Page 3

Building and Executing Aggressive Research Plans in a Large National Laboratory Consortium: Insights from the Co-Optimization of Fuels and Engines Initiative

This report describes lessons learned in the establishment, execution and termination of a large, multi-institutional consortium, derived from the Co-Optimization of Fuels and Engines experience. The decision to form a consortium comes with benefits (in advancing challenging multidisciplinary research) and costs (in time and additional management funds). Once the decision is made, key elements to a strong start include establishing a shared vision and goals; engaging an experienced project manager early; instituting feedback and oversight mechanisms to ensure relevance, strong performance, and situational awareness. Once a consortium is up and running, DOE and leadership should strike the right balance between competition and collaboration; foster an environment that builds trust; and adjust the organizational structure as needed to maintain collaboration. Finally, DOE and the labs can plan effectively for a smooth transition as a consortium winds down. This report provides some additional lessons and details on these lessons that we hope future DOE and lab leaders will find useful as they contemplate standing up new consortia.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

The First Tri-Lab Workshop on Formal Verification: Capabilities, Challenges, Research Opportunities, and Exemplars

The First Tri-Lab Workshop on Formal Verification was held in Santa Fe, New Mexico, on December 5th, 2023. This workshop gathered staff from Sandia, Los Alamos, and Lawrence Livermore National Laboratories and NASA’s Jet Propulsion Laboratory. This report summarizes and expands on the presentations given and discussion had at this workshop. In this report, we describe the current capabilities and research needs related to formal methods at the NNSA labs. In particular, we identify medium-term and long-term research gaps in programming languages, formalization efforts of complex systems, embedded systems verification, hardware verification, cybersecurity, formal methods usability, workflows, numerical methods, the use of formal methods for artificial intelligence (and its converse, artificial intelligence for formal methods), and collaboration opportunities and considerations on these topics. We conclude with a small number of exemplar research problems related to these topics.

97 MATHEMATICS AND COMPUTING↗

Fleet Efficiency and Electrification Technical Assistance and Tools

Private enterprises, transit agencies, and governments around the world rely on NREL to evaluate their fleet electrification needs. From testing vehicle charging equipment in the lab, to working with fleets to adopt new types of vehicles, to helping agencies develop electric vehicle (EV) plans, NREL transportation analysts address a range of electrification challenges.

ADVANCED PROPULSION SYSTEMS↗

Wind 2H2 Project (CRADA Final Report)

The Xcel-NREL Wind Electrolysis R&D Project is designed to gain knowledge and insight about producing hydrogen from electricity for use as a vehicle fuel and as a “stored wind”. The project will analyze producing hydrogen directly from wind as well as from the electric grid. In addition, it will look at storing hydrogen and then using it to put electricity back onto the grid. Modifications were made to the original scope to also include electric vehicles integration with the electric grid. This report addresses Task 8 portion of the CRADA, focused on testing and measuring the attributes of plug-in electric vehicles.

33 ADVANCED PROPULSION SYSTEMS↗

Development of Machine-Learned Interatomic Potentials to Predict Structure, Transport, and Reactivity in Platinum-Based Fuel Cells

Machine-learned interatomic potentials (MLIPs) have rapidly progressed in accuracy, speed, and data efficiency in recent years. However, training robust MLIPs in multicomponent systems remains a challenge. In this work, we train an MLIP to describe hydrated Nafion ionomers and platinum catalysts, which are important components of fuel cells, by constructing a diverse training set to describe the bulk polymer and interfacial catalyst–polymer interactions well. We use our trained MLIP to study the properties of the platinum–Nafion system, including polymer structure, proton mobility in a bulk Nafion polymer and near a platinum-Nafion interface, and reactions near and far from the interface, finding excellent results for structure and reactions contained within our training set. Transport seems to be well described, with both vehicular transport and Grotthuss hopping captured, although converged calculations of diffusivities were not computed because they require calculations of tens of nanoseconds that are challenging with current state-of-the-art MLIPs. The combined insights that this model provides can be leveraged to optimize fuel cell performance, and the approach can be applied to other chemical processes and devices where structure, transport, and reactivity all contribute to the overall observed performance.

33 ADVANCED PROPULSION SYSTEMS↗

ELECTRIFICATION OF A HEAVY-DUTY OFF-ROAD MATERIAL HANDLER: ENERGY SAVINGS AND EMISSION REDUCTIONS

Federal regulations are driving the adoption of electrification technologies to reduce carbon dioxide equivalent (CO2e) emissions, a metric that quantifies the global warming potential of various greenhouse gases in terms of carbon dioxide (CO2). Although no specific CO2 regulations exist for heavy-duty off-road machines, future reductions are likely, given stricter emissions standards for on-road vehicles. The heavy-duty off-road sector offers significant fuel-saving potential, as its focus has traditionally been on reliability and performance rather than fuel efficiency. This dissertation examines fuel and CO2e savings opportunities on a heavy-duty off-road material handler, the Pettibone Cary-Lift 204i, from stock configuration to simple modifications to a complete teardown and reconfiguration of the machine with a plug-in series hybrid architecture using electrified hydraulics. The study begins by modeling the baseline machine’s fuel and energy consumption, calibrating with experimental data from custom operating cycles. An energy analysis identifies key areas for fuel savings. Two simple powertrain modifications result in a combined 16.2% fuel savings. Next, a Pugh-style analysis narrows a list of electrified architectures, leading to high-fidelity models that evaluate total lifetime CO2e and costs. Higher electrification levels reduce CO2e emissions but increase costs, and electricity grid emissions significantly impact CO2e for plug-in architectures. A plug-in series hybrid is chosen for the project. In its base control form, 49% fuel and 29% CO2e savings are expected from the plug-in series hybrid compared to the baseline machine. Further savings are pursued through regenerative braking (6.3%) and load-following hydraulic control (17.8%), totaling 24.1% fuel savings, and leading to a total of 61% fuel and 41% CO2e savings compared to the baseline. Battery chemistries and charging strategies are also analyzed for cost and CO2e impacts, finding LFP batteries as superior due to longevity, and overnight level 2 charging usually at a lower cost but resulting in higher emissions than opportunity DC fast-charging (DCFC). DCFC emissions are highly dependent on grid emissions, and DCFC cost is highly dependent on grid demand charges. Finally, artificial intelligence is applied to operating cycle recognition. Neural network accuracy ranges from 81% to 99%, with applications to worksite efficiency and safety improvements.

24 POWER TRANSMISSION AND DISTRIBUTION↗

Identifying Electric Vehicles to Best Serve University Fleet Needs and Support Sustainability Goals

University fleets represent an enticing opportunity to explore the near-term feasibility of achieving net-zero-carbon emissions in transportation. In many instances, universities operate much like a small, self-contained ecosystem with all the same transportation needs as a larger municipality, but with a smaller geographic footprint. Their fleets often include a wide variety of vehicle types serving the campus, including low-speed vehicles (e.g., golf carts), light-duty sedans, SUVs, and pickups, as well as medium-duty trucks and delivery vehicles. The mix of vehicle and operational needs combined with broader activities related to net-zero campuses makes universities and colleges unique microcosms to determine the feasibility of and path to achieving net-zero fleets. As the availability of electric drivetrains expands beyond light-duty sedans, fleets need to understand when it will be operationally and financially appropriate to start adding electric drivetrains to their fleets. To better understand these opportunities, NREL contracted Sawatch Labs to analyze the role electric vehicles (EVs) can have in helping universities meet net-zero emissions and fleet sustainability goals they have instituted.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Ampaire ARPA-e Electric Flight Testbed

A hybrid-electric aircraft flying testbed was developed in this program with the intent to serve as a dedicated, enduring testbed to test and evaluate ARPA-e CIRCUITS Program and other electrified aviation technologies in relevant flight environments. This testbed enabled rapid development cycles of novel and innovative technologies in the electrified aviation space, maturing them from a research lab environment to flying in an aircraft. By providing research groups with the means to test their transformative technologies in a real-world, aircraft environment, the path to validating the safety and reliability of their technologies for future commercial opportunities was greatly accelerated. Three core technologies were integrated and tested: an inverter/motor drive built by the University of Arkansas, a solid-state circuit breaker (iBreaker) built by the Illinois Institute of Technology, and a Flying Capacitor Multi-level (FCML) DC/DC converter built by the University of California, Berkeley. In each of these cases, the requirements established for safety of flight resulted in a holistic approach to the designs, evoking a deeper understanding of the potential failure modes and mitigations necessary to build a robust and flightworthy system. Further, the integration into a hybrid-electric aircraft de-risked the potential electrical and mechanical issues that cannot easily be experienced or replicated in a lab environment. The experiments were also required to undergo representative temperature, shock, and vibration testing as the FAA prescribes for this category of aircraft, facilitating familiarity with the relevant design and test guidelines necessary to commercialize the technologies. This testbed unlocks the massive potential of core power electronics technologies necessary for a safe, robust, and efficient electric aviation future. With quick iterative design, test, and flight cycles, these core technologies are on a quicker path to technology readiness level maturity and commercialization, enabling a more sustainable future for the aviation industry.

24 POWER TRANSMISSION AND DISTRIBUTION↗

EVs@Scale Lab Consortium Bi-Annual Stakeholder Meeting, 17 August 2022, Golden, Colorado [Slides]

The U.S. Department of Energy (DOE) Electric Vehicles at Scale Lab Consortium (EVs@Scale Lab Consortium) is accelerating research to support the establishment of a secure and scalable national network of charging infrastructure. This network will be critical to support tens of millions of light-, medium-, and heavy-duty EVs on American roads by 2030. The EVs@Scale Lab Consortium brings together national laboratories and key stakeholders to conduct infrastructure research and development (R&D) that advances innovations in, and sets unified standards for, high-power and wireless charging. The effort will also develop technologies to integrate vehicle charging with the power grid, and develop cybersecurity measures to protect drivers, vehicles, equipment, and the grid. The first hybrid EVs@Scale Lab Consortium Biannual Stakeholder Meeting was held at NREL on August 17, 2022, to identify research, development, and deployment needs to accelerate technology development for electric vehicles at scale and explore opportunities for collaboration across government, academia, and industry.

33 ADVANCED PROPULSION SYSTEMS↗

Electric Vehicles at Scale (EVs@Scale) Laboratory Consortium

The U.S. Department of Energy (DOE) Electric Vehicles at Scale Lab Consortium (EVs@Scale Lab Consortium) is accelerating research to support the establishment of a secure and scalable national network of charging infrastructure. This network will be critical to support tens of millions of light-, medium-, and heavy-duty EVs on American roads by 2030. The EVs@Scale Lab Consortium brings together national laboratories and key stakeholders to conduct infrastructure research and development (R&D) that advances innovations in, and sets unified standards for, high-power and wireless charging. The effort will also develop technologies to integrate vehicle charging with the power grid, and develop cybersecurity measures to protect drivers, vehicles, equipment, and the grid.

ADVANCED PROPULSION SYSTEMS,POWER TRANSMISSION AND↗

Automated Transit Fleet Electrification Planning in Response to Route Dynamics, Vehicle Utilization, and Local Climate

Transit electrification is difficult, requiring the consideration of many factors including route dynamics, vehicle utilization, and local ambient temperatures. Incumbent planning tools typically rely upon static vehicle efficiency numbers which do not consider local factors specific to each fleet. This paper summarizes a collaboration between NREL and Microgrid Labs, which produced an automated sizing tool capable of producing vehicle battery and motor sizing for drop-in electrification. Furthermore, the workflow also exports the electric-vehicle supply equipment needed to support fleet electrification. The paper summarizes the model theory and includes a sample pilot study performed in support of the Via Mobility transit fleet.

33 ADVANCED PROPULSION SYSTEMS↗

EV SALaD 2023 Demonstration: Best Practices and Mitigations for Protecting EVSE Infrastructure

The Electric Vehicle Secure Architecture Laboratory Demonstration (EV SALaD) program is a demonstration of cybersecurity best practices for high-power electric vehicle (EV) charging infrastructure led by Idaho National Laboratory (INL), in collaboration with other DOE National Laboratories participating in the EVs at Scale Consortium.a Sandia National Laboratories (SNL) and Pacific Northwest National Laboratory (PNNL) participated in the first 2-year (FY22-23) demonstration cycle for EV SALaD. This report documents the FY23 demonstration, the second in a series of demonstrations and collaborations in deploying and operating cybersecure EV charging infrastructure. It includes a summary of improvements from the FY22 demonstration, technical analysis of the FY23 demonstration, how the research demonstrates cyber-physical and cybersecurity best practices for high-power EV charging infrastructure, and related impacts to national and energy security. For EV SALaD, the FY22 demonstration focused on the detection, ranking, and prioritization of anomalous events for high-power EV charging. The FY23 demonstration additionally included the demonstration of cybersecurity best practices, which included protection and mitigation solutions to prevent, respond, and recover from anomalous events. During the demonstrations, the multi-lab EV SALaD team conducted a Test Effect Payload (TEP)b evaluation on extreme fast charger (XFC) hardware equipped with Cerberus, a detection and response solution, to demonstrate anomaly detection and mitigation cybersecurity best practices against cyber-enabled events.

33 ADVANCED PROPULSION SYSTEMS↗

Refining Control, Charging, and Battery Chemistry for CO 2 e Savings in Heavy-Duty Off-Road Plug-In Series Hybrid

With current and future regulations continuing to drive reductions in carbon dioxide equivalent (CO 2 e) emissions in the on-road industry, the off-road industry is also likely to be regulated for fuel and CO 2 e savings. This work focuses on converting a heavy-duty off-road material handler from a conventional diesel powertrain to a plug-in series hybrid, achieving a 49% fuel reduction and 29% CO 2 e reduction via simulation. Control strategies were refined for energy savings, including a regenerative braking strategy to increase regenerative braking and a load-following hydraulic strategy to decrease electrical energy consumption. The load-following hydraulic control shuts off the hydraulic electric machine when it is not needed—an approach not previously seen in a load-sensing, pressure-compensated system. Furthermore, these strategies achieved a 24.1% fuel savings, resulting in total savings of 61% in fuel and 41% in CO 2 e in the plug-in series compared to the conventional machine. Beyond control strategies, this study evaluated battery chemistry and charging strategy refinements for total cost of ownership (TCO) and lifetime CO 2 e. LFP batteries emerged as the most cost-effective and least emitting due to their longer lifespan, which reduced replacement frequency. Charging comparisons showed that Level 2 charging (L2C) typically resulted in lower TCO but higher lifetime CO 2 e than DC fast charging (DCFC). DCFC costs were heavily influenced by local demand charges, and DCFC emissions were heavily influenced by local grid emissions.

33 ADVANCED PROPULSION SYSTEMS↗

EVs@Scale Lab Consortium Semi-Annual Stakeholder Meeting

The U.S. Department of Energy (DOE) Electric Vehicles at Scale Lab Consortium (EVs@Scale Lab Consortium) is accelerating research to support the establishment of a secure and scalable national network of charging infrastructure. This network will be critical to support tens of millions of light-, medium-, and heavy-duty EVs on American roads by 2030. The EVs@Scale Lab Consortium brings together national laboratories and key stakeholders to conduct infrastructure research and development (R&D) that advances innovations in, and sets unified standards for, high-power and wireless charging. The effort will also develop technologies to integrate vehicle charging with the power grid, and develop cybersecurity measures to protect drivers, vehicles, equipment, and the grid. The first hybrid EVs@Scale Lab Consortium Semiannual Stakeholder Meeting was held at ANL on September 27-28, 2023, to identify research, development, and deployment needs to accelerate technology development for electric vehicles at scale and explore opportunities for collaboration across government, academia, and industry.

advanced charging and grid interface technologies↗

Nov. 2024 EVs@Scale High-Power Charging Deep Dive Technical Meeting

EVs@Scale Lab Consortium is addressing challenges, developing solutions, and enabling technologies for transportation electrification ecosystem. The consortium has five research pillars one of which focuses on high power charging (HPC). HPC pillar brings together hardware and software expertise, capabilities, and facilities related to high power EV charging, charge management, and grid integration. Deep-dive technical meetings are organized twice a year and provides an opportunity for more industry engagement and technical feedback for the national labs throughout the project lifecycle. High-Power Charging pillar has two active projects: (i) Next-Gen Profiles (NGP) and (ii) High-Power Electric Vehicle Charging Hub Integration Platform (eCHIP). This presentation summarizes the progress made in both projects during the past six months focusing on specific topics. There will be two deep-dive technical meetings twice a year. Every deep-dive meeting will focus on different aspects of the project progress.

ADVANCED PROPULSION SYSTEMS,DIRECT ENERGY CONVERSI↗

2024 Electric Vehicles at Scale Semiannual Stakeholder Meeting

The U.S. Department of Energy (DOE) Electric Vehicles at Scale Lab Consortium (EVs@Scale Lab Consortium) is accelerating research to support the establishment of a secure and scalable national network of charging infrastructure. This network will be critical to support tens of millions of light-, medium-, and heavy-duty EVs on American roads by 2030. The EVs@Scale Lab Consortium brings together national laboratories and key stakeholders to conduct infrastructure research and development (R&D) that advances innovations in, and sets unified standards for, high-power and wireless charging. The effort will also develop technologies to integrate vehicle charging with the power grid, and develop cybersecurity measures to protect drivers, vehicles, equipment, and the grid. The first hybrid EVs@Scale Lab Consortium Semiannual Stakeholder Meeting was held at ANL on September 27-28, 2023, to identify research, development, and deployment needs to accelerate technology development for electric vehicles at scale and explore opportunities for collaboration across government, academia, and industry.

advanced charging and grid interface technologies↗

VTO 2022 Annual Progress Report: Vertical GaN Device Development

This project is part of a multi-lab consortium that leverages U.S. research expertise and facilities at national labs and universities to significantly advance electric drive power density and reliability, while simultaneously reducing cost. The final objective of the consortium is to develop a 100 kW traction drive system that achieves 33 kW/L, has an operational life of 300,000 miles, and a cost of less than $\$$6/kW. One element of the system is a 100 kW inverter with a power density of 100 kW/L and a cost of $\$$2.7/kW. New materials such as wide bandgap semiconductors, soft magnetic materials, and ceramic dielectrics, integrated using multi-objective co optimization design techniques, will be utilized to achieve these program goals. This project focuses on a subset of the power electronics work within the consortium, specifically the design, fabrication, and evaluation of vertical GaN power devices suitable for automotive applications.

33 ADVANCED PROPULSION SYSTEMS↗

EVs@Scale High-Power Charging (HPC) Pillar Deep-Dive Technical Meeting

EVs@Scale Lab Consortium is addressing challenges, developing solutions, and enabling technologies for transportation electrification ecosystem. The consortium has five research pillars one of which focuses on high power charging (HPC). HPC pillar brings together hardware and software expertise, capabilities, and facilities related to high power EV charging, charge management, and grid integration. Deep-dive technical meetings are organized twice a year and provides an opportunity for more industry engagement and technical feedback for the national labs throughout the project lifecycle. High-Power Charging pillar has two active projects: (i) Next-Gen Profiles (NGP) and (ii) High-Power Electric Vehicle Charging Hub Integration Platform (eCHIP). This presentation summarizes the progress made in both projects during the past six months focusing on specific topics. There will be two deep-dive technical meetings twice a year. Every deep-dive meeting will focus on different aspects of the project progress.

ADVANCED PROPULSION SYSTEMS↗