Search NASA⌕ Search

SEARCH · Search NASA

Results for “parallel hybrid propulsion”

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.

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

53 records · Page 3
All sourcesNASA NTRSDOE OSTI
NASA NTRS1980

Advanced propulsion system for hybrid vehicles

A number of hybrid propulsion systems were evaluated for application in several different vehicle sizes. A conceptual design was prepared for the most promising configuration. Various system configurations were parametrically evaluated and compared, design tradeoffs performed, and a conceptual design produced. Fifteen vehicle/propulsion systems concepts were parametrically evaluated to select two systems and one vehicle for detailed design tradeoff studies. A single hybrid propulsion system concept and vehicle (five passenger family sedan)were selected for optimization based on the results of the tradeoff studies. The final propulsion system consists of a 65 kW spark-ignition heat engine, a mechanical continuously variable traction transmission, a 20 kW permanent magnet axial-gap traction motor, a variable frequency inverter, a 386 kg lead-acid improved state-of-the-art battery, and a transaxle. The system was configured with a parallel power path between the heat engine and battery. It has two automatic operational modes: electric mode and heat engine mode. Power is always shared between the heat engine and battery during acceleration periods. In both modes, regenerative braking energy is absorbed by the battery.

Norrup, L. V.↗
NASA NTRS1998

High Rate Digital Demodulator ASIC

The architecture of High Rate (600 Mega-bits per second) Digital Demodulator (HRDD) ASIC capable of demodulating BPSK and QPSK modulated data is presented in this paper. The advantages of all-digital processing include increased flexibility and reliability with reduced reproduction costs. Conventional serial digital processing would require high processing rates necessitating a hardware implementation in other than CMOS technology such as Gallium Arsenide (GaAs) which has high cost and power requirements. It is more desirable to use CMOS technology with its lower power requirements and higher gate density. However, digital demodulation of high data rates in CMOS requires parallel algorithms to process the sampled data at a rate lower than the data rate. The parallel processing algorithms described here were developed jointly by NASA's Goddard Space Flight Center (GSFC) and the Jet Propulsion Laboratory (JPL). The resulting all-digital receiver has the capability to demodulate BPSK, QPSK, OQPSK, and DQPSK at data rates in excess of 300 Mega-bits per second (Mbps) per channel. This paper will provide an overview of the parallel architecture and features of the HRDR ASIC. In addition, this paper will provide an over-view of the implementation of the hardware architectures used to create flexibility over conventional high rate analog or hybrid receivers. This flexibility includes a wide range of data rates, modulation schemes, and operating environments. In conclusion it will be shown how this high rate digital demodulator can be used with an off-the-shelf A/D and a flexible analog front end, both of which are numerically computer controlled, to produce a very flexible, low cost high rate digital receiver.

Ghuman, Parminder↗
NASA NTRS2002

A Three-Dimensional Parallel Time-Accurate Turbopump Simulation Procedure Using Overset Grid System

The objective of the current effort is to provide a computational framework for design and analysis of the entire fuel supply system of a liquid rocket engine, including high-fidelity unsteady turbopump flow analysis. This capability is needed to support the design of pump sub-systems for advanced space transportation vehicles that are likely to involve liquid propulsion systems. To date, computational tools for design/analysis of turbopump flows are based on relatively lower fidelity methods. An unsteady, three-dimensional viscous flow analysis tool involving stationary and rotational components for the entire turbopump assembly has not been available for real-world engineering applications. The present effort provides developers with information such as transient flow phenomena at start up, and nonuniform inflows, and will eventually impact on system vibration and structures. In the proposed paper, the progress toward the capability of complete simulation of the turbo-pump for a liquid rocket engine is reported. The Space Shuttle Main Engine (SSME) turbo-pump is used as a test case for evaluation of the hybrid MPI/Open-MP and MLP versions of the INS3D code. CAD to solution auto-scripting capability is being developed for turbopump applications. The relative motion of the grid systems for the rotor-stator interaction was obtained using overset grid techniques. Unsteady computations for the SSME turbo-pump, which contains 114 zones with 34.5 million grid points, are carried out on Origin 3000 systems at NASA Ames Research Center. Results from these time-accurate simulations with moving boundary capability are presented along with the performance of parallel versions of the code.

Kiris, Cetin↗
NASA NTRSDate not supplied

Electrical Energy Storage Design Space Exploration for a Hybrid-Electric Six-Passenger Quadrotor

Hybrid-electric architectures are a promising means to achieve clean and efficient aircraft propulsion needed for small, short-range electric vertical takeoff and landing class vehicles. This paper explores the design space for a six-passenger quadrotor hybrid-electric propulsion system and shows that hybrid architectures that are more efficient than engine-only architectures can be built with near-term battery technology (approximately 150 Wh/kg at the pack level). Data obtained shows that hybrid-electric propulsion systems can achieve 37 percent block fuel reduction and 35 percent total energy cost savings over a 120 nautical mile mission compared to conventional turboshaft architectures. This work suggests that hybrids are likely the most efficient architectures that can be produced in the near term for this class of vehicle and motivates further development in this area.

parallel hybrid electric aircraft↗
NASA NTRS2001

A Three Dimensional Parallel Time Accurate Turbopump Simulation Procedure Using Overset Grid Systems

The objective of the current effort is to provide a computational framework for design and analysis of the entire fuel supply system of a liquid rocket engine, including high-fidelity unsteady turbopump flow analysis. This capability is needed to support the design of pump sub-systems for advanced space transportation vehicles that are likely to involve liquid propulsion systems. To date, computational tools for design/analysis of turbopump flows are based on relatively lower fidelity methods. An unsteady, three-dimensional viscous flow analysis tool involving stationary and rotational components for the entire turbopump assembly has not been available for real-world engineering applications. The present effort provides developers with information such as transient flow phenomena at start up, and non-uniform inflows, and will eventually impact on system vibration and structures. In the proposed paper, the progress toward the capability of complete simulation of the turbo-pump for a liquid rocket engine is reported. The Space Shuttle Main Engine (SSME) turbo-pump is used as a test case for evaluation of the hybrid MPI/Open-MP and MLP versions of the INS3D code. CAD to solution auto-scripting capability is being developed for turbopump applications. The relative motion of the grid systems for the rotor-stator interaction was obtained using overset grid techniques. Unsteady computations for the SSME turbo-pump, which contains 114 zones with 34.5 million grid points, are carried out on Origin 3000 systems at NASA Ames Research Center. Results from these time-accurate simulations with moving boundary capability will be presented along with the performance of parallel versions of the code.

Kiris, Cetin↗
NASA NTRS2019

Optimal Control within the Context of Multidisciplinary Design, Analysis, and Optimization

Multidisciplinary design, analysis and optimization involves modeling the interactions of complex systems across a variety of disciplines. The optimization of such systems can be a computationally expensive exercise with multiple levels of nested nonlinear solvers running under an optimizer.The application of optimal control in project development often involves performing trajectory optimization for fixed vehicle designs or parametric sweeps across some key vehicle properties.This information is then relayed to the subsystem design teams who update their designs and relay some bulk characteristics back to the trajectory optimization procedure.This iteration is then repeated until the design closes.However, with increasing interest in more tightly coupled systems, such as electric and hybrid-electric aircraft propulsion and boundary layer ingestion, this process is prone to ignore subtle coupling between vehicle subsystem designs and vehicle operation on a given mission.Integrating trajectory optimization into a tightly coupled multidisciplinary design procedure can be computationally prohibitive, depending on the complexity of the subsystem analyses and the optimal control technique applied.To address these issues a new optimal control software tool, Dymos, has been developed.Dymos is built upon NASA's OpenMDAO software and can leverage its capabilities to efficiently compute gradients for the optimization and optimize complex models in parallel on distributed memory systems.This report provides some explanation into the numerical methods employed in Dymos and provides several use cases that demonstrate its performance on traditional optimal control problems and improvements ino techniques have been used extensively in recent decades to solve a variety of optimal control problems, typically in the form of aerospace vehicle trajectory optimization.

pseudospectral↗
NASA NTRS2013

Estimating the Effects of Astronaut Career Ionizing Radiation Dose Limits on Manned Interplanetary Flight Programs

The Hybrid Inflatable DSH combined with electric propulsion and high power solar-electric power systems offer a near TRL-now solution to the space radiation crew dose problem that is an inevitable aspect of long term manned interplanetary flight. Spreading program development and launch costs over several years can lead to a spending plan that fits with NASA's current and future budgetary limitations, enabling early manned interplanetary operations with space radiation dose control, in the near future while biomedical research, nuclear electric propulsion and active shielding research and development proceed in parallel. Furthermore, future work should encompass laboratory validation of HZETRN calculations, as previous laboratory investigations have not considered large shielding thicknesses and the calculations presented at these thicknesses are currently performed via extrapolation.

Koontz, Steven L.↗
NASA NTRS2006

NASA Tech Briefs, January 2006

Topics covered include: Semiautonomous Avionics-and-Sensors System for a UAV; Biomimetic/Optical Sensors for Detecting Bacterial Species; System Would Detect Foreign-Object Damage in Turbofan Engine; Detection of Water Hazards for Autonomous Robotic Vehicles; Fuel Cells Utilizing Oxygen From Air at Low Pressures; Hybrid Ion-Detector/Data-Acquisition System for a TOF-MS; Spontaneous-Desorption Ionizer for a TOF-MS; Equipment for On-Wafer Testing From 220 to 325 GHz; Computing Isentropic Flow Properties of Air/R-134a Mixtures; Java Mission Evaluation Workstation System; Using a Quadtree Algorithm To Assess Line of Sight; Software for Automated Generation of Cartesian Meshes; Optics Program Modified for Multithreaded Parallel Computing; Programs for Testing Processor-in-Memory Computing Systems; PVM Enhancement for Beowulf Multiple-Processor Nodes; Ion-Exclusion Chromatography for Analyzing Organics in Water; Selective Plasma Deposition of Fluorocarbon Films on SAMs; Water-Based Pressure-Sensitive Paints; System Finds Horizontal Location of Center of Gravity; Predicting Tail Buffet Loads of a Fighter Airplane; Water Containment Systems for Testing High-Speed Flywheels; Vapor-Compression Heat Pumps for Operation Aboard Spacecraft; Multistage Electrophoretic Separators; Recovering Residual Xenon Propellant for an Ion Propulsion System; Automated Solvent Seaming of Large Polyimide Membranes; Manufacturing Precise, Lightweight Paraboloidal Mirrors; Analysis of Membrane Lipids of Airborne Micro-Organisms; Noninvasive Diagnosis of Coronary Artery Disease Using 12-Lead High-Frequency Electrocardiograms; Dual-Laser-Pulse Ignition; Enhanced-Contrast Viewing of White-Hot Objects in Furnaces; Electrically Tunable Terahertz Quantum-Cascade Lasers; Few-Mode Whispering-Gallery-Mode Resonators; Conflict-Aware Scheduling Algorithm; and Real-Time Diagnosis of Faults Using a Bank of Kalman Filters.

Source record↗
NASA NTRS2019

Towards Articulated Mobility and Efficient Docking for the DuAxel Tethered Robot System

Sites of increasing interest for planetary science,such as craters, cold traps, and vents lie in terrains that are inaccessible to state-of-the-art rovers. The Jet Propulsion Laboratory, in collaboration with Caltech, is actively developing a tethered mobile robot, Axel, for traversing and exploring extremely steep terrain, such as Recurring Slope Lineae on Mars and vertical pits on the Moon. However, on Mars, where landing-site uncertainty is high due to the presence of an atmosphere, Axel may need to traverse several kilometers from its lander untethered due to a finite tether carrying capacity (⇠300m). This paper proposes a novel design for a hybrid mobility system that allows a pair of Axel rovers to dock, lock, and drive long distances as a four-wheeled, articulated steering vehicle. The design improves upon prior efforts to achieve DuAxel mobility by leveraging two actuated docking mechanisms attached on opposite ends of a central module to enable ‘sit/stand’ functionality; the prior DuAxel system was limited to skid steering, which was inefficient due to Axel’s grouser-style, high-friction wheels. In the proposed system, the ‘sit’ configuration is achieved by aligning each dock parallel to the surface, allowing one Axel to detach and explore while the other remains docked and serves as a backup. While ‘sitting’, the central module rests on the ground and is outfitted with shovel-style wedges for passive anchoring to sandy terrain (an optional drill can be integrated for anchoring to rock). In order to ‘stand’, the exploring Axel reattaches, locks, and both docks are rotated until Axel’s tether caster arm is upright and the central module is lifted off the ground. Once upright, each Axel rotates about a pivot point for articulated, all-wheel steering, which is accomplished by applying differential wheel torques. The main contributions of this paper are i) a detailed systems design of the docking mechanism and central module, ii) kinematic modeling of articulated mobility and ‘sit/stand’ docking functionality, and iii) initial testing in a relevant environment to characterize the mobility of the proposed system.

Nesnas, Issa↗
NASA NTRS2024

Mission and Vehicle-Level Updates for the Parallel Electric-Gas Architecture with Synergistic Utilization Scheme (PEGASUS) Concept Aircraft

NASA created the PEGASUS concept with the goal of lowering mission energy (a surrogate for operating cost) compared to other regional aircraft by leveraging electrified aircraft propulsion (EAP). Since its inception, researchers have explored multiple facets of PEGASUS in varying fidelity but have not completed a rigorous, integrated design. The goal of this memorandum is to provide an updated design using recent studies and improved methods. This memorandum explores the initial vehicle concept and concept of operations, while considering ways to improve both the mission concept of operations and the integrated vehicle-level performance. Additionally, the design and analysis methodologies for EAP-enabled aircraft concepts are improved in several areas. This research incorporates new propulsion-airframe integration and wing weight surrogates to model the impacts of wingtip propulsors on the configuration. Detailed weight and balance calculations enable calculating dynamic stability and flight qualities within the conceptual design environment. Ultimately, the vehicle is optimized to reduce "well-to-wake" equivalent CO2, CO2e, rather than minimizing either fuel (or total energy) consumption or maximum takeoff weight. Using fuel/energy or takeoff weight leads to conflicting optima for hybrid-electric aircraft. Two aircraft are developed to provide points of comparison for PEGASUS: an advanced conventional turboprop vehicle and a hybrid-electric variant. The results show that the PEGASUS concept can reduce CO2e relative to the advanced turboprop or a hybrid-electric propulsion architecture, albeit with an increase in maximum takeoff weight. PEGASUS's maximum takeoff weight is 55% heavier than the advanced conventional turboprop but releases 18% less CO2e for a 400 nmi mission. Over the same mission, PEGASUS's maximum takeoff weight is 47% heavier than the comparator hybrid-electric vehicle but releases 12% less CO2e. This study shows that the PEGASUS configuration reduces CO2e through its use of wingtip propulsors and that its benefit is not solely a result of switching to a hybrid-electric propulsion architecture. PEGASUS achieves this reduction in CO2e while maintaining satisfactory Level 1 or 2 flight qualities for all of its longitudinal- and lateral-directional modes.

Hybrid-electric↗
NASA NTRS2017

Simulation Propulsion System and Trajectory Optimization

A number of new aircraft concepts have recently been proposed which tightly couple the propulsion system design and operation with the overall vehicle design and performance characteristics. These concepts include propulsion technology such as boundary layer ingestion, hybrid electric propulsion systems, distributed propulsion systems and variable cycle engines. Initial studies examining these concepts have typically used a traditional decoupled approach to aircraft design where the aerodynamics and propulsion designs are done a-priori and tabular data is used to provide inexpensive look ups to the trajectory ana-ysis. However the cost of generating the tabular data begins to grow exponentially when newer aircraft concepts require consideration of additional operational parameters such as multiple throttle settings, angle-of-attack effects on the propulsion system, or propulsion throttle setting effects on aerodynamics. This paper proposes a new modeling approach that eliminated the need to generate tabular data, instead allowing an expensive propulsion or aerodynamic analysis to be directly integrated into the trajectory analysis model and the entire design problem optimized in a fully coupled manner. The new method is demonstrated by implementing a canonical optimal control problem, the F-4 minimum time-to-climb trajectory optimization using three relatively new analysis tools: Open M-DAO, PyCycle and Pointer. Pycycle and Pointer both provide analytic derivatives and Open MDAO enables the two tools to be combined into a coupled model that can be run in an efficient parallel manner that helps to cost the increased cost of the more expensive propulsion analysis. Results generated with this model serve as a validation of the tightly coupled design method and guide future studies to examine aircraft concepts with more complex operational dependencies for the aerodynamic and propulsion models.

Optimization↗
NASA NTRS2001

Time-Dependent Simulations of Turbopump Flows

The objective of the current effort is to provide a computational framework for design and analysis of the entire fuel supply system of a liquid rocket engine, including high-fidelity unsteady turbopump flow analysis. This capability is needed to support the design of pump sub-systems for advanced space transportation vehicles that are likely to involve liquid propulsion systems. To date, computational tools for design/analysis of turbopump flows are based on relatively lower fidelity methods. An unsteady, three-dimensional viscous flow analysis tool involving stationary and rotational components for the entire turbopump assembly has not been available for real-world engineering applications. The present effort will provide developers with information such as transient flow phenomena at start up, impact of non-uniform inflows, system vibration and impact on the structure. In the proposed paper, the progress toward the capability of complete simulation of the turbo-pump for a liquid rocket engine is reported. The Space Shuttle Main Engine (SSME) turbo-pump is used as a test case for evaluation of the hybrid MPI/Open-MP and MLP versions of the INS3D code. The relative motion of the grid systems for the rotor-stator interaction was obtained using overset grid techniques. Time-accuracy of the scheme has been evaluated with simple test cases. Unsteady computations for the SSME turbo-pump, which contains 114 zones with 34.5 million grid points, are carried out on Origin 2000 systems at NASA Ames Research Center. Results from these time-accurate simulations with moving boundary capability will be presented along with the performance of parallel versions of the code.

Kris, Cetin C.↗
NASA NTRS2019

The Evaluation of Composite Energy Absorbers for Use in UAM EVTOL Vehicle Impact Attenuation

The demand for new personal air-taxi services is leading to the development of lightweight Vertical Take-off and Landing (eVTOL) vehicles with electric propulsion for the Urban Air Mobility (UAM) industry. Manufacturers (OEMs) are considering many different designs to develop a vehicle that is able to take-off, cruise, and land autonomously with seating arrangements ranging between 2 and 15 passengers. It is unclear at present how the eventual market will mature; however, one of the common design characteristics noted by many of the OEMs is the use of advanced materials such as composites. A test and analysis program was initiated at NASA Langley Research Center (LaRC) in 2018 to evaluate the impact attenuation capabilities of various composite material systems with the goal of eventual implementation into an eVTOL vehicle. A series of 3-inch diameter by 6-inch length tubular specimens were fabricated from different material systems which included both traditional carbon and hybrid woven layers of fibers. Additionally, a subset of specimens were filled with closed-cell polyisocyanurate foam to help both with stabilization and crush response. The ultimate goal of the test program was to design a specimen capable of limiting the sustained crush acceleration to 20 g through a stable crush progression. After a series of material tests, these specimens were evaluated under both static and dynamic conditions for impact energy attenuation characteristics and crush stability. Additionally, a series of simulation models were developed in parallel to the test efforts. It is anticipated that the models developed using the component level test efforts can be used to help guide the development of a design for use in full-scale eVTOL vehicle applications.

Littell, Justin↗
NASA NTRS2007

Engineering and Safety Partnership Enhances Safety of the Space Shuttle Program (SSP)

Project Management must use the risk assessment documents (RADs) as tools to support their decision making process. Therefore, these documents have to be initiated, developed, and evolved parallel to the life of the project. Technical preparation and safety compliance of these documents require a great deal of resources. Updating these documents after-the-fact not only requires substantial increase in resources - Project Cost -, but this task is also not useful and perhaps an unnecessary expense. Hazard Reports (HRs), Failure Modes and Effects Analysis (FMEAs), Critical Item Lists (CILs), Risk Management process are, among others, within this category. A positive action resulting from a strong partnership between interested parties is one way to get these documents and related processes and requirements, released and updated in useful time. The Space Shuttle Program (SSP) at the Marshall Space Flight Center has implemented a process which is having positive results and gaining acceptance within the Agency. A hybrid Panel, with equal interest and responsibilities for the two larger organizations, Safety and Engineering, is the focal point of this process. Called the Marshall Safety and Engineering Review Panel (MSERP), its charter (Space Shuttle Program Directive 110 F, April 15, 2005), and its Operating Control Plan emphasizes the technical and safety responsibilities over the program risk documents: HRs; FMEA/CILs; Engineering Changes; anomalies/problem resolutions and corrective action implementations, and trend analysis. The MSERP has undertaken its responsibilities with objectivity, assertiveness, dedication, has operated with focus, and has shown significant results and promising perspectives. The MSERP has been deeply involved in propulsion systems and integration, real time technical issues and other relevant reviews, since its conception. These activities have transformed the propulsion MSERP in a truly participative and value added panel, making a difference for the safety of the Space Shuttle Vehicle, its crew, and personnel. Because of the MSERP's valuable contribution to the assessment of safety risk for the SSP, this paper also proposes an enhanced Panel concept that takes this successful partnership concept to a higher level of 'true partnership'. The proposed panel is aimed to be responsible for the review and assessment of all risk relative to Safety for new and future aerospace and related programs.

Duarte, Alberto↗
NASA NTRS2001

Unsteady Turbopump Flow Simulations

The objective of the current effort is two-fold: 1) to provide a computational framework for design and analysis of the entire fuel supply system of a liquid rocket engine; and 2) to provide high-fidelity unsteady turbopump flow analysis capability to support the design of pump sub-systems for advanced space transportation vehicle. Since the space launch systems in the near future are likely to involve liquid propulsion system, increasing the efficiency and reliability of the turbopump components is an important task. To date, computational tools for design/analysis of turbopump flow are based on relatively lower fidelity methods. Unsteady, three-dimensional viscous flow analysis tool involving stationary and rotational components for the entire turbopump assembly has not been available, at least, for real-world engineering applications. Present effort is an attempt to provide this capability so that developers of the vehicle will be able to extract such information as transient flow phenomena for start up, impact of non-uniform inflow, system vibration and impact on the structure. Those quantities are not readily available from simplified design tools. In this presentation, the progress being made toward complete turbo-pump simulation capability for a liquid rocket engine is reported. Space Shuttle Main Engine (SSME) turbo-pump is used as a test case for the performance evaluation of the hybrid MPI/Open-MP and MLP versions of the INS3D code. Relative motion of the grid system for rotor-stator interaction was obtained by employing overset grid techniques. Time-accuracy of the scheme has been evaluated by using simple test cases. Unsteady computations for SSME turbopump, which contains 106 zones with 34.5 Million grid points, are currently underway on Origin 2000 systems at NASA Ames Research Center. Results from these time-accurate simulations with moving boundary capability and the performance of the parallel versions of the code will be presented.

Centin, Kiris C.↗
NASA NTRS2006

Embedded Sensors for Measuring Surface Regression

The development and evaluation of new hybrid and solid rocket motors requires accurate characterization of the propellant surface regression as a function of key operational parameters. These characteristics establish the propellant flow rate and are prime design drivers affecting the propulsion system geometry, size, and overall performance. There is a similar need for the development of advanced ablative materials, and the use of conventional ablatives exposed to new operational environments. The Miniature Surface Regression Sensor (MSRS) was developed to serve these applications. It is designed to be cast or embedded in the material of interest and regresses along with it. During this process, the resistance of the sensor is related to its instantaneous length, allowing the real-time thickness of the host material to be established. The time derivative of this data reveals the instantaneous surface regression rate. The MSRS could also be adapted to perform similar measurements for a variety of other host materials when it is desired to monitor thicknesses and/or regression rate for purposes of safety, operational control, or research. For example, the sensor could be used to monitor the thicknesses of brake linings or racecar tires and indicate when they need to be replaced. At the time of this reporting, over 200 of these sensors have been installed into a variety of host materials. An MSRS can be made in either of two configurations, denoted ladder and continuous (see Figure 1). A ladder MSRS includes two highly electrically conductive legs, across which narrow strips of electrically resistive material are placed at small increments of length. These strips resemble the rungs of a ladder and are electrically equivalent to many tiny resistors connected in parallel. A substrate material provides structural support for the legs and rungs. The instantaneous sensor resistance is read by an external signal conditioner via wires attached to the conductive legs on the non-eroding end of the sensor. The sensor signal can be transmitted from inside a high-pressure chamber to the ambient environment, using commercially available feedthrough connectors. Miniaturized internal recorders or wireless data transmission could also potentially be employed to eliminate the need for producing penetrations in the chamber case. The rungs are designed so that as each successive rung is eroded away, the resistance changes by an amount that yields a readily measurable signal larger than the background noise. (In addition, signal-conditioning techniques are used in processing the resistance readings to mitigate the effect of noise.) Hence, each discrete change of resistance serves to indicate the arrival of the regressing host material front at the known depth of the affected resistor rung. The average rate of regression between two adjacent resistors can be calculated simply as the distance between the resistors divided by the time interval between their resistance jumps. Advanced data reduction techniques have also been developed to establish the instantaneous surface position and regression rate when the regressing front is between rungs.

Gramer, Daniel J.↗
DOE OSTI2025

Numerical and experimental analysis of mechanically induced failure in electric vehicle battery modules

Mitigating thermal runaway and cell-to-cell propagation is essential for improving the safety of electric and hybrid vehicles. Enhancing digital twin capabilities to predict battery mechanical abuse is particularly critical for automotive and aerospace applications, where crashworthiness is a key concern. Understanding failure conditions and propagation in battery modules during mechanical abuse is complex due to interactions between structural deformation, heat transfer, electrochemical processes, exothermic reactions and mechanical fracture. While prior studies have focused on modeling cell-level behavior, extending these models to module or pack level is necessary for a system level understating of electric vehicle safety. This study develops coupled large deformation finite element models that simultaneously solve for electrochemistry, material failure, internal short circuit and thermal runaway propagation. The models account for mechanical and thermal interactions between lithium-ion cells and other battery components while the contact interfaces are evolving with time. Model-predicted voltage, temperature and force responses are compared with experimental data for validation. The results demonstrate that the approach captures key failure mechanisms, including thermal propagation through heat transfer, electrical propagation from short circuits in parallel-connected cells, and mechanical propagation via penetration and crack formation. These findings show that computational models are valuable tools for understanding battery module failure and providing insight that can reduce the need for extensive experimental testing.

25 ENERGY STORAGE↗