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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
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

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↗
DOE OSTI2023

Emissions minimization on road networks via Generic Second Order Models

In this paper we consider the problem of estimating emissions due to vehicular traffic on complex networks, and minimizing their effect by regulating traffic at junctions. For the traffic evolution, we consider a Generic Second Order Model, which encompasses the majority of two-equations (i.e., second-order) models available in the literature, and extend it to road networks with merge and diverge junctions. The dynamics on the whole network is determined by selecting a solution to the Riemann Problems at junctions, i.e., the Cauchy problems with constant initial data on each incident road. The latter are solved by assuming the maximization of the flow and assigning a traffic distribution coefficient for outgoing roads of diverges, and a priority rule for incoming roads of merges. A general emission model is considered and its parameters are tuned to the $ {\mathrm{NO_{x}}} $ emission rate. The minimization of emissions is then formulated in terms of the traffic distribution and priority parameters, taking into account travel times. A comparison is provided between roundabouts with optimized parameters and traffic lights, which correspond to time-varying traffic priorities. Our approach can be adapted to manage traffic in complex networks in order to reduce emissions while keeping travel time at acceptable levels.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2020

DC Fast Charging Infrastructure for Electrified Road Trips

To assess DC fast charging station network required for electrified road trips by 2030 in California, a new charging infrastructure simulation tool/model, EVI-Pro (Electric Vehicle Infrastructure Projection) RoadTrip, has been developed. In contrast to the existing EVI-Pro model that is primarily for short-distance travels, EVI-Pro RoadTrip is exclusively focused on road trips (long-distance travels, 100 or miles per day per vehicle). Also, the charging paradigm or strategy is different. EVI-Pro RoadTrip is built upon waypoint charging, in which vehicles are forced to stop to charge or replenish the on-board batteries, along the routes between origins and destinations. On the other hand, EVI-Pro is based on destination charging, in which charging is conducted when vehicles are parked in destinations (e.g., work, home). EVI-Pro RoadTrip takes coordinate-level origin and destination data for road trips (intra-state as well as domestic or international out-of-state) and estimates energy consumption and charging needs along the routes between origins and destinations on a minute-by-minute resolution. Based on charging demands for electrified road trips across the state, the optimal locations of charging stations are determined accounting for preferred land use types (e.g., commercial areas) and station service area (e.g., 5 or less miles). Based on station-by-station charging load profiles, the required number of plugs/connectors is estimated for each station and entire state. By comparing hosting capacity of the electric grid (circuit-level) and the charging load output from EVI-Pro RoadTrip, capacity deficit is also evaluated.

ADVANCED PROPULSION SYSTEMS,ENERGY STORAGE↗
DOE OSTI2022

Performance and cost of fuel cells for off-road heavy-duty vehicles

Hydrogen fuel cell-powered off-road vehicles can replace hydrocarbon-powered off-road vehicles to reduce carbon dioxide and criteria pollutant emissions in the agriculture, construction, and mining industries. Vehicle manufacturers and customers recognize health and environmental benefits of emissions reductions but are ultimately compelled by the total cost of ownership of their vehicles. In this study, we conduct a technoeconomic evaluation for three hallmark off-road vehicles, tractors, wheel loaders, and excavators, comparing vehicles with hydrogen fuel cell + battery hybrid powertrains to traditional diesel powertrains. Stakeholder-valued performance metrics include fuel cell engine power, engine durability, hydrogen consumption rate, hydrogen storage system volume, and energy-regenerative drivetrain efficiency. The total cost of ownership includes capital, operating and maintenance, fuel, and fuel storage costs. State-of-the-art fuel cell powered wheel loaders and excavators are currently cost competitive with diesel platforms. If targeted improvements to cost, performance, and durability improvements of fuel cell stacks and storage systems are achieved, fuel cell systems would be cost competitive for tractors and significantly lower total cost of ownership options for wheel loaders and excavators.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2020

Observation of Road Salt Aerosol Driving Inland Wintertime Atmospheric Chlorine Chemistry

Inland sources of particulate chloride for atmospheric nitryl chloride (ClNO2) formation remain unknown and unquantified, hindering air quality assessments. Globally each winter, tens of millions of tons of road salt are spread on roadways for deicing. Here, we identify road salt aerosol as the primary chloride aerosol source, accounting for 80–100% of ClNO 2 formation, at an inland urban area in the wintertime. This study provides experimental evidence of the connection between road salt and air quality through the production of this important reservoir for nitrogen oxides and chlorine radicals, which significantly impact atmospheric composition and pollutant fates. A numerical model was employed to quantify the contributions of chloride sources to ClNO 2 production. The traditional method for simulating ClNO 2 considers chloride to be homogeneously distributed across the atmospheric particle population; yet, we show that only a fraction of the particulate surface area contains chloride. Our new single-particle parametrization considers this heterogeneity, dramatically lowering overestimations of ClNO 2 levels that have been routinely reported using the prevailing methods. The identification of road salt as a ClNO 2 source links this common deicing practice to atmospheric composition and air quality in the urban wintertime environment.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2020

GradeIT (Road Grade Inference Tool)

The National Renewable Energy Laboratory (NREL) has developed the Road Grade Inference Tool, "GradeIT". This tool is a modular Python package the leverages the United States Geological Survey’s (USGS) 1/3 arc-second Digital Elevation Model (DEM), an open and free public dataset. Roadway gradient (slope) has a strong influence on vehicle energy consumption behavior and longitudinal dynamics. Therefore, any tools, models, or analyses that consider vehicle energy consumption or driving profiles is incomplete without accurate elevation and grade information. Despite the acute need for this data, it is rarely collected alongside GPS (latitude and longitude) data, and tools to post-process GPS data to append elevation and grade are difficult to come by. GradeIT satisfies this significant need in the research community. Utilization of the USGS DEM makes the underlying data available to any potential user and ensures continuous data anywhere in the continental United States. The USGS DEM is a great resource; however, in order to be useful for automotive and traffic engineering applications, significant interpolation and filtering is required to achieve an accurate representation of gradient on the roadway. GradeIT employs a two-dimensional interpolation to approximate elevation at a point on the road from the nearest nodes in the DEM. Then, GradeIT applies multiple filtering techniques to smooth the elevation profile to a realistic road topology. Finally, road grade is derived from the elevation profile and returned as the primary output.

Holden, Jacob↗
DOE OSTI2024

Road Lidar Dataset for the TxDOT Austin District

This is a road lidar data collection for developing road elevation models and road inundation mapping methodologies, a joint work between ORNL and The University of Texas at Austin. This dataset is generated as part of the flood transportation infrastructure, partly funded by the NOAA CIROH project. ORNL is a project partner for high-performance computing-empowered flood inundation mapping methodology R&D. The dataset is computed using a GPU-accelerated lidar data processing workflow developed at ORNL. The lidar data source is from TxGIO, the state lidar data collection site. The output dataset is in two formats: laz and copc. It is organized by TxDOT's maintenance sections, covering the Austin District. Data size: 3.86 billion road lidar points, 1.67% of the entire lidar data input Projection: EPSG:32614 (WGS84/UTM zone 14N) Website: https://web.corral.tacc.utexas.edu/nfiedata/road3d/austin_district/AustinMaintenanceSections_H_epsg6343_V_epsg5703/ LICENSE FOR USE -- MAPS AND DATA DISCLAIMER This resource is shared under the Creative Commons Attribution CC BY, http://creativecommons.org/licenses/by/4.0/ MAPS AND DATA DISCLAIMER The Oak Ridge National Laboratory (ORNL) shall not be held liable for improper or incorrect use of the data described or information contained on this map or associated series of maps. The data and related map graphics are not legal, land survey or engineering documents and are not intended to be used as such. ORNL gives no warranty, express or implied, as to the accuracy, reliability, utility or completeness of this information. The user of these maps and data assumes all responsibility and risk for the use of the maps and data. ORNL disclaims all warranties, representations or endorsements either express or implied, with regard to the information contained in this map product, including, but not limited to, all implied warranties of merchantability, fitness for a particular purpose or non-infringement. This preliminary map product is for research and review purposes only. It is not intended to be used for emergency management operational or life safety decisions at the local or regional governmental level or by the general public. Users requiring information regarding hazardous conditions or meteorological conditions for specific geographic areas should consult directly with their city or county emergency management office.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2025

TxDOT Road Elevation Model Dataset

This dataset provides three formats of Road Elevation Model (REM) data: 3D road line/polygon GeoPackage (GPKG), road lidar LAZ and COPC LAZ, and road digital surface model (DSM) GeoTIFF. Data are produced from the ~50TB TxGIO (formerly TNRIS) state lidar collections. This dataset is currently organized by maintenance section in each TxDOT district. Computation is done on GPU computing resources at Oak Ridge National Laboratory (ORNL), through a Strategic Partnership Project with UT Austin and an NSF ACCESS computing allocation award that enables fast massive data movement between TACC Corral and ORNL CADES/OLCF using Globus. In addition to this release from ORNL, a copy of this dataset can also be downloaded at https://web.corral.tacc.utexas.edu/nfiedata/road3d/.

13 HYDRO ENERGY↗
DOE OSTI2020

Computational Analysis of Water Film Thickness During Rain Events for Assessing Hydroplaning Risk Part 2: Rough Road Surfaces

Hydroplaning occurs when a water film forms on a road during a rain event and vehicles are traveling at a speed that does not provide sufficient time for the tires to push the water film out of the tire path. Under these conditions, the tire loses contact with the road and the driver may lose control over the vehicle. The present study is a part of a multiyear research effort aimed at gaining a better understanding of the factors that contribute to hydroplaning risk in order to minimize the occurrence of hydroplaning accidents. Three-dimensional computational fluid dynamics (CFD) analysis was used to investigate the water film thickness on multilane roads, one of the key parameters in evaluating hydroplaning risk. In the first part of the study, water films forming on wide roadways, i.e. multilane highways with 2, 4, and 6 lanes per side, were analyzed, with varying cross slope, longitudinal slope, and rainfall rate. Roadways with and without curbs and drainage were included in the analysis. The analysis in the first part was limited to nearly smooth asphalt or concrete surfaces because the maximum roughness height that can be specified in a CFD model using wall functions to determine shear stress at the road surface boundary is one half the thickness of computational cell layer adjacent to the boundary and the need to resolve the vertical velocity distribution in a thin water film requires cell layers that are a fraction of a millimeter thick. In this part of the study, the analysis was extended to consider the influence of pavement roughness over a range extending up 3.6 mm on the development of water film thickness. Various methods of modeling roughness were investigated and are presented: the roughness height model, a meshed-out geometry of the macrotexture of the pavement, and a porous region model. The computational results were analyzed and compared with experimental measurements performed by Gallaway et al.

42 ENGINEERING↗
DOE OSTI2022

Los Alamos National Laboratory Floodplain Assessment for the West Road Post and Cable Fencing Project

The National Nuclear Security Administration (NNSA), a semi-autonomous agency within the U.S. Department of Energy (DOE), is proposing to take action at Los Alamos National Laboratory (LANL) to install post and cable or in-kind barriers along West Road at selected locations near the Los Alamos County ice-skating rink in Los Alamos Canyon (Figure 1). The proposed project is intended to improve vehicular and pedestrian safety on West Road by reducing traffic hazards associated with unsafe roadside parking and reduce wildland fire hazards associated with vehicles driving and parking on vegetation. West Road crosses approximately 0.35 miles (mi.) (1,900 feet (ft.)) of the Los Alamos Canyon floodplain at the bottom of Los Alamos Canyon. Project activities within the floodplain include blocking access to the informal roadside parking along either side of West Road in Los Alamos Canyon.

42 ENGINEERING↗
DOE OSTI2021

A Hybrid Heavy-Duty Diesel Power System for Off-Road Applications - Concept Definition

A multi-year Power System R&D project was initiated with the objective of developing an off-road hybrid heavy-duty concept diesel engine with front end accessory drive-integrated energy storage. This off-road hybrid engine system is expected to deliver 15-20% reduction in fuel consumption over current Tier 4 Final-based diesel engines and consists of a downsized heavy-duty diesel engine containing advanced combustion technologies, capable of elevated peak cylinder pressures and thermal efficiencies, exhaust waste heat recovery via SuperTurbo™ turbocompounding, and hybrid energy recovery through both mechanical (high speed flywheel) and electrical systems. The first year of this project focused on the definition of the hybrid elements using extensive dynamic system simulation over transient work cycles, with hybrid supervisory controls development focusing on energy recovery and transient load assist, in Caterpillar’s DYNASTY™ software environment. Three key off-road applications were the focus of the hybrid concept definition with an aim of understanding the system’s modular capability for the diverse off-road heavy-duty market. Core engine performance 1D and 3D simulations isolated the efficiency contributions from the downsized engine, turbocompounding, and in-cylinder thermal barrier coatings. A fuel consumption improvement range of 14 to 24% was predicted, resulting in successful project progression to the design and experimental validation phase. Furthermore, an overview of the experimental engine and hybrid system status concludes the discussion along with the multi-year project’s next steps.

33 ADVANCED PROPULSION SYSTEMS↗
NASA NTRS1989

Road boundary detection

A method for extracting road boundaries using the monochrome image of a visual road scene is presented. The statistical information regarding the intensity levels present in the image along with some geometrical constraints concerning the road are the basics of this approach. Results and advantages of this technique compared to others are discussed. The major advantages of this technique, when compared to others, are its ability to process the image in only one pass, to limit the area searched in the image using only knowledge concerning the road geometry and previous boundary information, and dynamically adjust for inconsistencies in the located boundary information, all of which helps to increase the efficacy of this technique.

Sowers, J.↗
DOE OSTI2024

Solar PV Road Setbacks: Ordinances (2022) and Extrapolated Trends

This dataset represents solar energy setback requirements from roads based on county ordinances as of April 2022. A setback requirement is a minimum distance from a road that an energy project may be developed, and these varied widely across the counties in which they existed. Two versions are provided: one reflecting only the county ordinances and another incorporating extrapolated trends. In the extrapolated version, a default setback of 30 meters was applied in counties without specific road setback regulations. A TIF data file and a PNG map of the data are provided for both versions, showing areas where solar energy is prohibited or permitted across the contiguous United States. For further details and citation, please refer to the publication linked below: Lopez, Anthony, Pavlo Pinchuk, Michael Gleason, Wesley Cole, Trieu Mai, Travis Williams, Owen Roberts, Marie Rivers, Mike Bannister, Sophie-Min Thomson, Gabe Zuckerman, and Brian Sergi. 2024. Solar Photovoltaics and Land-Based Wind Technical Potential and Supply Curves for the Contiguous United States: 2023 Edition. Golden, CO: National Renewable Energy Laboratory. NREL/TP-6A20-87843.

Array↗
DOE OSTI2024

Design, Modeling, and Control of a Hardware-in-the-Loop Testbed for Off-Road Vehicles

This paper presents the design, modeling, and control of a hardware-in-the-loop (HIL) testbed for off-road vehicles. The proposed HIL testbed employs a transient hydrostatic dynamometer to load a diesel engine to emulate any loading cycles of a wheel loader, which is a representative off-road vehicle. A fully validated wheel loader model is used to calculate the engine load, including both the drive and work functions. Besides, iterative learning control (ILC) has been designed for the loading torque tracking of the hydrostatic dynamometer to ensure accurate emulation of real-world operation scenarios. The developed HIL testbed is used to demonstrate more than 26% energy benefits of automated wheel loaders through systematic optimization compared with human-operated wheel loaders. As a result, this HIL testbed serves as a robust platform for advancing research and development across various off-road vehicles, including excavators, tractors, and harvesters.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2024

Improving Efficiency of Off-Road Vehicles by Novel Integration of Electric Machines and Advanced Combustion Engines

Modern off-road equipment will increasingly rely on electrified implements that will deliver precision control with a smaller footprint than hydraulics. The primary energy converter, however, will be an onboard reciprocating internal combustion engine because of the power density of hydrocarbon fuels in comparison to electrical energy storage and the remote locations where much of this equipment is deployed. Adding energy storage and electric machines creates opportunities to improve efficiency while reducing emissions. This program investigated approaches to take advantage of the extra flexibility that an enhanced electrical system to enable high-efficiency, low-emissions combustion technologies. The current program evaluated hybridization of both the torque application and air-handling systems to maximize efficiency while minimizing cost. This program designed, analyzed and tested a hybrid off-road vehicle consisting of a series electric powertrain with energy storage, an electrified air system, and a 33% downsized diesel engine. Detailed comparisons were made between the base powertrain and the developed powertrain using powertrain simulations, engine testing, and vehicle testing. The key results of the study are: • The resulting vehicle reduces fuel consumption by 5% to 15% at equal productivity. The primary improvements were due to recovery of regenerative braking losses for cycles where large transients are encountered. • The electrified air system was an enabler to allow engine downsizing. This was most important for duty-cycles where the engine primarily operated at moderate loads and had few low speed high torque conditions. • Engine level improvements showed re-optimization of the powertrain is possible when electrified air handing is available. Increased exhaust gas recirculation and advanced injection timing allowed up to a 15% reduction in brake specific fuel consumption at equal NOx and transient response. Compared to the larger engine, the downsized engine achieves up to an 18% reduction in brake specific fuel consumption over the non-road transient cycle. • The life cycle analysis and total cost of ownership study showed that the hybrid powertrain has the potential to reduce 5-year CO2 and total cost of ownership by ~6% over the baseline vehicle. The results also indicated that a pure battery electric vehicle is not feasible in this application and is likely to increase the CO2 emissions due to the CO2 from battery production. A hybrid powertrain with low carbon fuels shows the potential to substantially reduce CO2 and total cost of ownership.

02 PETROLEUM↗
DOE OSTI2025

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↗
DOE OSTI2022

Off-Road Vehicle Decarbonization and Energy Systems Integration: R&D Gaps and Opportunities

This report summarizes findings from the Off-Road Decarbonization and Energy Systems Integration workshop, hosted by the National Renewable Energy Laboratory (NREL) from March 22-24, 2022. The workshop focused on the importance of collaboration among the off-road vehicle industry and government to address barriers and opportunities for decarbonization. The workshop aligns with priorities of the U.S. Department of Energy (DOE) Vehicle Technologies Office and Hydrogen and Fuel Cell Technologies Office to decarbonize transportation in the agriculture, mining, construction, and military industries. This decarbonization effort is also intended to support original equipment manufacturers, industry associations, technology developers, utilities, and consultants. The sections within this report correspond to the three topic areas covered in the 3-day workshop: a high-level perspective of needs and challenges, vehicle and equipment decarbonization strategies, and energy systems integration opportunities.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2024

A Hybrid Heavy Duty Diesel Power System for Off-Road Applications—Concept Validation

A multiyear power system R&D program was completed with the objective of developing an off-road hybrid heavy duty diesel engine with front end accessory drive-integrated energy storage. This system was validated to deliver 10.5–25.6% reduction in fuel consumption over current Tier 4 Final-based 18L diesel engines, over various off-road machine application cycles. The power system consisted of a downsized heavy-duty diesel 13L engine containing advanced combustion technologies, capable of elevated peak cylinder pressures and thermal efficiencies, thermal barrier coatings, exhaust waste heat recovery via SuperTurbo™ turbocompounding, and hybrid energy assisting and recovery through both mechanical and electrical systems. Following the concept definition, design, and analysis phases of the program, the final phase focused on building and validating the performance and efficiency in laboratory tests. While aspects of the system such as start/stop and reduced off-road cooling package energy losses were only analytically evaluated, the main 13L concept engine with full hybrid system was successfully built and tested in steady-state and in transient certification and real-world application cycles. Extensive simulations in Caterpillar's DYNASTY™ software environment utilized the validation test data to assess performance more fully and confidently over varied cycles and strategies. An average fuel consumption reduction of 17.9% was realized, and the majority (~13%) of the benefit stemmed from the core concept 13L engine. In conclusion, a total cost of ownership analysis provides context to commercial viability and where adoption focus should be placed.

33 ADVANCED PROPULSION SYSTEMS↗