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A Hybrid Modulation Method for Single-Stage Soft-Switching Inverter Based on Series Resonant Converter
Pseudo-dc-link inverters are promising due to the single-stage configuration. The inverters can be isolated by high-frequency transformers, which also provide the freedom of step-up/down through winding turns ratio. Conventionally, a pseudo-dc-link inverter is based upon a pulsewidth modulation converter like flyback converter, but the accompanying switching losses can degrade efficiency and overall system performance. Alternatively, resonant converters (e.g., series resonant converter) seem to fit the need as they typically display soft-switching characteristics. However, the relevant research results are scarce because of two main reasons: high resonant current and limited soft-switching range. To overcome the difficulties, a hybrid modulation method is proposed in this article for a pseudo-dc-link inverter based on series resonant converter. In high-line region, the inverter operates with variable-frequency modulation, which leads to zero-voltage switching and relatively low-resonant current. In low-line region, the inverter operates with a short-pulse density modulation so that switching losses are greatly curtailed without excessive resonant current. The merits in both regions together contribute toward the high efficiency of the inverter. This article presents the operational principle of the proposed modulation as well as a comparison with other modulation methods. In addition, a 400 V-230 Vac, 2-kW prototype was built to verify the proposed modulation and the peak efficiency reaches 98.0%.
Evaluation of Prototype Membrane Based Air Conditioner
A prototype cooling system that uses water as refrigerant was built and sent to Oak Ridge National Laboratory (ORNL) for laboratory performance evaluation. The prototype uses electrochemical compressor technology. The compressor consists of nanostructured polymer membranes that transfer water molecules isothermally. Performance evaluation at ORNL was aimed at characterizing the cooling performance of the prototype at different evaporating and condensing temperatures. Evaluation concluded that the compressor performed as expected, however, the integrated cooling system did not provide cooling.
Replacing photomultiplier tubes with silicon photomultipliers for nuclear safeguards applications
Photomultiplier tubes (PMTs) have been used for decades as the default light detection technology for scintillator-based radiation monitors. PMTs come with a handful of disadvantages, however, including large volume usage, fragility, high-voltage requirements, and susceptibility to magnetic fields. Arrays of silicon photomultipliers (SiPMs) are a possible alternative to PMTs providing similar performance while offering improvements in the areas listed. We focus on straightforward “drop-in replacement” evaluations by imposing a single channel output of the SiPM signal and a backend electronics data acquisition and analysis routine identical to that used for PMTs. In the realm of nuclear safeguards, the primary performance metric for gamma spectroscopy is detector resolution, and for neutron detection it is pulse shape discrimination (PSD) to separate neutron and gamma signals. In this work we present the results of replacing a PMT with a 2” x 2” SiPM array mounted, in turn, to the same 2” x 2” cylindrical sodium iodide (NaI) crystal. The ultimate comparison for this gamma spectrometry is confirmation of uranium enrichment standards, ranging from depleted uranium to 93% highly enriched uranium (HEU), by analyzing the resulting spectra with both a simple integral scaling in key energy regions of the spectrum, as well as with the NaIGEM software package. In addition to the gamma spectroscopy work, we will present the latest results on comparing the PSD capabilities of a 4” x 4” SiPM array to a 5” PMT. As with the gamma spectroscopy evaluations, the light detectors are mounted in turn to the same liter-scale organic scintillators. This neutron-focused work includes evaluation of prototype SiPM readout boards with a single output signal summed over 256 individual SiPM pixels, and evident tradeoffs between PSD capability and fast response.
Mechanical Design and Evaluation of the MP-11-Like Wire Scanner Prototype
A wire scanner (WS) is a linearly actuated diagnostic device that uses fiber wires (such as Tungsten or Silicon Carbide) to obtain the position and intensity profile of the proton beam at the Los Alamos Neutron Science Center (LANSCE) particle accelerator. LANSCE will be installing approximately 86 new WS in the near future as part of the LANSCE Risk Mitigation project. These 86 new WS include the replacement of many current WS and some newly added to the current linear accelerator and other beam lines. The reason for the replacement and addition of WS is that many of the existing actuators have parts that are no longer readily available and are difficult to find, thus making maintenance very difficult. One of the main goals is to construct the new WS with as many commercially-available-off-the-shelf components as possible. In addition, faster beam scans (both mechanically and in term of data acquisition) are desired for better operation of the accelerator. This document outlines the mechanical design of the new MP-11-like WS prototype and compares it to a previously built and tested SNS-like WS prototype.
Crystal structure, energetics, and phase stability of strengthening precipitates in Mg alloys: A first-principles study
Magnesium alloys have attracted increasing interest due to their potential use as light-weight structural materials but their application is limited by their low strength compared to conventional alloys. Age hardening is commonly employed to form strengthening precipitates in such alloys, which impedes the motion of dislocations, and leads to improved strength. However, the exact composition, crystal structure, and energetics of many of these strengthening precipitates are either unknown or not clearly resolved, making the precise engineering and design of such alloys difficult. Toward this end, we use first-principles density functional theory calculations to elucidate the crystal structures and energetics of a very large set of precipitates in magnesium alloys. For cases where the precipitate crystal structure is not known, we comprehensively search over decorations of many prototype structures, including hcp superstructures, and in addition, perform global structural optimization using the Minima Hopping Method to predict suitable crystal structures. For all the strengthening precipitates, we calculate the formation energies, construct the respective zero temperature convex hulls, and analyze their stabilities. Here, we show that the bulk formation energies per solute atom (essentially, the solute chemical potentials) decrease along the observed sequences of precipitation, validating our calculations in Mg-{Nd, Gd, Y, Y-Nd, Nd-Zn, Gd-Zn, Y-Zn, Al, Zn, Sn, Al-Ca, Ca-Zn} alloy systems. In addition, we construct a monolayer model for the Guinier-Preston zones (GP zones) observed in the Mg-Nd-Zn system during early stages of age hardening, and thereby explain the formation of the γ" (Mg 5 (Nd,Zn)) phase from the GP zones, as observed in experiments.
Hierarchical Self-Assembly Pathways of Peptoid Helices and Sheets
Peptoids (N-substituted glycines) are a class of tailorable synthetic peptidomic polymers. Amphiphilic diblock peptoids have been engineered to assemble 2D crystalline lattices with applications in catalysis and molecular separations. Assembly is induced in an organic solvent/water mixture by evaporating the organic phase, but the assembly pathways remain uncharacterized. We conduct all-atom molecular dynamics simulations of Nbrpe6Nc6 as a prototypical amphiphilic diblock peptoid comprising an NH 2 -capped block of six hydrophobic N-((4-bromophenyl)ethyl)glycine residues conjugated to a polar NH 3 (CH 2 ) 5 CO tail. We identify a thermodynamically controlled assembly mechanism by which monomers assemble into disordered aggregates that self-order into 1D chiral helical rods then 2D achiral crystalline sheets. We support our computational predictions with experimental observations of 1D rods using small-angle X-ray scattering, circular dichroism, and atomic force microscopy and 2D crystalline sheets using X-ray diffraction and atomic force microscopy. Furthermore, this work establishes a new understanding of hierarchical peptoid assembly and principles for the design of peptoid-based nanomaterials.
Understanding and mitigating process drift in aerosol jet printing
Aerosol jet printing offers a versatile, high-resolution prototyping capability for flexible and hybrid electronics. Despite its rapid growth in recent years, persistent problems such as process drift hinder the adoption of this technology in production environments. Here we explore underlying causes of process drift during aerosol jet printing and introduce an engineered solution to improve deposition stability. In this work it is shown that the ink level within the cartridge is a critical factor in determining atomization efficiency, such that the reduction in ink volume resulting from printing itself can induce significant and systematic process drift. By integrating a custom 3D-printed cartridge with an ink recirculation system, ink composition and level within the cartridge are better maintained. This strategy allows extended duration printing with improved stability, as evidenced by 30 h of printing over 5 production runs. This provides an important tool for extending the duration and improving reliability for aerosol jet printing, a key factor for integration in practical manufacturing operations.
Exploring the Psychometrics of Common Post-Scenario Human Factors Questionnaires of Workload, Situation Awareness, and Perceived Difficulty
Abstract: The United States (U.S.) Department of Energy (DOE) Light Water Reactor Sustainability (LWRS) program has the primary mission of sustaining operation of the existing commercial nuclear power plants (NPPs) through a multi-pathway approach in conducting research and development (R&D). In this effort, the role of human factors engineering (HFE) has been an integral in ensuring new digital upgrades that are part of the overall main control room modernization strategy for various U.S. NPPs optimize human-system performance and do not introduce new human failure modes. In this process, testing and evaluation of concept (i.e., prototype) human machine interfaces (HMIs) are done in operator-in-the-loop studies at various stages of the HFE modification process, such as during design and verification and validation (V&V) [1]. During these studies, licensed operators go through select scenarios using a testbed, such as a full-scale simulator or at a NPP’s training simulator, to identify potential usability issues and provide general design feedback regarding the new digital HMIs. Human-system performance is measured and evaluated through a range of objective and self-report measures that capture aspects of plant performance, task performance, workload, situation awareness, and anthropometric and ergonomic concerns [2]. The use of post-scenario questionnaires is an acceptable method for gathering measures of workload and situation awareness. To this end, the NASA-Task Load Index (TLX) [e.g., 3, 4, & 5] and Situation Awareness Rating Technique (SART) [e.g., 6 & 7] are common standardized questionnaires used for evaluating workload and situation awareness, respectively. When combined, these questionnaires consist of a total of 15 questions, each using a different rating scale. Debriefs are also done through interviews with operators to gather design insight after each scenario. Since operator- and training simulator-time is limited, a concern during this post-scenario period of operator-in-the-loop studies is the limited time available to run scenarios, administer post-scenario questionnaires, and debrief within the allotted simulator time. To address this potential problem, this paper explores the psychometric characteristics of NASA-TLX, SART, and a common one-question post-scenario usability questionnaire (i.e., the single ease question – SEQ [8]) in effort to inform future development of a condensed questionnaire that captures aspects of workload and situation awareness. This exploratory work uses data from four different operator-in-the-loop studies completed under prior LWRS operator-in-the-loop studies. Findings from this paper should support future development of a consolidated questionnaire that may be used in operator-in-the-loop studies, when time is compressed, that conforms to the HFE scientific and regulatory requirements set for NPP control room modernization.
Internship Progress Summary: Fall 2016
This fall I had the opportunity to work at Los Alamos National Laboratory for the Technology Applications engineering group. I assisted two main projects during my appointment, both related to the Lab’s mission statement: “To solve national security challenges through scientific excellence.” My first project, a thermal source transfer unit, involved skills such as mechanical design, heat transfer simulation, and design analysis. The goal was to create a container that could protect a heat source and regulate its temperature during transit. I generated several designs, performed heat transfer simulations, and chose a design for prototyping. The second project was a soil drying unit for use in post blast sample analysis. To ensure fast and accurate sample processing, agents in the field wanted a system that could process wet dirt and turn it into dry powder. We designed a system of commercially available parts, and we tested the systems to determine the best methods and processes.
Optimization Using Metamodeling in the Context of Integrated Computational Materials Engineering (ICME)
Predictive Design Technologies, LLC (PDT) proposed to employ Integrated Computational Materials Engineering (ICME) tools to help the manufacturing industry in the United States regain the competitive advantage in the global economy. ICME uses computational materials science tools within a holistic system in order to accelerate materials development, improve design optimization, and unify design and manufacturing. With the advent of accurate modeling and simulation along with significant increases in high performance computing (HPC) power, virtual design and manufacturing using ICME tools provide the means to reduce product development time and cost by alleviating costly trial-and-error physical design iterations while improving overall quality and manufacturing efficiency. To reduce the computational cost necessary for the large-scale HPC simulations and to make the methodology accessible for small and medium-sized manufacturers (SMMs), metamodels are employed. Metamodels are approximate models (functional relationships between input and output variables) that can reduce the simulation times by one to two orders of magnitude. In Phase I, PDT, partnered with Mississippi State University (MSU), demonstrated the feasibility of the proposed methodology by employing MSU?s internal state variable (ISV) plasticity-damage model with the help of metamodels to optimize the microstructure-process-property-cost for tube manufacturing processes used by Plymouth Tube Company (PTC), which involves complicated temperature and mechanical loading histories. PDT quantified the microstructure-property relationships for PTC?s SAE J525 electric resistance-welded cold drawn low carbon hydraulic 1010 steel tube manufacturing processes at seven different material states and calibrated the ISV plasticity material parameters to fit experimental tensile stress-strain curves. PDT successfully performed large scale finite element (FE) simulations in an HPC environment using the ISV plasticity model in Abaqus FE analyses of the tube forming, sizing, drawing, welding, and normalizing processes. The simulation results coupled with the manufacturing cost data were used to develop prototype metamodeling (quick response) codes which could be used to predict and optimize the microstructure-process-property-cost relationships. The developed ICME metamodeling toolkits are flexible enough to be applied to other manufacturing processes (e.g. forging, forming, casting, extrusion, rolling, stamping, and welding/joining) and metamodeling codes can run on laptop computers. Based on the work completed in Phase I, in Phase II, PDT proposes to continue to refine the ISV model by correlating and incorporating the uncertainties in the microstructure, mechanical testing, and modeling. Following the model refinement, FE analyses will be simulated and will provide even more realistic predictions as they include an appropriate window of uncertainty. Using the HPC output (FE analyses) as input, the quick-response metamodel codes will more accurately predict and optimize the microstructure-process-property-cost relationships. Furthermore, PDT propose to employ the ICME metamodeling toolkits to help develop a new tube product using entirely new high strength steel. The modeling of the high strength steel manufacturing process will replace the costly and time consuming trial-and-error methods that were used in the tubing industry previously. This simulation-based process prototyping will greatly benefit our industrial partners by opening up new market spaces due to new products with greater capabilities.
Cost-effective retrofit technology for reducing peak power demand in small and medium commercial buildings
We describe a cost-effective retrofit technology that uses collective control of multiple rooftop air conditioning units to reduce the peak power consumption of small and medium commercial buildings. The proposed control uses a model of the building and air conditioning units to select an operating schedule for the air conditioning units that maintains a temperature set point subject to a constraint on the number of units that may operate simultaneously. A prototype of this new control system was built and deployed in a large gymnasium to coordinate four rooftop air conditioning units. Based on data collected while operating this prototype, we estimate that the cost savings achieved by reducing peak power consumption is sufficient to repay the cost of the prototype within a year.
Theory of inelastic multiphonon scattering and carrier capture by defects in semiconductors: Application to capture cross sections
Inelastic scattering and carrier capture by defects in semiconductors are the primary causes of hot-electron-mediated degradation of power devices, which holds up their commercial development. At the same time, carrier capture is a major issue in the performance of solar cells and light-emitting diodes. A theory of nonradiative (multiphonon) inelastic scattering by defects, however, is nonexistent, while the theory for carrier capture by defects has had a long and arduous history. As such, we report the construction of a comprehensive theory of inelastic scattering by defects, with carrier capture being a special case. We distinguish between capture under thermal equilibrium conditions and capture under nonequilibrium conditions, e.g., in the presence of an electrical current or hot carriers where carriers undergo scattering by defects and are described by a mean free path. In the thermal-equilibrium case, capture is mediated by a nonadiabatic perturbation Hamiltonian, originally identified by Huang and Rhys and by Kubo, which is equal to linear electron-phonon coupling to first order. In the nonequilibrium case, we demonstrate that the primary capture mechanism is within the Born-Oppenheimer approximation (adiabatic transitions), with coupling to the defect potential inducing Franck-Condon electronic transitions, followed by multiphonon dissipation of the transition energy, while the nonadiabatic terms are of secondary importance (they scale with the inverse of the mass of typical atoms in the defect complex). We report first-principles density-functional-theory calculations of the capture cross section for a prototype defect using the projector-augmented wave, which allows us to employ all-electron wave functions. We adopt a Monte Carlo scheme to sample multiphonon configurations and obtain converged results. The theory and the results represent a foundation upon which to build engineering-level models for hot-electron degradation of power devices and the performance of solar cells and light-emitting diodes.
Testing and modeling of diffusion bonded prototype optical windows under ITER conditions
Glass-metal joints are a part of ITER optical diagnostics windows. These joints must be leak tight for the safety (presence of tritium in ITER) and to preserve the vacuum. They must also withstand the ITER environment: temperatures up to 220 deg.C and fast neutron fluxes of {approx}3.10{sup 9} n/cm{sup 2}.s. At the moment, little information is available about glass-metal joints suitable for ITER. Therefore, we performed mechanical and thermal tests on some prototypes of an aluminium diffusion bonded optical window. Finite element modeling with Abaqus code was used to understand the experimental results. The prototypes were helium leaking probably due to very tiny cracks in the interaction layer between the steel and the aluminium. However, they were all able to withstand a thermal cycling test up to 200 deg. C; no damage could be seen after the tests by visual inspection. The prototypes successfully passed push-out test with a 500 N load. During the destructive push-out tests the prototypes broke at a 6-12 kN load between the aluminium layer and the steel or the glass, depending on the surface quality of the glass. The microanalysis of the joints has also been performed. The finite element modeling of the push-out tests is in a reasonable agreement with the experiments. According to the model, the highest thermal stress is created in the aluminium layer. Thus, the aluminium joint seems to be the weakest part of the prototypes. If this layer is improved, it will probably make the prototype helium leak tight and as such, a good ITER window candidate. (authors)
Thirty-Six Month Evaluation of UPS Diesel Hybrid-Electric Delivery Vans
This evaluation compared six hybrids and six standard diesels in UPS facilities in Phoenix, Arizona. Dispatch and maintenance practices are the same at both facilities. GPS logging, fueling, and maintenance records are used to evaluate the performance of these step delivery vans. The hybrids' average monthly mileage rate was 18% less than the diesel vans. The hybrids consistently were driven afewer number of miles throughout the evaluation period. The hybrids idled more and operating at slower speeds than the diesels, and the diesels spent slightly more time operating at greater speeds, accounting for much of the hybrids' fewer monthly miles. The average fuel economy for the hybrid vans is 13.0 mpg, 23% greater than the diesel vans' 10.6 mpg. Total hybrid maintenance cost/mile of $\$$0.141 was 9% more than the $\$$0.130 for the diesel vans. Propulsion-related maintenance cost/mile of $\$$0.037 for the hybrid vans was 25% more than the $\$$0.029 for the diesel vans. Neither difference was found to be statistically significant. The hybrid group had a cumulative average of 96.3% uptime, less than the diesel group's 99.0% uptime. The hybrids experienced troubleshooting and recalibrationissues related to prototype components that were primarily responsible for the lower uptime figures.
On-Site Manufacture of Large Cement Structures
ORNL worked with GE Renewable Energy to develop additive manufacturing capabilities that enable the manufacture of large cement structures on-site. This project resulted in the testing and definition of the materials and deposition functions necessary for an on-site additive manufacturing system. Test articles were manufactured using a medium-scale prototype system, and mechanical testing of the samples was performed.
Cummins Electric Truck with Range-Extending Engine (ETREE) Project (Final Technical Report)
The Cummins Electric Truck with Range Extending Engine (ETREE) program designed, developed, and demonstrated a range extending electric vehicle that employs an electrified propulsion system installed in a class 6 commercial vehicle (Peterbilt 220). This project was relevant to industry and the greater public because at the time of the project there were two keys to widespread electrified commercial vehicle adoption yet to be realize: 1) For pure electrified vehicle adoption, battery improvements are needed: Cost must decrease, and energy density must increase. 2) Electric vehicles must overcome fleet operator risks such as: operations in cold climates, hilly terrain, or where majority of conventional trucks are replaced with electrified vehicles. In the near to medium term these adoption hurdles were address by the objectives of this project. A plug-in hybrid vehicle that could be operated in all electric mode for most of its workday optimizing the use of grid energy with the ability to supplement energy demand with the onboard range extending engine. This project’s architecture provided ability to match a conventional class 6 commercial vehicle range and performance characteristics prior to the ubiquitous adoption of battery electric vehicle charging infrastructure as well. Additionally, the vehicles produced as part of this project can be considered a prototype for a commercially viable heavily electrified commercial vehicle because most of the physical hardware used for the project is commercially available in the market today. The ETREE program met its main objectives and demonstrated 65% fuel consumption reduction as compared to a conventional class 6 vehicle while meeting performance and range expectations. This was achieved by drawing upon the strengths of the assembled team: Cummins, PACCAR, the Ohio State University, Argonne National Laboratory and the National Renewable Energy Laboratory.
A High Performance Computing Platform for Performing High-Volume Studies With Windows-based Power Grid Tools
Serial Windows-based programs are widely used in power utilities. For applications that require high volume simulations, the single CPU runtime can be on the order of days or weeks. The lengthy runtime, along with the availability of low cost hardware, is leading utilities to seriously consider High Performance Computing (HPC) techniques. However, the vast majority of the HPC computers are still Linux-based and many HPC applications have been custom developed external to the core simulation engine without consideration for ease of use. This has created a technical gap for applying HPC-based tools to today’s power grid studies. To fill this gap and accelerate the acceptance and adoption of HPC for power grid applications, this paper presents a prototype of generic HPC platform for running Windows-based power grid programs on Linux-based HPC environment. The preliminary results show that the runtime can be reduced from weeks to hours to improve work efficiency.