Search NASA⌕ Search

SEARCH · Search NASA

Results for “Engineering prototypes”

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.

At least 667 records · Page 37
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Colloquium : Sliding and pinning in structurally lubric 2D material interfaces

A plethora of two-dimensional (2D) materials have been introduced in physics and engineering in the past two decades. Their robust, membranelike sheets permit (mostly require) deposition, giving rise to solid-solid dry interfaces whose mobility, pinning, and general tribological properties under shear stress are currently being understood and controlled, both experimentally and theoretically. Here, in this Colloquium simulated case studies of twisted graphene systems are used as a prototype workhorse tool to demonstrate and discuss the general picture of 2D material interface sliding. First highlighted is the crucial mechanical difference, often overlooked, between small and large incommensurabilities, which corresponds to, for example, small and large twist angles in graphene interfaces. In both cases, focusing on flat, structurally lubric or “superlubric” geometries, the generally separate scalings with the area of static friction in pinned states and of kinetic friction during sliding are elucidated and reviewed, tangled as they are with the effects of velocity, temperature, load, and defects. The roles of island boundaries and elasticity are also discussed, and compared when possible to results in the literature for systems other than graphene. It is proposed that the resulting picture of pinning and sliding should be applicable to interfaces in generic 2D materials that are of importance for the physics and technology of existing and future bilayer and multilayer systems.

2-dimensional systems↗
DOE OSTI2022

A 4 kV/120 A SiC Solid-State DC Circuit Breaker Powered By a Load-Independent IPT System

This article introduces a 4 kV/120 A solid-state dc circuit breaker (DCCB) based on discrete SiC mosfets. The DCCB is designed in a five-layer tower structure. Each layer consists of a circular main conduction branch and an attached gate driver. There are two primary benefits of the proposed DCCB. First, it reduces conduction loss with multiple devices in parallel. Second, it achieves an ultrafast response speed with SiC mosfets. Moreover, the gate drivers of the DCCB are powered by a domino inductive power transfer (IPT) system. It achieves the load-independent constant-voltage output characteristics, which means the outputs are immune to load variations. Additionally, an IPT system prototype is implemented to test the power transfer performance. At 500-kHz frequency, the total output power reaches 15.73 W, which is sufficient to power on five gate drivers, with a peak transfer efficiency of 75.4%. The IPT system is tested to power a 4 kV/120 A DCCB prototype. It validates that the DCCB is effective to turn off 120 A current within 3.5 μs.

42 ENGINEERING↗
DOE OSTI2021

Current-Source Solid-State DC Transformer Integrating LVDC Microgrid, Energy Storage, and Renewable Energy Into MVDC Grid

Solid-state DC transformer to integrate low-voltage DC (LVDC) microgrid, wind turbine (WT) generator, photovoltaic (PV), and energy storage (ES) into medium-voltage (MV) direct-current (MVDC) distribution grids is attractive. This paper proposes current-source DC solid-state transformer (SST) for MVDC collection system in WT, PV, and ES farms or as an interface between the MVDC grid and the LVDC microgrid. Compared to conventional current-source converter (CSC) based SSTs, a switch reduction scheme on reverse-blocking device bridges is proposed to reduce device count and the number of devices on the DC-link current path. Importantly, the proposed switch reduction scheme is generic and can be applied to the DC ports of DC-AC, AC-DC, or DC-DC hard-switching or soft-switching CSC-based SSTs. Based on this scheme, the proposed current-source DC SSTs are derived, which have reduced electrolytic-capacitor-less DC-link. The proposed DC SSTs also achieve single-stage isolated DC-DC or DC-AC conversion, full-range zero-voltage switching (ZVS) for main switches, zero-current switching (ZCS) for resonant switches, and controlled dv/dt. The proposed DC SSTs, operating principles, predictive control method, the ZVS, and the controlled dv/dt under voltage buck-boost ranges are verified with MV simulations and an experimental prototype based on SiC MOSFETs, diodes, and a nanocrystalline transformer.

14 SOLAR ENERGY↗
DOE OSTI2023

Medium-Voltage Isolated Auxiliary Power Supply Design for High Insulation Capability, Ultra-Low Coupling Capacitance, and Small Size

To fully utilize the benefits of medium-voltage (MV) silicon carbide (SiC)-based converter and achieve high power density, the isolated auxiliary power supply (IAPS) needs to be as small as possible. However, the high insulation and low coupling capacitance requirements, considering the high voltage and high dv / dt , are constraints of size reduction. This article proposes an MV IAPS design for high insulation capability, ultra-low coupling capacitance, and small size. The topology selection, efficiency, load regulation, coupling capacitance, and size reduction considerations are discussed. A 2.5 W MV IAPS is designed and built for a 10 kV SiC mosfet -based 13.8 kV/100 kW three-phase converter, achieving a partial discharge (PD) inception voltage of higher than 15 kV rms, ultra-low coupling capacitance of 1.03 pF, and smaller size than that of the commercial products as well as the state-of-art research prototypes. Experimental results of PD test, 10 kV SiC mosfet -based half-bridge test, and 13.8 kV/100 kVA three-phase converter full rating test are conducted for design validation.

42 ENGINEERING↗
DOE OSTI2021

Integration of a DER Management System in Riverside. Final report

The tasks in this project covered various aspects, including algorithm development, algorithm integration into a commercial Active Network Management (ANM) platform, hardware-in-the-loop (HIL) testing in an industry-standard testing platform, pilot demonstration in Riverside, California, and also cost and benefit analysis. The DERMS platform in this project can host different algorithms developed on different platforms (e.g., MATLAB and Python) and it can interact with different hardware devices (e.g., different PV inverters, battery inverters, and different sensors). The DER control solution are based on an advanced model-free, layered, and clustered DER control paradigm. At the core of the DER control algorithms was the concept of Extremum Seeking (ES), which is a model-free probing-based control technique. The ES-based control algorithms were tested on major real-world inverters; both individually and in a cluster. It was shown that even legacy equipment (or when paired with a few additional advanced equipment) can support such advanced control. The monitoring algorithms utilize a heterogeneous set of legacy and advanced sensor measurements, such as behind-the-meter DER sensors, distribution-level Phase Measurement Units, distribution-substation Supervisory Control and Data Acquisition (SCADA), and line current sensors, with their limited availability; in order to infer practical network conditions. Sensor data are utilized to achieve resource forecasting, phase identification, and distribution system state estimation. The technology that was developed and demonstrated in this project could be transformational to utilities, including the smaller municipal utilities such as in Riverside, which may not have the resources to deploy advanced distribution system and DERMS solutions in order to support high penetration of solar power integration. This project created a real-world prototype to provide utilities with an assessment of smart grid monitoring and control technologies.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2025

Cauer Prototype for Butterworth Filters: Lowpass, Highpass, Bandpass, and Bandstop Transformations

I had a need to develop a real, physical, analog filter with real RLC components. Having spent a career in theory, I had only ever designed filters for signal processing. I needed only the a and b coefficients. But converting a and b coefficients into RLC values was beyond me. Web searches returned nothing useful until I found Dr. Aaron Danner’s Designing Passive Butterworth Filters (10 - Passive Filters), part of an excellent YouTube series which introduced me to the Cauer prototype for Butterworth filters and Cauer topologies. Failing to find documentation on Cauer filter prototypes, I asked Anthropic’s Claude AI for assistance. Claude returned a few errors which I corrected. This is a comprehensive report on what I learned.

42 ENGINEERING↗
DOE OSTI2018

A Surveillance Infrastructure for Malaria Analytics: Provisioning Data Access and Preservation of Interoperability

Background: According to the World Health Organization, malaria surveillance is weakest in countries and regions with the highest malaria burden. A core obstacle is that the data required to perform malaria surveillance are fragmented in multiple data silos distributed across geographic regions. Furthermore, consistent integrated malaria data sources are few, and a low degree of interoperability exists between them. As a result, it is difficult to identify disease trends and to plan for effective interventions. Objective: We propose the Semantics, Interoperability, and Evolution for Malaria Analytics (SIEMA) platform for use in malaria surveillance based on semantic data federation. Using this approach, it is possible to access distributed data, extend and preserve interoperability between multiple dynamic distributed malaria sources, and facilitate detection of system changes that can interrupt mission-critical global surveillance activities. Methods: We used Semantic Automated Discovery and Integration (SADI) Semantic Web Services to enable data access and improve interoperability, and the graphical user interface-enabled semantic query engine HYDRA to implement the target queries typical of malaria programs. We implemented a custom algorithm to detect changes to community-developed terminologies, data sources, and services that are core to SIEMA. This algorithm reports to a dashboard. Valet SADI is used to mitigate the impact of changes by rebuilding affected services. Results: We developed a prototype surveillance and change management platform from a combination of third-party tools, community-developed terminologies, and custom algorithms. We illustrated a methodology and core infrastructure to facilitate interoperable access to distributed data sources using SADI Semantic Web services. This degree of access makes it possible to implement complex queries needed by our user community with minimal technical skill. We implemented a dashboard that reports on terminology changes that can render the services inactive, jeopardizing system interoperability. Using this information, end users can control and reactively rebuild services to preserve interoperability and minimize service downtime. Conclusions: We introduce a framework suitable for use in malaria surveillance that supports the creation of flexible surveillance queries across distributed data resources. The platform provides interoperable access to target data sources, is domain agnostic, and with updates to core terminological resources is readily transferable to other surveillance activities. A dashboard enables users to review changes to the infrastructure and invoke system updates. The platform significantly extends the range of functionalities offered by malaria information systems, beyond the state-of-the-art.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2016

Study on balance of axial force in helium circulator for HTR-PM - 18490

The helium circulator is one of the key equipment in the first loop of the High Temperature gas-cooled Reactor Pebble bed Module (HTR-PM). The active magnetic bearings are employed in the helium circulator, so that the inlet ring sealing clearance is about 5 to 10 times larger than that if the mechanical bearings are employed. Bigger clearance results in bigger leakage flow and bigger axial force. A new design of balance holes was proposed to reduce the axial aerodynamic force and the design principle was analyzed. To investigate the axial aerodynamic force due to leakage flow, numerical simulation of fluid dynamic was conducted in the impeller with two kinds of inlet ring sealing clearance and four types of balance holes, respectively. The calculation results shows that the balance holes with diameter 12 mm have high performance and that the designed balance holes reduce effectively about 78% of the axial aerodynamic force. The axial force was obtained from the measured real-time electric current of the axial active magnetic bearings in one helium circulator prototype. The comparison of experimental data with the CFD analysis results showed that the new design of balance holes was successful. (authors)

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2024

An Organic, Direct Bonded Copper, Multi-Layered, Ultra-Low Inductance Package for High-Power UWBG MOSFETs

The most common metalized substrates used in high-power switching packages consist of a ceramic layer such as Aluminum Nitride (AlN) sandwiched between two copper layers. Ceramic substrates are used because it has the key characteristic of having high dielectric strength while being thermally conductive. A large drawback to ceramic substrates is that they do not allow for a multi-layered circuit design. By replacing the traditional ceramic substrate with organic direct bonded copper (ODBC) we can open a wide range of possibilities when it comes to power module layout such as multi-layered circuits and double-sided cooling. Both benefits are critical while packaging high-performance Gallium Oxide (Ga2O3) MOSFETs. Because of Ga2O3's relatively poor thermal conductivity, a double-sided cooled package becomes necessary. Therefore, the use of ODBC provides the flexibility to fabricate copper traces carrying much higher currents, and by creating a multi-layered package, we can drastically reduce the parasitic inductance inside the power module. Achieving lower parasitic inductance is critical for an ultra-fast Ga2O3 package to avoid excessive voltage overshoot and ringing. Using ODBC, we have designed novel packages capable of handling the challenges presented by fast Ga2O3 switching. Using multi-physics modeling software, we can validate our design before building the prototype. Due to the simple process parameters needed to work with ODBC, we can rapidly create prototypes without using external vendors. This flexibility allows us to quickly design, build, and validate highly complex switching power modules to accommodate next generation, Ga2O3 switching devices.

ADVANCED PROPULSION SYSTEMS,ENGINEERING↗
DOE OSTI2024

The Spherical Tokamak for Energy Production: theme issue introduction

This theme issue collects together papers summarising the conceptual design of the Spherical Tokamak for Energy Production (STEP). In 2019, the UK government funded the first design stages of a prototype fusion powerplant based on a compact toroidal geometry, called STEP. The primary technical aims of STEP are to produce net energy, to be self-sufficient in tritium fuel and to demonstrate a maintenance regime that would extrapolate to appropriate availability for commercial powerplants. After 5 years and over 1000 person-years of detailed scientific and engineering conceptual design, this theme issue acts as a compendium of the current design basis for STEP, noting that this is a snapshot in time and that the design will continue to evolve. This article is part of the theme issue ‘Delivering Fusion Energy – The Spherical Tokamak for Energy Production (STEP)’.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2018

Prototype System for Detecting Interactions between Current Plant Configuration States and Component Manipulations Directed by In-Use Procedures

This research effort is a part of the Light Water Reactor Sustainability (LWRS) Program, which is a research and development (R&D) program sponsored by the Department of Energy. The LWRS Program is performed in close collaboration with industry R&D programs that provide the technical foundations for licensing and managing the long term, safe, and economical operation of current nuclear power plants (NPPs). The LWRS Program serves to help the United States (U.S.) nuclear industry adopt new technologies and engineering solutions that facilitate the continued safe operation of these NPPs and extension of their current operating licenses. The Outage Risk Management Improvement Pilot Project seeks to improve the management of nuclear power plant outages through the development of tools to assist in evaluating pending activities against requirements to detect undesired interactions. Significant efforts are expended to manage the nuclear risk of an outage. The utilities conduct pre outage risk assessments, based on a very detailed review of the outage schedule, to identify where combinations of outage work and equipment out of service would result in degraded conditions with respect to nuclear safety or regulatory compliance. Probabilistic risk assessment studies are conducted to quantify the incremental core damage frequency as a result of the outage activities and system unavailability. These studies are usually presented to site and fleet management, the site plant operational review committee, and the NPP’s independent Nuclear Safety Review Board for concurrence that the outage is planned safely and that reasonable measures have been taken to reduce the added risk of conducting the outage. During the outage, the plant configuration is monitored continuously to ensure that it conforms to the approved safety plan. Deviations must be assessed and approved by management committees and, in some cases, the plant operational review committee. In virtually all outage meetings and job briefings, the current nuclear safety status of the plant is communicated, including information on the specific equipment that is being relied on to meet the requirements of the nuclear safety plan. In addition, Operations and the Outage organizations implement several layers of physical and administrative barriers to prevent unintended interaction with the systems and equipment credited for nuclear safety. In spite of all these efforts, nuclear safety challenges still occur too frequently in outages. While some of these are due to failures of equipment credited for safety, the majority occur because of human error. These typically involve some form of interaction between work activities and plant configuration changes. Some of them are very subtle and are extremely challenging to detect in advance. Nevertheless, they are not acceptable and represent clear opportunities to improve nuclear safety during outages. This project will develop tools and strategies to minimize these interactions. This report describes a prototype tool designed to support plant personnel in controlling work during NPP outages to prevent unintended interactions. A software application was created to manage and display important configuration information and utilize natural language processing to access the impacts of upcoming procedures and work orders. Initial industry feedback is also presented.

99 GENERAL AND MISCELLANEOUS↗
DOE OSTI2017

Steady-State and Small-Signal Analysis of A-Source Converter

This paper presents a detailed steady-state analysis and ac small-signal modeling of the power stage of pulse-width modulated A-source converter. The voltage and current waveforms along with their corresponding expressions describing the converter operation are presented in detail. The input-to-output and input-to-capacitor dc voltage transfer functions are determined. The minimum inductance required to ensure continuous conduction mode is derived. The expressions for the semiconductor devices stresses are also presented. The dc, averaged equivalent circuit is derived using the circuit averaging technique. A complete derivation of the small-signal model including the converter parasitic resistances are presented followed by the power stage transfer functions relevant to the capacitor voltage loop, such as: 1) duty cycle-to-capacitor voltage; and 2) input-to-capacitor voltage. In addition, the expressions for the network input impedance and output impedance are derived. Finally, experimental validations of the derived small-signal models are performed, both in frequency and time domain for a laboratory prototype of an A-source converter. The theoretical predictions were in good agreement with the experimental results over a wide range of frequencies.

42 ENGINEERING↗
DOE OSTI2015

Production Facility System Reliability Analysis Report

This document describes the reliability, maintainability, and availability (RMA) modeling of the Los Alamos National Laboratory (LANL) design for the Closed Loop Helium Cooling System (CLHCS) planned for the NorthStar accelerator-based 99 Mo production facility. The current analysis incorporates a conceptual helium recovery system, beam diagnostics, and prototype control system into the reliability analysis. The results from the 1000 hr blower test are addressed.

Accelerator Design, Technology, and Operations↗
DOE OSTI2017

Develop and Manufacture an Ergonomically Sound Glovebox Glove Report

Ergonomic injury and radiation exposure are two safety concerns for the Plutonium Facility at Los Alamos National Laboratory (LANL). This facility employs the largest number of gloveboxes (GB) at LANL with approximately 6000 gloves installed. The current GB glove design dates back to the 1960’s and is not based on true hand anatomy, revealing several issues: short fingers, inappropriate length from the wrist to finger webbing, nonexistent joint angles and incorrect thumb placement. These design flaws are directly related to elbow (lateral epicondylitis) and thumb (DeQuervain’s tenosynovitis) injuries. The current design also contributes to increased wear on the glove, causing unplanned glove openings (failures) which places workers at risk of exposure. An improved glovebox glove design has three significant benefits: 1) it will reduce the risk of injury, 2) it will improve comfort and productivity, and 3) it will reduce the risk of a glovebox failures. The combination of these three benefits has estimated savings of several million dollars. The new glove design incorporated the varied physical attributes of workers ranging from the 5 th percentile female to the 95th percentile male. Anthropometric hand dimensions along with current GB worker dimensions were used to develop the most comprehensive design specifications for the new glove. Collaboration with orthopedic hand surgeons also provided major contributtions to the design. The new glovebox glove was developed and manufactured incorporating over forty dimensions producing the most comprehensive ergonomically sound design. The new design received a LANL patent (patent attorney docket No: LANS 36USD1 “Protective Glove”, one of 20 highest patents awarded by the Richard P. Feynman Center for Innovation. The glove dimensions were inputed into a solid works model which was used to produce molds. The molds were then shipped to a glove manufacturer for production of the new glovebox gloves. The new glovebox gloves were tested against the presently used glovebox gloves for design validity. The testing included a subjective survey and four dexterity tests. The prototype was statistically significant in 3 dexterity tests and favorable on 8 out of 10 survey questions. The more ergonomically sound glovebox glove will improve worker comfort, mitigate glovebox worker injuries, and reduce glove breaches.

42 ENGINEERING↗
DOE OSTI2014

The LSST Camera 500 watt -130 degC Mixed Refrigerant Cooling System

The LSST Camera has a higher cryogenic heat load than previous CCD telescope cameras due to its large size (634 mm diameter focal plane, 3.2 Giga pixels) and its close coupled front-end electronics operating at low temperature inside the cryostat. Various refrigeration technologies are considered for this telescope/camera environment. MMR-Technology’s Mixed Refrigerant technology was chosen. A collaboration with that company was started in 2009. The system, based on a cluster of Joule-Thomson refrigerators running a special blend of mixed refrigerants is described. Both the advantages and problems of applying this technology to telescope camera refrigeration are discussed. Test results from a prototype refrigerator running in a realistic telescope configuration are reported. Current and future stages of the development program are described. (auth)

42 ENGINEERING↗
DOE OSTI2015

Design of a high efficiency 30 kW boost composite converter

An experimental 30 kW boost composite converter is described in this paper. The composite converter architecture, which consists of a buck module, a boost module, and a dual active bridge module that operates as a DC transformer (DCX), leads to substantial reductions in losses at partial power points, and to significant improvements in weighted efficiency in applications that require wide variations in power and conversion ratio. A comprehensive loss model is developed, accounting for semiconductor conduction and switching losses, capacitor losses, as well as dc and ac losses in magnetic components. Based on the developed loss model, the module and system designs are optimized to maximize efficiency at a 50% power point. Experimental results for the 30 kW prototype demonstrate 98.5%peak efficiency, very high efficiency over wide ranges of power and voltage conversion ratios, as well as excellent agreements between model predictions and measured efficiency curves.

42 ENGINEERING↗
DOE OSTI2020

Multiscale-Informed Modeling of High Temperature Component Response with Uncertainty Quantification

This report summarizes a joint effort between Argonne National Laboratory, Idaho National Laboratory, and Los Alamos National Laboratory to develop and deploy constitutive models targeted at predicting the life of Grade 91 alloy components subjected to high temperature environments typical of those that structural components in advanced nuclear reactors would experience. Two distinct, but complementary constitutive modeling approaches have been taken here. The first employs a phenomenological viscoplastic model for which parameters have been calibrated based on experimental data for a wide range of Grade 91 alloy that has undergone a variety of processing. A Bayesian approach was used to derive distributions of uncertain parameters for this model based on this data set. The second approach is a reduced order model suitable for engineering-scale analysis that is based on the results of a large set of mesoscale simulations. Mesoscale models allow for the microstructure and composition of a particular alloy to be directly taken into account in the computation of the viscoplastic response, but are computationally expensive, which makes it impractical to directly call those models for the material constitutive response in an engineering-scale simulation. The reduced-order representation of the response of the underlying model used here allows for an engineering-scale model to take into account the characteristics of the underlying microstructure, while only incurring a reasonable computational expense. Both of these approaches have different strengths, and are applicable for different parts of the design/analysis process. The phenomenological models can be readily parameterized based on a set of experimental data for a given class of materials and used for scoping calculations. Once a specific material is chosen and adequately characterized, the reduced order models can accurately predict the response of that specific alloy, and because the models are based on predictive models of the underlying microstructure, they can be used to more confidently predict the response under conditions in regions where there is limited experimental data. Both of these models have been integrated in the Grizzly code, which is used here to perform proof-of-concept uncertainty quantification analyses of a simple component under prototypical conditions. The built- in stochastic analysis capabilities in the MOOSE framework that Grizzly is built on are used here to run large sets of simulations for this uncertainty quantification analysis. As would be expected, because the reduced order models are developed for a much more tightly defined alloy, they predict tighter distributions of the time to failure than the phenomenological models, which are calibrated to a broader set of data. Also important is that these simulations demonstrate that a reduced order modeling approach can be successfully deployed to propagate uncertainties from the material scale to practical engineering-scale component simulations.

42 ENGINEERING↗