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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 73 records · Page 4
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Electro-Thermo-Mechanical (ETM) Study on Submarine Dynamic Power Cables (SDPC) for Offshore Wind Transmission

Understanding the failure mechanisms of submarine dynamic power cables (SDPC) is critical for innovative design to meet the 2035 cost reduction target of U.S. DOE Floating Offshore Wind Shot. This is important because the current design suffers a significant failure rate in the field. This project conducted a systematic electro-thermo-mechanical (ETM) experimental study on the power cores extracted from a 15kV power cable with three cores of copper conductor, ethylene propylene rubber (EPR) insulation, and continuously corrugated welded aluminum armor (CCWA). An ETM testing system was developed by integrating a high voltage (HV) amplifier, two ceramic heaters, and a rod-plate transverse compression setup into a mechanical testing machine. Increasing temperature from room temperature (RT, 22 degree C) to 90 degree C resulted in the 67% decrease in the failure mechanical load as defined by the dielectric breakdown. Under creep mechanical loading, the dielectric breakdown time was decreased by 70% for a given mechanical load when the specimen temperature increased from RT to 90oC. The failure strain in both monotonic and creep mechanical loading modes was related to the maximum mechanical load applied. Although the dielectric breakdown occurred in the ETM test, the post-test measurement revealed an impressive recovery of electric resistance. The failure analysis on cross section of tested specimens indicated a sizable gap across insulation layer near the area between copper conductor and loading rod, which apparently resulted from online dielectric failure and offline elastic recovery of components including conductor and insulation layer.

17 WIND ENERGY↗
DOE OSTI2024

Hot-swappable no cable touch switch enclosure

A system for hot swapping a network switch without disconnecting the network switch connectors is provided. The system disaggregates the switch faceplate network cable connectors from the internal components of the network switch so that the internal switch components may be removed from the switch without disconnecting the switch network cables.

McDonald, Nicholas George↗
DOE OSTI2025

Modified Andronov-Hopf Oscillator-Based Grid-Forming Converter with Emulated Virtual Cable for Enhanced Power Sharing Performance

Nonlinear oscillator-based grid-forming converters offer superior dynamic and steady-state performance, making them an attractive solution for interconnecting renewable resources. This paper proposes a novel modified Andronov-Hopf oscillator to enhance the operating spectrum and facilitate the integration of renewable energy sources. An inner loop controller based on the Lyapunov energy function is implemented to achieve robust stability and performance, while a virtual cable emulation strategy enables seamless parallel operation. Comprehensive modeling and simulation studies validate the effectiveness of the proposed system, demonstrating its capabilities in addressing diverse operating scenarios, including grid faults, renewable energy fluctuations, and parallel operation. The proposed solution exhibits fast transient response, robust stability, and flexible operation, making it a valuable contribution to the field of renewable energy integration. The results of this study can be used to inform the design and implementation of next-generation grid-forming converters, enabling a more sustainable and reliable energy future. Additionally, the proposed system's ability to operate in both grid-connected and islanded modes makes it an ideal candidate for remote and off-grid renewable energy applications. The proposed solution's scalability and modularity also make it suitable for large-scale renewable energy integration. The proposed system is verified through MATLAB/Simulink and PLECS simulations, demonstrating its effectiveness in ensuring robust and efficient operation.

Andronov-Hopf Oscillator (AHO)↗
DOE OSTI2024

Photovoltaic Cable Connectors: A Comparative Assessment of the Present State of the Industry

The consequences of failure for balance-of-systems components (such as photovoltaic (PV) cable connectors) include offline module string(s); low system voltage; arc, ground, insulation, and overtemperature faults; triggered fuse(s); system shutdown; and fire. The degradation modes for connectors are studied here through an industry survey and its subsequent examination, which are compared with field-degraded specimens. A total of 117 specimens were obtained from a variety of locations and climates or accelerated tests. A failure analysis for connectors from PV installations was developed (and applied to 54 specimens), including nondestructive examinations (photography, a custom resistance-current scan, and X-ray computed tomography) and destructive examinations (featuring milling of the external plastic, extraction of the internal convolute spring, and potting and polishing in cross section). Surface and through-thickness composition of the metal pins and springs was quantified using scanning electron microscopy with energy-dispersive X-ray spectroscopy. Fourier transform infrared spectroscopy was used to verify the base polymer materials and compare the chemical structure of the connector body, bushing, end nut, and o-ring. Thermogravimetric analysis and differential scanning calorimetry were used to further verify the degradation of the same polymeric components.

cable connectors↗
DOE OSTI2024

Photovoltaic Cable Connectors: A Comparative Assessment of the Present State of the Industry [Slides]

The consequences of failure for balance of systems (BoS) components (such as PV cable connectors) include offline module string(s); low system voltage; arc, ground, insulation, and over-temperature faults; triggered fuse(s); system shutdown; and fire. The degradation modes for connectors are studied here through an industry survey and its subsequent examination, which are compared to field-degraded specimens. 117 specimens were obtained from a variety of locations and climates or accelerated tests. A failure analysis for connectors from PV installations was developed (and applied to 54 specimens) including nondestructive examinations (photography, a custom resistance-current scan, and X-ray computed tomography) and destructive examinations (featuring milling of the external plastic, extraction of the internal convolute spring, and potting and polishing in cross-section). Surface and through-thickness composition of the metal pins and springs was quantified using scanning electron microscopy with energy-dispersive X-ray spectroscopy. Fourier-transform infrared spectroscopy was used to verify the base polymer materials and compare the chemical structure of the connector body, bushing, end nut, and o-ring. Thermogravimetric analysis and differential scanning calorimetry were used to further verify the degradation of the same polymeric components. Updated from 2023 NIST/UL Workshop on Photovoltaic Materials Durability (website: https://events.ul.com/WPMogn?rt=aAuoWsl4E0KaORLCMeOgfA) and 2024 PVRW workshop (https://pvrw.nrel.gov/past-proceedings).

14 SOLAR ENERGY↗
DOE OSTI2026

Lab-Scale Cable-Driven Parallel Robot Prototype for Automated Prefabricated Component Manipulation

This paper presents the design and evaluation of a lab-scale cable-driven parallel robot (CDPR) developed as a flexible platform for automated installation of prefabricated components onto exterior building envelopes. Traditional manual installation methods for prefabricated components, which depend on scaffolding, cranes, cherry pickers, and verbal coordination, are not only labor-intensive and error-prone but also face significant limitations in dense urban environments due to site access constraints. To address these challenges, we developed a lab-scale CDPR platform capable of autonomously transporting building envelope components from a designated pickup zone to their target installation location, minimizing the need for human intervention. This study describes the system’s mechanical design, actuation architecture, real-time feedback system, and control strategy of the CDPR, and evaluates its performance in a laboratory environment. The robot’s actuation system uses torque control for end-effector manipulation. The robot’s real-time pose feedback comes from a construction-grade total station and a wireless inertial measurement unit (IMU), which together support precise end-effector control. Experimental results demonstrate the successful integration of the hardware, sensing, state estimation, and control subsystems. Preliminary tests showed that our lab-scale prototype can position the end effector with an error of less than 3 mm, which is a level of precision not previously achieved by existing CDPRs in construction applications. The key findings are twofold: (1) torque-only control is necessary but not sufficient for minimizing final pose error, and (2) incorporating real-time pose feedback can achieve the desired placement accuracy.

Liu, Yifang [Oak Ridge National Laboratory (ORNL),↗
DOE OSTI2025

Magnetic and Mechanical Analysis of Bi-2212 Rutherford Cable in a Cos-Theta Sub-Scale Dipole Coil

The U.S. Magnet Development Program (US-MDP) explores high-field accelerator magnets compatible with operational conditions beyond the limits of Nb$_3$Sn technology. The ongoing R&D High-Temperature Superconductors (HTS) suggests using Bi$_2$Sr$_2$CaCu$_2$O$_{8-x}$ (Bi-2212) as superconducting element. Bi-2212 Rutherford cables maintain a high critical current (I$_C$) when exposed to a large external magnetic field. However, Bi-2212 exhibits an oversensitive stress-strain response when subject to large Lorentz forces. This paper reports on the magnetic and mechanical analysis of the Bi-2212 cosine-theta insert being developed at Fermilab for a hybrid magnet composed of two external layers of Nb$_3$Sn and two internal layers of Bi-2212. We performed a FEM analysis of the insert to estimate the HTS stress state in the coil's strands under magnetic and mechanical loads.

43 PARTICLE ACCELERATORS↗
DOE OSTI2025

Radio Frequency Field Programable Gate Array Implementation of Reflectometry Cable Monitoring

PNNL has developed an innovative cable testing system that leverages the Xilinx RF System-on-Chip (RFSoC) technology to create a more flexible and capable measurement tool than traditional approaches. The architecture is designed on the ZCU111 development board and takes advantage of the high-speed digital to analog converters (DAC) and analog to digital converters (ADC) to generate and capture digitally synthesized waveforms. The platform allows engineers to easily adjust power, frequency, duration and modulation on the fly rather than being locked into fixed hardware configurations

Tedeschi, Jonathan [Pacific Northwest National Lab↗
DOE OSTI2024

Modeling of Bi-2212 strand and Rutherford cable in a dipole coil insert

The U.S. Magnet Development Program (US-MDP) explores high-field accelerator magnets compatible with op- erational conditions beyond the limits of Nb3Sn technology. The ongoing R&D High-Temperature Superconductors (HTS) suggests using Bi2Sr2CaCu2O8−x (Bi-2212) as superconducting element. Bi-2212 Rutherford cables maintain a high critical current (IC ) when exposed to a large external magnetic field. However, Bi-2122 exhibits an oversensitive stress-strain response when subject to large Lorentz forces. This paper reports on the magnetic and mechanical analysis of the Bi-2212 cosine-theta insert being developed at Fermilab for a hybrid magnet composed of 2 external layers of Nb3Sn and 2 internal layers of Bi-2212. We performed a FEM analysis of the insert to estimate the HTS stress state in the coil s strands under magnetic and mechanical loads.

D'Agliano, A.↗
DOE OSTI2024

Cost-effective Conductor, Cable, and Coils for High Field Rotating Electric Machines

The purpose of the DOE-AMMTO-funded project was to significantly reduce industrial energy intensity through manufacturing innovations. The project focused on superconducting technology for industrial motors to dramatically increase efficiency. The bottleneck in deploying high temperature superconducting (HTS) motors was high cost and low yield of the conductor manufacturing process. The process yield is low because of the defects in the conductor, forcing the manufacturers to cut off defective sections after characterizing each millimeter. Additionally, the piece lengths tend to be low because of the defects. The project tackled the low-yield manufacturing process challenge by devising an innovative method to use defective conductors in bundled cables without losing performance by engineering current sharing among the conductors. The innovation not only lowers the cost of the conductor but also enhances the reliability of HTS motors and other devices to mitigate the defects that might form during the fabrication and operation of the device. With the increasing interest in REBa2Cu3O7-x (REBCO)-coated conductors for various power, energy, and magnet applications, ensuring the reliability of HTS devices is of significant interest. The EERE funding allowed us to make significant progress in understanding the defects in manufactured conductors and the implications of the defects in superconducting electric motors and other superconducting power and energy applications.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2026

Super Conducting REBCO Cable Wrapper

Future upgrades to CERN particle accelerator magnets require flat, high-temperature superconducting cables, created by wrapping brittle REBCO tape around a Rutherford copper core. Because current manual wrapping processes are time-consuming and prone to damaging the delicate ceramic tape, our team was tasked with automating the fabrication. We developed a modular, wrapping machine featuring adjustment for repeatable 10°to 45° wrap angles and a precise magnetic tensioning mechanism. While full-scale testing is pending final machined parts, our 3D-printed prototype successfully validates the system’s motion and sets the stage for future testing.

Gillen, Kameron [Northern Illinois U.]↗
DOE OSTI2025

Dynamic Modeling, Trajectory Optimization, and Linear Control of Cable-Driven Parallel Robots for Automated Panelized Building Retrofits

The construction industry faces a growing need for automation to reduce costs, improve accuracy and productivity, and address labor shortages. One area that stands to benefit significantly from automation is panelized prefabricated building envelope retrofits, which can improve a building’s energy efficiency in heating and cooling interior spaces. In this paper, we propose using cable-driven parallel robots (CDPRs), which can effectively lift and handle large objects, to install these panels. However, implementing CDPRs presents significant challenges because of their nonlinear dynamics, complex trajectory planning, and precise control requirements. To tackle these challenges, this work focuses on a new application of established control and trajectory optimization theories in a CDPR simulation of a building envelope retrofit under real-world conditions. We first model the dynamics of CDPRs, highlighting the critical role of damping in system behavior. Building on this dynamic model, we formulate a trajectory optimization problem to generate feasible and efficient motion plans for the robot under operational and environmental constraints. Given the high precision required in the construction industry, accurately tracking the optimized trajectory is essential. However, challenges such as partial observability and external vibrations complicate this task. To address these issues, a Linear Quadratic Gaussian control framework is applied, enabling the robot to track the optimized trajectories with precision. Simulation results show that the proposed controller enables precise end effector positioning with errors under 4 mm, even in the presence of external wind disturbances. Through comprehensive simulations, our approach allows for an in-depth exploration of the system’s nonlinear dynamics, trajectory optimization, and control strategies under controlled yet highly realistic conditions. The results demonstrate the feasibility of CDPRs for automating panel installation and provide insights into their practical deployment.

CDPR↗
DOE OSTI2026

Hygrothermal aging effects on polyimide and acrylate-based adhesive materials in high-performance flat-flex cable assemblies

Flat-flex assemblies are widely used across a diverse range of technologies, including consumer electronics, automotive systems, aerospace and defense applications, and medical devices, due to their compact form factor and flexibility. However, environmental stressors like temperature and humidity are known to degrade performance over time, though the main mechanisms for degradation remain unknown. Here, in this work, we examined the aging behavior of copper/polyimide/adhesive laminate systems under varying temperature and humidity conditions, focusing on material degradation and its effects on mechanical and dielectric properties. Results show that peel strength and breakdown voltage decrease with exposure time, temperature, and humidity; spectroscopic characterization revealed that the adhesive, and not the polyimide, is the weak link in the material stack-up. The adhesive, identified as a butyl acrylate-acrylonitrile (BA-AN) copolymer, exhibited age-related spectral changes that correlated with exposure severity and duration. Hydrolysis at BA ester and AN nitrile groups was identified as the primary degradation mechanism, producing amides, acids, and alcohols. We developed a mechanistic model that connects kinetic parameters for BA-AN spectral band decay to peel strength and breakdown voltage, and implicates hydrolysis at the AN moiety, not BA, in performance decrements. Modeling predictions at ambient conditions indicate faster decline in peel strength than dielectric strength at early times, followed by plateauing of both properties at longer times. These findings provide critical insights into laminate aging mechanisms and highlight the importance of addressing BA-AN degradation to improve the long-term reliability of these systems in high-humidity environments.

organic↗