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DOE OSTI2021

MADE3D: Enabling the Next-Generation High-Torque- Density Wind Generators by Additive Design and 3D Printing

Direct-drive wind turbine generators are increasing in popularity, thanks to recent project developments - especially offshore, where reliability and efficiency are major cost drivers. Yet, high capital costs are forcing many original equipment manufacturers to consider lightweight, high-torque density generators for next-generation multi-megawatt turbines that may be difficult to realize by traditional design or manufacturing methods. In this study, we present a new design framework enabled by advanced machine learning and multimaterial additive manufacturing to perform a magnetic topology optimization that maximizes the torque per rotor active mass for a 15-megawatt direct-drive permanent magnet wind generator. A comparison of the proposed approach against conventional topology optimization demonstrated a significant increase in computational efficiency and accuracy in performance predictions. Results using single and multimaterial compositions for rotor core and magnets identify a wider choice of 3D printable designs for a given specification. A hybrid combination of sintered and dysprosium-free polymer-bonded magnets shows good potential for torque performance by saving material costs up to 8.75%. More than 30% improvement in rotor torque densities is identified which can marginally improve the overall generator torque density. With the rapid evolution of multipowder deposition technologies, this study can greatly inspire a new paradigm for design-driven manufacturing with novel material compositions and lightweight, low-cost, high-strength multimaterial geometries that were previously unexplored for direct-drive generators.

3D printing↗

DOE OSTI2024

Microscopic origin of tunable assembly forces in chiral active environments

Across a variety of spatial scales, from nanoscale biological systems to micron-scale colloidal systems, equilibrium self-assembly is entirely dictated by—and therefore limited by—the thermodynamic properties of the constituent materials. In contrast, nonequilibrium materials, such as self-propelled active matter, expand the possibilities for driving the assemblies that are inaccessible in equilibrium conditions. Recently, a number of works have suggested that active matter drives or accelerates self-organization, but the emergent interactions that arise between solutes immersed in actively driven environments are complex and poorly understood. Here, we analyze and resolve two crucial questions concerning actively driven self-assembly: (i) how, mechanistically, do active environments drive self-assembly of passive solutes? (ii) Under which conditions is this assembly robust? We employ the framework of odd hydrodynamics to theoretically explain numerical and experimental observations that chiral active matter, i.e., particles driven with a directional torque, produces robust and long-ranged assembly forces. Overall, these developments constitute an important step towards a comprehensive theoretical framework for controlling self-assembly in nonequilibrium environments.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Analysis and Experimental Testing of a New Type of Variable Stiffness Magnetic Spring with a Linear Stroke Length

In this paper a new type of variable stiffness magnetic spring is proposed. The magnetic spring is composed of radially magnetized outer rotor magnets coupled with axially magnetized inner cylindrical magnets. It is shown that this magnet arrangement creates a highly linear stroke length. By rotating the inner magnetic rotor, the stiffness of the spring can be adjusted. The force as a function of stroke length and torque required to adjust the stiffness were computed using finite element analysis and then verified using an experimental test setup.

16 TIDAL AND WAVE POWER↗

DOE OSTI2023

Water ingress testing of Pressure Cooker 1006027150 REVAB-021

The requirements of this water ingress test are defined in PA-RD-01009, TA-55 Criticality Safety Requirements. “The container design should be capable of preventing the entry of more than 50 ml water when subjected to water spray at a flow of up to 2 inches water per hour for 2 hours or when immersed in water up to a depth of 6 inches above the top of the container for the same period of time.” The six allen screw fasters on the lid of the container were torqued to approximately 45 inch-pounds with a calibrated torque wrench in a crisscross pattern to ensure equal force distribution. The container management team of ORI-2 has developed a standard practice of gathering 5 data points to increase the statistical confidence in the data. This method has been demonstrated in previous LA-URs and approved official memorandums as follows: LANL Memo, SPE-2: 19-016 dated August 22, 2019; LANL Memo, SPE-2:19-020 dated September 24, 2019; and LA-UR-19-28268, Water Ingress Testing of Commercially Available Containers for the TA-55 Criticality Safety Program.

42 ENGINEERING↗

DOE OSTI2021

Modular anti-rotation drilling systems and methods

Drilling tools are frequently subject to rotation with respect to the central drilling axis caused by torque. A mechanical linkage can be configured to apply force that is proportional to the weight-on-bit on the borehole surface while transmitting axial loads used to generate weight-on-bit. The device can be used to manage drill string twist that could lead to drilling dysfunctions.

Su, Jiann-Cherng↗

DOE OSTI2024

Nonsteady Load Responses of Wind Turbines to Atmospheric and Mountain-Generated Turbulence Eddies, With Impacts on the Main Bearing: A Validation Study

Previous computational and field experiments identify three characteristic time scales in the aerodynamic responses of utility-scale wind turbine loads to atmospheric boundary layer (ABL) turbulence: a 30-90 second time scale for the passage of high/low speed "streaks" through the rotor plane, the blade and rotor rotation time scales (approximately 1 to 5 seconds), and a sub-second time scale created by blade rotation through gradients within eddy coherent structure. In the current study we compare aerodynamic load responses from daytime ABL turbulence quantified with large-eddy simulation and a actuator line model of the NREL 5 MW wind turbine with analysis of field data from the NREL/GE 1.5 MW wind turbine 5 kilometers east of the Rocky Mountain Front Range in Colorado. In addition, we contrast the responses to the passage of the mountain-generated eddies embedded within the westerly winds with the ABL eddies embedded within northerly/southerly winds. These analyses are in context with the nonsteady forcing of the main bearing by the aerodynamic generation of nontorque bending moments on the main shaft. Potentially relevant to main bearing failure mechanisms, both computational and field data show that the magnitudes of turbulence-generated nontorque bending moments, that we show generate nonsteady force on the main bearing, are of order, and often larger than, torque (which underlies power). However, the temporal variations in these two responses are uncorrelated, implying that the aerodynamic mechanisms that drive power and main bearing response are fundamentally different. We find this to be the case in the field with both mountain-generated eddies (westerly winds) and ABL-generated eddies (northerly/southerly winds). Whereas the time and length scales are comparable, the mountain eddies were somewhat more energetic than the northerly/southerly ABL eddies. Interestingly, however, the fluctuations in nontorque bending moment that force the main bearing were found to be stronger when forced by the ABL eddies than the mountain eddies. The field studies validate the key results from the computational study and show even stronger response in the nontorque bending moment than in the computer simulations. In all cases, the torque and nontorque bending moments are temporally uncorrelated, torque and power are driven by time variations in rotor-averaged horizontal wind velocity and nontorque bending moments are driven by time changes in the degree of nonuniformity in the distribution of velocity over the rotor plane. Thus the results generalize the mechanisms underlying nonsteady aerodynamic forcing to classes of turbulence eddy types with strength of order or stronger than ABL eddies with transverse scale of order the wind turbine rotor. These include atmospheric turbulence eddies, topography-generated turbulence eddies and, by extension, impacts of turbine-wake-scale turbulence eddies on downstream wind turbine rotors.

17 WIND ENERGY↗

DOE OSTI2023

Electrification: 2023 Final Progress Report

This project proposes to develop a high-power density, high speed traction motor architecture called QMag, driven by a high-power density motor drive inverter using silicon carbide semiconductor devices. This new architecture will achieve the efficiency and power density targets by means of innovative winding and rotor structures, high bandwidth controls, and advanced thermal management solutions. The project team will pursue the goals of the project systematically, through Finite Element Analysis for machine design, through simulation and co-simulation techniques for power electronics and controls evaluation, and finally system design, fabrication, testing and evaluation. If this project successfully achieves and demonstrates the DOE targets for power density, cost, and reliability, the technology has the potential to become a core enabler of the flagship higher power product portfolio in commercial traction businesses, which has so far been confined to DC, induction, Brush Less DC (BLDC), Permanent Magnet AC (PMAC), and reluctance machines.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2025

Magnetosphere Evolution and Precursor-driven Electromagnetic Signals in Merging Binary Neutron Stars

We detail new force-free simulations to investigate magnetosphere evolution and precursor electromagnetic (EM) signals from binary neutron stars. Our simulations fully follow a representative inspiral motion, capturing the intricate magnetospheric dynamics and their impact on EM outflows. We explore a range of stellar magnetic moment orientations and relative strengths, finding that the magnetospheres and Poynting flux evolution are strongly configuration dependent. The Poynting flux exhibits pulsations at twice the orbital frequency, 2Ω, and is highly anisotropic, following a power-law dependence on orbital frequency. The index ranges from 1 to 6, shaped by the intricate dynamics of the magnetospheres. Furthermore, we present the first computation of (1) the EM forces acting on the star surfaces, revealing the presence of torques that, for highly magnetized stars, could influence the orbital dynamics or break the crust; (2) the high-energy emission signals from these systems by adopting the established isolated pulsar theory. Assuming curvature radiation in the radiation-reaction limit, we find that photons could reach TeV–PeV energies in the last ∼ms for magnetic field strengths 10 10 –10 15 G. However, our analysis of single photon magnetic pair production suggests that these photons are unlikely to escape, with the MeV band emerging as a promising observational window for precursor high-energy emission. In this framework, we construct high-energy emission skymaps and light curves, exploring observational implications. Finally, we propose potential precursor radio emission and delayed afterglow echoes from magnetized outflows, which may contribute to late-time rebrightening in short gamma-ray bursts or to orphan afterglows.

79 ASTRONOMY AND ASTROPHYSICS↗

DOE OSTI2022

UAE6 - Wind Tunnel Tests Data - UAE6 - Sequence E - Raw Data

Sequence E: Yaw Releases (P) This test sequence used a downwind, rigid turbine with a 3.4° cone angle. The wind speeds ranged from 7 m/s to 17 m/s. Initial yaw angles of ±90° were achieved. The blade tip pitch was 3°. The rotor rotated at 72 RPM. Blade and probe pressure measurements were collected. The teeter dampers were replaced with rigid links, and these two channels were flagged as not applicable by setting the measured values in the data file to –99999.99 Nm. The teeter link load cell was pre-tensioned to 40,000 N. The turbine was positioned at each specified yaw angle. A 30- second data set was collected with the yaw brake engaged. These points used a letter for the last digit beginning with A and proceeding through the alphabet as repeat points were needed. These points were plotted and compared to ascertain the functionality of the instrumentation. The files ending in numbers beginning with 0 and increasing with each repetition represent yaw release points. Once the fixed-position yaw test was complete, the yaw drive was engaged to hold the turbine. The yaw brake was released, and the yaw drive was disabled allowing the turbine to yaw freely. The yaw drive was disabled about 5 seconds into the campaign, and the turbine was allowed to yaw freely for the rest of the 30-second duration. When the yaw drive is disabled, no torque is applied to the motor, and the inertia and yawing force of the nacelle and rotor overcomes the friction and inertia of the yaw gear and motor. The yaw releases were repeated five times at each condition. Four additional campaigns were collected to determine the turbine’s natural yaw error by releasing the brake at 0° yaw error. These file names use the E designation, followed by two digits for wind speed, followed by XXXX, followed by the repetition digit.

17 WIND ENERGY↗

DOE OSTI2022

Twisted bilayered graphenes at magic angles and Casimir interactions: correlation-driven effects

Twisted bilayered graphenes (TBGs) at magic angles are systems housing long ranged periodicity of moiré patterns together with short ranged periodicity associated with the individual graphenes. Such materials are a fertile ground for novel states largely driven by electronic correlations. Here we find that the ubiquitous Casimir force can serve as a platform for macroscopic manifestations of the quantum effects stemming from the magic angle bilayered graphenes properties and their phases determined by electronic correlations. In conclusion, by utilizing comprehensive calculations for the electronic and optical response, we find that Casimir torque can probe anisotropy from the Drude conductivities in nematic states, while repulsion in the Casimir force can help identify topologically nontrivial phases in magic angle TBGs.

36 MATERIALS SCIENCE↗

DOE OSTI2024

The Dynamics of Debris Disk Creation in Neutron Star Mergers

Abstract The detection of GW170817/AT2017gfo inaugurated an era of multimessenger astrophysics, in which gravitational-wave and multiwavelength photon observations complement one another to provide unique insight into astrophysical systems. A broad theoretical consensus exists, in which the photon phenomenology of neutron star mergers largely rests upon the evolution of the small amount of matter left on bound orbits around the black hole or massive neutron star remaining after the merger. Because this accretion disk is far from inflow equilibrium, its subsequent evolution depends very strongly on its initial state, yet very little is known about how this state is determined. Using both snapshot and tracer particle data from a numerical relativity/MHD simulation of an equal-mass neutron star merger that collapses to a black hole, we show how gravitational forces arising in a nonaxisymmetric, dynamical spacetime supplement hydrodynamical effects in shaping the initial structure of the bound debris disk. The work done by hydrodynamical forces is ∼10 times greater than that due to time-dependent gravity. Although gravitational torques prior to remnant relaxation are an order of magnitude larger than hydrodynamical torques, their intrinsic sign symmetry leads to strong cancellation; as a result, hydrodynamical and gravitational torques have a comparable effect. We also show that the debris disk’s initial specific angular momentum distribution is sharply peaked at roughly the specific angular momentum of the merged neutron star’s outer layers, a fewr g c, and identify the regulating mechanism.

Astronomy & Astrophysics↗

DOE OSTI2024

Insights into posttranslational regulation of skeletal muscle contractile function by the acetyltransferases, p300 and CBP

Here, mice with skeletal muscle-specific and inducible double knockout of the lysine acetyltransferases, p300 (E1A binding protein p300) and CBP (cAMP-response element-binding protein binding protein), referred to as i-mPCKO, demonstrate a dramatic loss of contractile function in skeletal muscle and ultimately die within 7 days. Given that many proteins involved in ATP generation and cross-bridge cycling are acetylated, we investigated whether these processes are dysregulated in skeletal muscle from i-mPCKO mice and, thus, whether they could underlie the rapid loss of muscle contractile function. Just 4–5 days after inducing knockout of p300 and CBP in skeletal muscle from adult i-mPCKO mice, there was ~90% reduction in ex vivo contractile function in the extensor digitorum longus (EDL) and a ~65% reduction in in vivo ankle dorsiflexion torque, as compared with wild type (WT; i.e., Cre negative) littermates. Despite this profound loss of contractile force in i-mPCKO mice, there were no genotype-driven differences in fatigability during repeated contractions, nor were there genotype differences in mitochondrial-specific pathway enrichment of the proteome, intermyofibrillar mitochondrial volume, or mitochondrial respiratory function. As it relates to cross-bridge cycling, remarkably, the overt loss of contractile function in i-mPCKO muscle was reversed in permeabilized fibers supplied with exogenous Ca 2+ and ATP, with active tension being similar between i-mPCKO and WT mice, regardless of Ca 2+ concentration. Actin-myosin motility was also similar in skeletal muscle from i-mPCKO and WT mice. In conclusion, neither mitochondrial abundance/function, nor actomyosin cross-bridge cycling, are the underlying driver of contractile dysfunction in i-mPCKO mice.

59 BASIC BIOLOGICAL SCIENCES↗

DOE OSTI2020

Optical matter machines: angular momentum conversion by collective modes in optically bound nanoparticle arrays

The creation of optically powered self-assembling nano-to-meso-scale machines that do work is a long-standing goal in photonics. We demonstrate an optical matter (OM) machine that converts the spin angular momentum (SAM) of light into orbital angular momentum (OAM) to do mechanical work. The specific OM machine we study is based on a sixfold symmetric hexagonally ordered nanoparticle array that operates as an OM “gear” that is assembled and made to rotate in a circularly polarized Gaussian beam. The rotational symmetry of the OM gear leads to a selection rule for the allowed scattering modes based on their angular momentum. Electrodynamics calculations show that the collective scattering modes with the largest angular momentum scatter strongly in the transverse direction. Simulations and experiments show that the angular momentum that accompanies the scattered light causes a “negative torque” response on the OM gear and drives a “probe” particle placed outside the OM gear around the gear in an asymmetric force field analogously to Brownian ratchets. The gear–probe OM machine concept can be expanded to applications in nanofluidics and particle sorting.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

DOE OSTI2022

Techno-Economic Implications of Electrical Machine Scaling for Wave Energy Converters

The sizing of an electrical machine for a Wave Energy Converter (WEC) can have a substantial impact on the overall sizing, cost, and rating of the device. An electrical generator is typically part of the power take-off (PTO) system, which is the mechanism by which the energy absorbed by the prime mover is transformed into useable electrical. For practically all WECs, the rate of change of actuation is predominantly determined by the wave resource (i.e., the wave height and frequency) and devices will see a sinusoidally varying velocity according to the wave conditions. The same can then be said for both directly and indirectly coupled PTOs with electrical generators. This techno-economic study investigates electrical machine scaling and associated cost implications through core machine design theory, manufacturer data, supporting literature, and the DOE sponsored Reference Model Project (RMP). The RMP was a partnered effort to develop open-source marine energy (ME) point designs as reference models (RMs) to benchmark ME technology performance and costs, methods for design and analysis of ME technologies, estimations for capital costs, operational costs, and levelized costs of energy (LCOE). The results from this study show torque is directly related to (1) the physical size of the machine required to increase the airgap sheer stresses, (2) the amount of active material, (3) the support structure, (4) bearing size and rating, and (5) offshore cable rating, all of which have a significant effect on overall system costs in terms of both CAPEX and OPEX. This paper aims to be a critical benchmark in helping determine an “optimal” nameplate rating for wave energy devices and their associated PTO. With an optimized rating and sizing process, WEC costs can be reduced, and overall performance can be improved.

cables↗

DOE OSTI2022

Techno-Economic Implications of Electrical Machine Scaling for Wave Energy Converters: Preprint

cables↗

DOE OSTI2022

Techno-Economic Implications of Electrical Machine Scaling for Wave Energy Converters

The sizing of an electrical machine for a Wave Energy Converter (WEC) can have a substantial impact on the overall sizing, cost, and rating of the device. An electrical generator is typically part of the power take-off system, which is the mechanism by which the energy absorbed by the prime mover is transformed into usable electrical energy. For practically all WECs, the rate of change of actuation is predominantly determined by the wave resource (i.e., the wave height and frequency), and devices will see a sinusoidal varying velocity according to the wave conditions. The same can then be said for both directly and indirectly coupled power take-offs with electrical generators. This techno-economic study investigates electrical machine scaling and associated cost implications through core machine design theory, manufacturer data, supporting literature, and the Reference Model Project sponsored by the U.S. Department of Energy. The Reference Model Project was a partnered effort to develop open-source marine energy point designs as reference models to benchmark marine energy technology performance and costs, methods for design and analysis of marine energy technologies, estimations for capital costs, operational costs, and levelized cost of energy. The results from this study show torque is directly related to (1) the physical size of the machine required to increase the air-gap sheer stresses, (2)the amount of active material, (3) the support structure, (4) bearing size and rating, and (5) offshore cable rating, all of which have a significant effect on overall system costs in terms of both capital and operational expenditures. This paper aims to be a critical benchmark in helping determine an "optimal" nameplate rating for wave energy devices and their associated power take-offs. With an optimized rating and sizing process, WEC costs can be reduced and overall performance can be improved.

cables↗

DOE OSTI2022

Nonsteady Load Responses to Daytime Atmospheric Turbulence Eddies on the DOE 1.5 MW Wind Turbine at NREL

Field data collected from the NREL/GE 1.5MW wind turbine (WT) and met tower (MetT) at the NREL Wind Technology Center near Boulder, CO June-October 2018 were analyzed to quantify the impacts of turbulence eddies on the load responses measured from sensors on the main shaft, blade and tower. The passage of individual mountain-generated eddies from the met tower to the WT were critically determined by correlating the optimal time shifts in signal between MetT and nacelle anemometers with mean advection time. Loading responses from mountain eddy passage were compared with atmospheric eddies from the north/south, unimpeded by the mountains, and found to be similar. Whereas time variations in torque were highly correlated with time changes in horizontal eddy velocity, the out-of-plane bending moments on the main shaft (directly forcing the main bearing) were uncorrelated with horizontal eddy velocity. This result is consistent with a previous LES study indicating that the main bearing is forced by asymmetrical interactions between the WT rotor and turbulence eddies, while power fluctuations respond primarily to advective eddy velocity. Surprisingly, the nacelle anemometer produced statistics very similar to the MetT.

ENGINEERING,WIND ENERGY↗

DOE OSTI2023

Nonsteady Load Responses to Mountain-Generated Turbulence Eddies on the DOE 1.5 MW Wind Turbine at the National Wind Technology Center

Field data collected from the NREL/GE 1.5MW wind turbine and met tower at the NREL Wind Technology Center near Boulder, Colorado from June-October 2018 were analyzed to quantify the impacts of turbulence eddies on the load responses measured from sensors on the main shaft, blade and tower. The passage of individual mountain-generated eddies from the met tower to the wind turbine were critically determined by correlating the optimal time shifts in signal between met tower and nacelle anemometers with mean advection time. Loading responses from mountain eddy passage were compared with atmospheric eddies from the north/south, unimpeded by the mountains, and found to be similar. Whereas time variations in torque were highly correlated with time changes in horizontal eddy velocity, the out-of-plane bending moments on the main shaft (directly forcing the main bearing) were uncorrelated with horizontal eddy velocity. This result is consistent with a previous LES study indicating that the main bearing is forced by asymmetrical interactions between the rotor and turbulence eddies, while power fluctuations respond primarily to advective eddy velocity. Surprisingly, the nacelle anemometer produced statistics very similar to the met tower.

ENGINEERING,WIND ENERGY↗