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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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DOE OSTI2020

Energy Efficient Thermoplastic Composite Manufacturing

The objective of the project was to establish an effective and affordable method to lay-up and consolidate/join large thermoplastic composite aerospace structure with cycle times measured in minutes rather than hours. Composite airplane designs have proven efficient and effective however future potential product production rates are challenging what the current systems can efficiently produce due to material lay-down constraints and extended thermal cycle times. The ability to lay-up then rapidly heat, consolidate, and cool large complex composite structures plus very accurately tool them (i.e. matching CTE of composite materials) along with very precise thermal control is a difficult challenge. Current systems such as autoclave processing of thermoset materials require long cycle times due to method of heating and the large associated thermal masses. These extended cycle times inhibit the ability to meet higher rate production scenarios due to the need for multiple sets of equipment and tools. Thermoplastic composite materials were used to facilitate more rapid cycle times via the elimination of a need for a cure dwell at temperature. Also, utilized induction heating along with smart susceptors to enable the quick cycle times needed while providing precise intrinsic thermal control. The intrinsic control of the induction heating process via the smart susceptors along with the use of laser assisted fiber placement were the key innovations areas developed. The ability to rapidly heat and then precisely control the temperature of the consolidation component was paramount to the success of this project. It is this unique processing attribute coupled with the thermoplastic material characteristics along with rapid lay-up methods that are novel and advantageous. While many requirements and influencing factors decide the materials and processes utilized for future airplane construction, the forecast of accelerated production rates and the recent performance successes of composites in airplane construction provide an opportunity for this processing technology to have significant influence. During the course of this project a number of key accomplishments were completed. They are as follows: The needed laser assisted fiber placement capabilities have been developed and validated on a component of meaningful scale and complexity. Subsequently, a thermoplastic preform of the part scale-up part design was laser assisted fiber placed and made availalbe for consolidation. An induction consolidation system was sized, designed, and fabricated resulting in the full capability to consolidate the scale-up component. The tool for induction consolidating of the scale-up component was designed and fabricated. An aluminum pressure bladder was welded and formed for use as the pressurization membrane to perform the needed application of pressure on the part at temperature to achieve consolidation. The induction consolidation system consisting of the restraint, induction power supply, induction tool with integrated induction coils and smart susceptor liners, along with the aluminum bladder were successfully used to consolidate a large thermoplastic skin. The capability of accomplishing rapid heat-up rates and cool down rates for consolidation of large thermoplastic skins with precise thermal control and even pressure application at the consolidation temperature was validated. The general conclusion is that the use of induction consolidation with smart susceptors is an effective method to rapidly and efficiently consolidate large thermoplastic composite components and enable affordable high rate manufacturing of composites. More specific conclusions generated by this project are as follows: A restraint type induction consolidation system provides an affordable option over the standard press when using the induction consolidation processing method. Aluminum bladders can be formed to the complex shapes needed and supply uniform pressure for consolidation and co-consolidation of thermoplastic composite materials. Straightforward modifications can be made to existing fiber placement robotic systems to enable their use for thermoplastic lay-up applications.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2022

Enhancement of detachment control with simplified real-time modelling on the KSTAR tokamak

Abstract Detachment control based on ion saturation current I sat measurements from Langmuir probes (LPs) is implemented in the KSTAR tokamak and shown to be capable of following dynamic and constant target trajectories with good accuracy, in H-mode, by moderating the flow rate of nitrogen or deuterium. I sat controllers normalize I sat in order to form attachment fraction ( A frac ) as their control parameter. The KSTAR implementation of A frac control differs from previous work in that it continuously calculates a model for attached I sat and uses that as the denominator in A frac , whereas prior implementations either record peak I sat at rollover as they pass it or take estimated I s a t , r o l l o v e r as a manual input prior to the shot. The KSTAR controller therefore does not need to keep track of rollover status and keep separate targets for pre- and post-rollover states, and it can automatically adapt to changes in scenario at any time. It is also less vulnerable to noise as it will not lock in an outlier as a rollover point.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2023

Design of Multicomponent Peptide Fibrils with Ordered and Programmable Compositional Patterns

Advanced applications of biomacromolecular assemblies require a stringent degree of control over molecular arrangement, which is a challenge to current synthetic methods. Here we used a neighbor-controlled patterning strategy to build multicomponent peptide fibrils with an unprecedented capacity to manipulate local composition and peptide positions. Eight peptides were designed to have regulable nearest neighbors upon co-assembly, which, by simulation, afforded 412 different patterns within fibrils, with varied compositions and/or peptide positions. The fibrils with six prescribed patterns were experimentally constructed with high accuracy. The controlled patterning also applies to functionalities appended to the peptides, as exemplified by arranging carbohydrate ligands at nanoscale precision for protein recognition. Importantly, this study offers a route to molecular editing of inner structures of peptide assemblies, prefiguring the uniqueness and richness of patterning-based material design.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2017

Solid state light source driver establishing buck or boost operation

A solid state light source driver circuit that operates in either a buck convertor or a boost convertor configuration is provided. The driver circuit includes a controller, a boost switch circuit and a buck switch circuit, each coupled to the controller, and a feedback circuit, coupled to the light source. The feedback circuit provides feedback to the controller, representing a DC output of the driver circuit. The controller controls the boost switch circuit and the buck switch circuit in response to the feedback signal, to regulate current to the light source. The controller places the driver circuit in its boost converter configuration when the DC output is less than a rectified AC voltage coupled to the driver circuit at an input node. The controller places the driver circuit in its buck converter configuration when the DC output is greater than the rectified AC voltage at the input node.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2019

Systems and methods of delivering rectified voltage to a load

Palmer, Fred↗

DOE OSTI2020

Four-phase interleaved TCM DC-DC buck converter with matrix inductor in battery charging application

In this paper, a 1-kW DC-DC buck converter with a four-phase interleaved matrix inductor is proposed for battery charging applications. It is well-known that the DC bias on the inductor will cause high core loss as it changes the B–H characteristic. Typically, the transient conduction mode employed in high voltage applications for zero-voltageswitching of devices would cause higher inductor current ripple. The conventional approach to reduce the effect of DC bias and inductor current ripple is employing multi-phases. However, the cost and size of the converter will increase significantly. This paper proposes the matrix inductor which has a small volume and reduces the effect of the DC bias by flux sharing and flux cancellation at the same time, results in low inductor core loss. With the interleaved operations the output current ripple can be lower which is suitable for battery charging application. Besides, the comparison of the synchronous and interleaved operation is presented. A 1-kW prototype is built and the experimental results show that the peak efficiency is 99.1% and 99.2% for synchronous and interleaved control, respectively. Additionally, the output current ripple of the interleaved operation is reduced by 85% in comparison with the synchronous operation.

14 SOLAR ENERGY↗

DOE OSTI2022

MPC4CLR (Model-Predictive-Control-for-Critical-Load-Restoration-in-Power-Distribution-Systems) [SWR-22-24]

Model predictive control (MPC) is a system or process control technique for making decisions under uncertainty via rolling look-ahead optimizations at each control step where only the current step decisions are applied, and the rest are discarded. In this work, we developed an MPC for a critical load restoration (CLR) in power distribution systems to recover system service (electricity delivery) following an extreme event-triggered substation outage. The method considers the problem of controlling distributed energy resources (DERs) of the distribution system with the objective of achieving maximum load pick up while satisfying distribution network flow and voltage constraints. A linearized optimal power flow (OPF) model is employed to represent the physics of the network. The problem formulation is augmented with a ramping (up) reserve product for the DERs to ensure improved and upward monotonic load restoration as time evolves. Simulation analysis and performance tests are performed using a modified IEEE 13-bus test feeder integrated with wind, solar, microturbine, and energy storage battery. The software is developed using various software packages in Julia and Python. The MPC model is implemented using the JuMP optimization language in Julia while the data analytics including renewable generation and load demand forecasts, running the MPC simulation and visualizations is performed in Python.

Eseye, Abinet Tesfaye↗

DOE OSTI2021

EXTRACTING HUMAN RELIABILITY FINDINGS FROM HUMAN FACTORS STUDIES IN THE HUMAN SYSTEMS SIMULATION LABORATORY

Modernization of U.S. nuclear power plants (NPPs) is widespread, with most plants currently replacing and transitioning equipment, control systems, and human system interfaces (HSI)s from analog to digital displays. This conversion remedies the obsolescence of analog parts along with needs for increased intuitiveness of design, safety, and capabilities. The Human Factors and Reliability team at Idaho National Laboratory (INL) carried out twelve control room modernization studies in the newly designed Human Systems Simulation Laboratory (HSSL) over nine years. The HSSL was constructed as a testbed for evaluating human factors techniques and performance measures, HSI frameworks, and cutting-edge operational concepts in NPPs. Installing a full-scope training simulator enabled direct design and evaluation work on the same instrumentation and control (I&C) and HSIs located at U.S. plants. The subsequent addition of glass top bays afforded crews opportunities to implement operations via the simulator using full-scale representations of their home NPP. Additionally, functional HSI prototypes were created, providing an environment for operator-in-the-loop benchmark studies. The HSSL has assisted in upgrades of six commercial NPP control rooms and served as an invaluable proving ground for new NPP operations technology. Human reliability analysis (HRA) was not originally the focus of the studies; however, data relating to HRA such as type and frequency of human errors can be extracted from the studies. INL is currently extracting data from the HSSL study reports to apprise how information gathered from simulation, HSI, and other related studies can create a broad look across different data sources to help inform HRA methods.

99 GENERAL AND MISCELLANEOUS↗

DOE OSTI2024

Wind plant wake losses: Disconnect between turbine actuation and control of plant wakes with engineering wake models

Wake losses from neighboring plants may become a major factor in wind plant design and control as additional plants are constructed in areas with high wind resource availability. Because plant wakes span a large range of physical scales, from turbine rotor diameter to tens of kilometers, it is unclear whether conventional wake models or turbine control strategies are effective at the plant scale. Wake steering and axial induction control are evaluated in the current work as means of reducing the impact of neighboring wind plants on power and levelized cost of electricity. FLOw Redirection and Induction in Steady State (FLORIS) simulations were performed with the Gauss–Curl Hybrid and TurbOPark wake models as well as two operation and maintenance models to investigate control setpoint sensitivity to wake representation and economic factors. Both wake models estimate losses across a range of atmospheric conditions, although the wake loss magnitude is dependent on the wake model. Annual energy production and levelized cost of electricity are driven by wind direction frequency, with frequently aligned plants experiencing the greatest losses. However, both wake steering and axial induction are unable to mitigate the impact of upstream plants. Wake steering is constrained by plant geometry, since wake displacement is much less than the plant wake width, while axial induction requires curtailing the majority of turbines in upstream plants. Individual turbine strategies are limited by their effective scale and model representation. New wake models that include plant-scale physics are needed to facilitate the design of effective plant wake control strategies.

Scott, Ryan (ORCID:0000000328107574)↗

DOE OSTI2017

An efficient MILP framework for integrating nonlinear process dynamics and control in optimal production scheduling calculations

The emphasis currently placed on enterprise-wide decision making and optimization has led to an increased need for methods of integrating nonlinear process dynamics and control information in scheduling calculations. The inevitable high dimensionality and nonlinearity of first-principles dynamic process models makes incorporating them in scheduling calculations challenging. In this work, we describe a general framework for deriving data-driven surrogate models of the closed-loop process dynamics. Focusing on Hammerstein–Wiener and finite step response (FSR) model forms, we show that these models can be (exactly) linearized and embedded in production scheduling calculations. The resulting scheduling problems are mixed-integer linear programs with a special structure, which we exploit in a novel and efficient solution strategy. A polymerization reactor case study is utilized to demonstrate the merits of this method. Finally, our framework compares favorably to existing approaches that embed dynamics in scheduling calculations, showing considerable reductions in computational effort.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2014

Status Report on the Development of Micro-Scheduling Software for the Advanced Outage Control Center Project

The long-term viability of existing nuclear power plants (NPPs) in the United States (U.S.) is dependent upon a number of factors, including maintaining high capacity factors, maintaining nuclear safety, and reducing operating costs, particularly those associated with refueling outages. Refueling outages typically take 20-30 days, and for existing light water NPPs in the U.S., the reactor cannot be in operation during the outage. Furthermore, given that many NPPs generate between $1-1.5 million/day in revenue when in operation, there is considerable interest in shortening the length of refueling outages. Yet, refueling outages are highly complex operations, involving multiple concurrent and dependent activities that are difficult to coordinate. Finding ways to improve refueling outage performance while maintaining nuclear safety has proven to be difficult. The Advanced Outage Control Center project is a research and development (R&D) demonstration activity under the Light Water Reactor Sustainability (LWRS) Program. LWRS is a R&D program which works with industry R&D programs to establish technical foundations for the licensing and managing of long-term, safe, and economical operation of current NPPs. The Advanced Outage Control Center project has the goal of improving the management of commercial NPP refueling outages. To accomplish this goal, this INL R&D project is developing an advanced outage control center (OCC) that is specifically designed to maximize the usefulness of communication and collaboration technologies for outage coordination and problem resolution activities. This report describes specific recent efforts to develop a capability called outage Micro-Scheduling. Micro-Scheduling is the ability to allocate and schedule outage support task resources on a sub-hour basis. Micro-Scheduling is the real-time fine-tuning of the outage schedule to react to the actual progress of the primary outage activities to ensure that support task resources are optimally deployed with the least amount of delay and unproductive use of resources. The remaining sections of this report describe in more detail the scheduling challenges that occur during outages, how a Micro-Scheduling capability helps address those challenges, and provides a status update on work accomplished to date and the path forward.

99 GENERAL AND MISCELLANEOUS↗

DOE OSTI2015

Fast Acting Eddy Current Driven Valve for Massive Gas Injection on ITER

Tokamak plasma disruptions present a significant challenge to ITER as they can result in intense heat flux, large forces from halo and eddy currents, and potential first-wall damage from the generation of multi-MeV runaway electrons. Massive gas injection (MGI) of high Z material using fast acting valves is being explored on existing tokamaks and is planned for ITER as a method to evenly distribute the thermal load of the plasma to prevent melting, control the rate of the current decay to minimize mechanical loads, and to suppress the generation of runaway electrons. A fast acting valve and accompanying power supply have been designed and first test articles produced to meet the requirements for a disruption mitigation system on ITER. The test valve incorporates a flyer plate actuator similar to designs deployed on TEXTOR, ASDEX upgrade, and JET [1 3] of a size useful for ITER with special considerations to mitigate the high mechanical forces developed during actuation due to high background magnetic fields. The valve includes a tip design and all-metal valve stem sealing for compatibility with tritium and high neutron and gamma fluxes.

Fast Acting Eddy current↗

DOE OSTI2020

A Tradeoff Analysis of Series / Parallel Three-Phase Converter Topologies for Wireless Extreme Chargers

In this paper, extreme fast charging (XFC) technology is studied considering the charge rates of 300 kW for wireless power transfer (WPT) applications. Tradeoff analysis of series and parallel connection of three-phase WPT system are presented by comparisons of voltage and current stresses on power electronics active / passive components. In addition, star (Y) / delta (Δ) connection configurations for three-phase wireless power transfer coupling coils are analyzed with series and LCC resonant compensation circuits. The system series and parallel connection controllability is also reviewed considering voltage and current balance techniques with output control. In a conclusion of evaluation analysis, it is revealed that each component of 300 kW wireless charging network must be designed for high fast charging system and the overall system operation need to be strategically planned for high power charging and infrastructure deployment.

Asa, Erdem↗

DOE OSTI2016

Transfer and Transition: Interagency Coordination for Managing Public Lands at UMTRCA Title II Sites in Wyoming – 16614

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2016

Transfer and Transition: Interagency Coordination for Managing Public Lands at UMTRCA Title II Sites in Wyoming - 16614

By the end of fiscal year 2025, the U.S. Department of Energy (DOE) Office of Legacy Management (LM) is anticipating adding 17 sites remediated under Title II of the Uranium Mill Tailings Radiation Control Act (UMTRCA) to the current inventory of 90 sites that it manages. Among the new sites are ones where federal public lands occur within the proposed long-term care boundary, the boundary determined by the Nuclear Regulatory Commission and LM as necessary to maintain site protectiveness for the entombed uranium mill tailings and residual groundwater contamination. For these sites, public land withdrawals for land and minerals will need to be established. LM's primary mission at UMTRCA sites is to protect the public and the environment from exposure to contamination at the sites. For the sites with public lands or federally controlled minerals that will be transferring to LM, the Office will apply to the Department of the Interior (DOI) Bureau of Land Management (BLM) for new, public land and mineral withdrawals. At most current LM UMTRCA sites that involved public lands and minerals, DOI granted DOE 'full administrative jurisdiction' and permanent withdrawals. Hence, these withdrawals are, permanently, no longer subject to public land, mining, and mineral-leasing laws and regulations. LM is coordinating with DOI/BLM in Wyoming to permanently withdraw full and partial jurisdiction at future UMTRCA Title II sites in that state. This approach would allow LM to fully administer surface lands and minerals, where necessary, and DOI and LM to administer surface lands and leasable minerals where it would not jeopardize sites' radiological safety and long-term public and environmental protection. This 'shared-jurisdiction approach' will meet LM's strategic goal of protecting human health and the environment but also allow BLM to fulfill their mission to 'manage and conserve the lands under the mandate of multiple-use and sustained yield'. In addition, LM could also fulfill the fourth goal of its Strategic Plan, to optimize land use and assets. The portions of the sites where LM will ask for full jurisdiction are those that contain the disposal cell and any adjacent lands and minerals required to maintain and protect it. It is anticipated that the shared jurisdiction portion of the withdrawal would largely coincide with land where known or projected contaminated groundwater from the past ore processing exists or will migrate over time. Examples of BLM-authorized activities on the shared jurisdiction portions of the withdrawals may include livestock grazing, wildlife habitat improvement projects, recreation, and rights of ways for roads, pipelines, utilities, and communication sites. In addition, BLM could authorize subsurface uses such as oil and gas, coal, or geothermal development or groundwater pumping from deeper aquifers if the proposal would not disturb groundwater contamination. For areas of the withdrawal where the agencies will share jurisdictional authority, DOE LM and BLM will develop an interagency agreement (IA) to define acceptable uses and associated roles and responsibilities. To ensure maximum protection of human health and the environment, each site's IA will include a provision allowing DOE LM the right of first refusal against any action it believes might affect radiological safety at the site. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2021

Cybersecurity of Wide Area Monitoring, Protection and Control Systems for HVDC Applications

The flexibility provided by High Voltage Direct Current (HVDC) systems can be further extended by Wide Area Monitoring, Protection, and Control (WAMAPC) systems. WAMPAC systems enable many HVDC applications and, on the other hand, inevitably introduce cybersecurity concerns that need to be addressed. In this work, a security domain layer and decision framework is reported to detect and mitigate the impact of false data injection (FDI) attacks targeting HVDC stations. Specifically, a rule-based cyber-attack detection method is introduced and implemented on Raspberry Pi and tested on the real-time HVDC simulation facility on the real-time digital simulator (RTDS) platform at ABB U.S. Corporate Research Center.

cybersecurity↗

DOE OSTI2026

Small-Signal Analysis of Current-Limiting Grid-Forming Inverters

Grid-forming (GFM) inverters are equipped with a current limiter to protect the device during grid disturbances. Because the intervention of the current limiter can compromise the transient stability of the GFM inverter, various types of current limiter designs and additional frequency-stabilization control methods have been proposed in recent literature to aid in transient GFM inverter stability; however, the small-signal stability implications of adding these additional control blocks during, in particular, off-nominal conditions are not fully understood. To address this challenge, this paper presents a generic small-signal model of a GFM inverter that incorporates various types of current limiters and frequency stability-enhancing controls. With the proposed model, we analyze the root causes of inverter instability, which reveals two critical design trade-offs. First, due to current-limiter engagement caused by a disturbance, the GFM inverter dynamics are altered, which can lead to voltage oscillations. Second, additional frequency-stabilization controls can improve the small-signal stability of the GFM inverter, but at the cost of reduced power and voltage support to the grid. Comprehensive hardware experiments validate the theoretical concept and analysis. The findings in this work underscore the importance of incorporating both transient-response and small-signal dynamics requirements into the design procedure of GFM current limiters and frequency-stabilization controls.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2015

Note: Cryogenic heat switch with stepper motor actuator

A mechanical cryogenic heat switch has been developed using a commercially available stepper motor and control electronics. The motor requires 4 leads, each carrying a maximum, pulsed current of 0.5 A. With slight modifications of the stepper motor, the switch functions reliably in vacuum at temperatures between 300 K and 4 K. The switch generates a clamping force of 262 N at room temperature. At 4 K it achieves an “on state” thermal conductance of 5.04 mW/K and no conductance in the “off state.” The switch is optimized for cycling an adiabatic demagnetization refrigerator.

42 ENGINEERING↗