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DOE OSTI2022

Evaluating the current perceived cost of ownership for buses and trucks in China

Decarbonizing commercial vehicles, including buses, trucks, and special purpose vehicles, is essential for China to achieve its carbon neutrality target by 2060. However, understanding the adoption barriers of alternative fuel technologies for commercial vehicles has largely been limited to the total cost of ownership approach that mainly considers tangible costs. Additionally, this study proposes a perceived cost of ownership (PCO) model, which monetizes both tangible and implicit costs, including charging annoyance for buses and trucks by size and classification under different use scenarios. In the case study for China's current bus and truck market, the PCO of alternative fuel technologies, such as battery electric vehicles (BEVs) and fuel cell electric vehicles (FCEVs) are 27%–129% and 31%–86% higher than the most economically competitive powertrains – the compressed natural/liquefied petroleum gas technology and hybrid electric technology. BEVs could be cost-effective in the mini/midsize bus segment or in the daily short-distance driving scenario, and FCEVs could firstly be deployed in cities with a low hydrogen price. Though the implicit costs caused by range anxiety and charging annoyance account for at least 27% of BEV's PCO, making BEV uncompetitive, the battery swapping technique could reduce the implicit cost and overall cash outflow for BEV owners.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

NASA NTRS2014

Drag Reduction Through Distributed Electric Propulsion

One promising application of recent advances in electric aircraft propulsion technologies is a blown wing realized through the placement of a number of electric motors driving individual tractor propellers spaced along each wing. This configuration increases the maximum lift coefficient by providing substantially increased dynamic pressure across the wing at low speeds. This allows for a wing sized near the ideal area for maximum range at cruise conditions, imparting the cruise drag and ride quality benefits of this smaller wing size without decreasing takeoff and landing performance. A reference four-seat general aviation aircraft was chosen as an exemplary application case. Idealized momentum theory relations were derived to investigate tradeoffs in various design variables. Navier-Stokes aeropropulsive simulations were performed with various wing and propeller configurations at takeoff and landing conditions to provide insight into the effect of different wing and propeller designs on the realizable effective maximum lift coefficient. Similar analyses were performed at the cruise condition to ensure that drag targets are attainable. Results indicate that this configuration shows great promise to drastically improve the efficiency of small aircraft.

Stoll, Alex M.↗

DOE OSTI2023

Electric Vehicles for Consumers

More consumers are choosing electric vehicles (EVs) as new, competitively priced models with longer ranges hit the market. More public charging stations are also rapidly becoming available, and some offer quick charges to get drivers back on the road in minutes. New EVs are released all the time, with models designed to meet a wider variety of needs. To learn whether an EV is right for you, assess your driving requirements, available vehicles, and cost considerations. Easily compare costs and benefits of specific vehicles using the FuelEconomy.gov vehicle comparison tool.

ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2021

A Multirange Vehicle Speed Prediction With Application to Model Predictive Control-Based Integrated Power and Thermal Management of Connected Hybrid Electric Vehicles

Abstract Connectivity and automated driving technologies have opened up new research directions in the energy management of vehicles which exploit look-ahead preview and enhance the situational awareness. Despite this advancement, the vehicle speed preview that can be obtained from vehicle-to-vehicle/infrastructure (V2V/I) communications is often limited to a relatively short time-horizon. The vehicular energy systems, specifically those of the electrified vehicles, consist of multiple interacting power and thermal subsystems that respond over different time-scales. Consequently, their optimal energy management can greatly benefit from long-term speed prediction beyond that available through V2V/I communications. Accurately extending the look-ahead preview, on the other hand, is fundamentally challenging due to the dynamic nature of the traffic environment. To address this challenge, we propose a data-driven multirange vehicle speed prediction strategy for arterial corridors with signalized intersections, providing the vehicle speed preview for three different ranges, i.e., short-, medium-, and long-range. The short-range preview is obtained by V2V/I communications. The medium-range preview is realized using a neural network (NN), while the long-range preview is predicted based on a Bayesian network (BN). The predictions are updated in real-time based on the current state of traffic and incorporated into a multihorizon model predictive control (MH-MPC) for integrated power and thermal management (iPTM) of connected vehicles. The results of design and evaluation of the performance of the proposed data-informed MH-MPC for iPTM of connected hybrid electric vehicles (HEVs) using traffic data for real-world city driving are reported.

Automation & Control Systems↗

DOE OSTI2023

Electric Vehicles for Consumers

charging↗

DOE OSTI2022

Crystallization pathways and interfacial drivers for the formation of hierarchical architectures

The development of structural hierarchy on various length scales during crystallization process is ubiquitous in biological systems and is also observed in synthetic nanomaterials. The driving forces for the formations of complex architectures range from local interfacial interactions, that modify interfacial speciation, local supersaturation, and nucleation barriers, to macroscopic interparticle forces. Although it is enticing to interpret the formation of hierarchical architectures as the assembly of independently nucleated building blocks, often crystallization pathways follow monomer-by-monomer addition with structural complexity arising from interfacial chemical coupling and strongly correlated fluctuation dynamics in the electric double layers. Here, the mechanism of the development of structural hierarchy through heterogeneous nucleation, coupled interfacial nucleation and assembly, and oriented attachment of independently nucleated particles is discussed. In this article, the emphasis is made on the discussion of the underlying interfacial forces and chemical coupling that drives crystallization pathways towards the formation of structural hierarchy.

36 MATERIALS SCIENCE↗

DOE OSTI2020

Smart Composite Pressure Vessels (SCPV) with Integrated Health Monitoring

The U.S. Department of Energy (DOE) is promoting and developing more energy efficient and environmentally friendly technologies that will enable America to use less petroleum. Hydrogen fuel cells – which directly convert the chemical energy in hydrogen to electricity with only water and heat as byproducts – are a very attractive solution that can enable this to happen. To date, DOE's efforts have culminated in commercial demonstration of on-board vehicular hydrogen storage systems that can allow for a driving range of greater than 300 miles. This requires storing 5 Kgs of hydrogen onboard a light vehicle. In order to store this quantity of hydrogen, the hydrogen gas needs to be stored in a composite overwrapped pressure vessel (COPV) at a very high internal pressure. The objective of the program was to demonstrate continuous and predictable health-monitoring of composite pressure vessels. A higher confidence in the operational safety of the vessels will lead to reduced burst factor of safety imposed by regulatory standards and hence will help reduce the structural wall thickness that drives the cost of the vessel. Highly optimized Type III (metal lined) and Type IV (polymer lined) COPVs that are manufactured using filament winding process have been designed and qualified for the above mentioned application. However, the main structural component of the COPVs is carbon fiber and the high cost of carbon fiber composite in a pressure vessel is a primary challenge in reducing the cost of gaseous hydrogen storage. Continuous and remote monitoring of structural health of the COPVs as well as optimization of the strength translation of carbon fibers have the potential to allow for reduced factor of safety, thereby reduced amount of carbon and associated cost of the vessel. In the current program, the project team including Steelhead Composites (SHC), University of Tennessee, Knoxville (UTK), Teijin Carbon America, Oak Ridge National Laboratory (ORNL) and LUNA designed, fabricated, and tested smart composite pressure vessels with integrated sensors. Iterative loops of design and testing using coupons, subscale STEB vessels and full size vessels proved that a new generation of high performance carbon fiber can be used for efficient design of Type 3 vessels for H2 storage. Novel analysis techniques were developed to predict the initiation and propagation of interlaminar damage inside the composite shell due to impact damage, a real threat in practical operation. Such an analysis scheme is typically not used in tank design but is an essential tool for health monitoring of composite vessels. Remote sensing of the key signatures of the tank’s operating parameters such as pressure, acceleration and humidity was demonstrated using a unique device that can wirelessly transmit and stream the data to a remote server. Fiber optic sensors were successfully integrated during fabrication of the tanks. These sensors provide a wealth of information regarding the structural health of the vessel when it is subsequently pressurized or subjected to impact damage. Excellent correlation was demonstrated between the fiber optic sensor and mechanical strain gage data, and between the measurements and analytical predictions.

08 HYDROGEN↗

NASA NTRS2019

Electrical Propulsive Fuselage Concept for Transonic Transport Aircraft

NASA is broadly engaged in Electrified Aircraft Propulsion (EAP) efforts across air vehicle sizes and electric aircraft propulsion approaches. EAP enables a wide range of propulsion airframe integration options as well as the use of rechargeable energy storage in an aircraft. This paper is limited to a discussion of boundary layer ingestion (BLI) systems which are located on the fuselage of the aircraft and use electrical drive systems. We term that combination an "electrical propulsive fuselage". The benefits, challenges, and design parameters of an electrically driven fuselage BLI system are considered. Five existing types of fuselage BLI implementation approaches which can be implemented using either electrical or mechanical drive systems are reviewed. An overview of boundary layer types, fan response to boundary layer, and electrical system for aircraft propulsion is presented. An idea distributed electric propulsive fuselage is proposed.

Electrified Aircraft Propulsion↗

DOE OSTI2026

Charge And Dynamic Current On Tubular Antennas For Various Drive Conditions

The mixed boundary value problem of a tubular conductor is solved using an approximate representation of its Fourier coefficients. A two term solution is derived, which represents the solution over an extremely broad range of aspect ratios. This representation is used to find the electrostatic solution and capacitance of a charged tube as well as the solution of a tube in a uniform field and its dipole moment. This second case is directly useful as a model for a monopole electric field probe. This approximation is a special case of a representation using a combination of Chebyshev and Legendre polynomials. Combining the charged tube and tube in a uniform field allows the solution of voltage driven tubular antennas. Comparisons are made with numerical solutions using piecewise sinusoidal representations of the current. The results are also generalized to the dynamic case and up to and beyond the first resonance. Simple corrections for finite gap and delta gap drives to magnetic frill drives are examined using infinite tube integral transform representations. Corrections between magnetic frill drives and coaxial drives are also given. Approximate drive corrections using conformal mapping and an effective radius are also discussed. Finally, this efficient current representation is applied to the magnetic problem involving simple tubular solenoids.

97 MATHEMATICS AND COMPUTING↗

NASA NTRS2012

Experimental Investigation of a Direct-drive Hall Thruster and Solar Array System at Power Levels up to 10 kW

As NASA considers future exploration missions, high-power solar-electric propulsion (SEP) plays a prominent role in achieving many mission goals. Studies of high-power SEP systems (i.e. tens to hundreds of kilowatts) suggest that significant mass savings may be realized by implementing a direct-drive power system, so NASA recently established the National Direct-Drive Testbed to examine technical issues identified by previous investigations. The testbed includes a 12-kW solar array and power control station designed to power single and multiple Hall thrusters over a wide range of voltages and currents. In this paper, single Hall thruster operation directly from solar array output at discharge voltages of 200 to 450 V and discharge powers of 1 to 10 kW is reported. Hall thruster control and operation is shown to be simple and no different than for operation on conventional power supplies. Thruster and power system electrical oscillations were investigated over a large range of operating conditions and with different filter capacitances. Thruster oscillations were the same as for conventional power supplies, did not adversely affect solar array operation, and were independent of filter capacitance from 8 to 80 ?F. Solar array current and voltage oscillations were very small compared to their mean values and showed a modest dependence on capacitor size. No instabilities or anomalous behavior were observed in the thruster or power system at any operating condition investigated, including near and at the array peak power point. Thruster startup using the anode propellant flow as the power 'switch' was shown to be simple and reliable with system transients mitigated by the proper selection of filter capacitance size. Shutdown via cutoff of propellant flow was also demonstrated. A simple electrical circuit model was developed and is shown to have good agreement with the experimental data.

Snyder, John S.↗

DOE OSTI2025

Virtual Power Plant Profiles and Inventory

Increased adoption of distributed energy resources (DERs), growing quantities of renewable energy on the grid, and load growth from buildings, industry, and data centers are driving the need for increased demand flexibility and solutions to reliably and cost-effectively balance electricity supply and demand. In order to deploy DERs on a similar scale as conventional supply-side resources, utilities and state decision-makers are exploring a range of programmatic approaches and market designs, including Virtual Power Plants (VPP). Based on interviews with more than twenty subject matter experts on VPPs, the Insights into Scaling Virtual Power Plants report and appendix outlines actions that utilities and regulators can take to expand VPPs, organized around successful VPP designs, deployment, and operation. The companion report, Virtual Power Plant Profiles and Inventory describes three conceptual profiles that can be used as a starting point to facilitate clear discussions among regulators, utilities, solution providers, and stakeholders about various VPP strategies. It also includes details on more than 790 demand response programs and net energy metering solar plus battery programs, and 180 VPP programs. The Inventory is provided below as a separate file.

24 POWER TRANSMISSION AND DISTRIBUTION↗

NASA NTRS1978

Preliminary power train design for a state-of-the-art electric vehicle

The state-of-the-art (SOTA) of electric vehicles built since 1965 was reviewed to establish a base for the preliminary design of a power train for a SOTA electric vehicle. The performance of existing electric vehicles were evaluated to establish preliminary specifications for a power train design using state-of-the-art technology and commercially available components. Power train components were evaluated and selected using a computer simulation of the SAE J227a Schedule D driving cycle. Predicted range was determined for a number of motor and controller combinations in conjunction with the mechanical elements of power trains and a battery pack of sixteen lead-acid batteries - 471.7 kg at 0.093 MJ/Kg (1040 lbs. at 11.7 Whr/lb). On the basis of maximum range and overall system efficiency using the Schedule D cycle, an induction motor and 3 phase inverter/controller was selected as the optimum combination when used with a two-speed transaxle and steel belted radial tires. The predicted Schedule D range is 90.4 km (56.2 mi). Four near term improvements to the SOTA were identified, evaluated, and predicted to increase range approximately 7%.

Ross, J. A.↗

DOE OSTI2021

Future Cost Benefits Analysis for Electrified Vehicles from Advances Due to U.S. Department of Energy Targets

The U.S. Department of Energy’s Vehicle Technologies Office (DOE-VTO) supports research and development (R&D), as well as deployment of efficient and sustainable transportation technologies, that will improve energy efficiency and fuel economy and enable America to use less petroleum. To accelerate the creation and adoption of new technologies, DOE-VTO has developed specific targets for a wide range of powertrain technologies (e.g., engine, battery, electric machine, lightweighting, etc.). This paper quantifies the impact of VTO R&D on vehicle energy consumption and cost compared to expected historical improvements across vehicle classes, powertrains, component technologies and timeframes. We have implemented a large scale simulation process to develop and simulate tens of thousands of vehicles on U.S. standard driving cycles using Autonomie, a vehicle simulation tool developed by Argonne National Laboratory. Results demonstrate significant additional reductions in both cost and energy consumption due to the existence of VTO R&D targets compared to predicted historical trends. It is observed that, over time, the fuel consumption of different electrified vehicles is expected to decrease by 40–50% and a reduction of 45–55% for vehicle manufacturing costs owing to significant improvements through various VTO R&D targets.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2022

Rare Earth Permanent Magnets: Supply Chain Deep Dive Assessment

The report “America’s Strategy to Secure the Supply Chain for a Robust Clean Energy Transition” lays out the challenges and opportunities faced by the United States in the energy supply chain as well as the federal government plans to address these challenges and opportunities. It is accompanied by several issue-specific deep dive assessments, including this one, in response to Executive Order 14017 “America’s Supply Chains,” which directs the Secretary of Energy to submit a report on supply chains for the energy sector industrial base. The Executive Order is helping the federal government to build more secure and diverse U.S. supply chains, including energy supply chains. This report focuses on the supply chain for rare earth permanent magnets, specifically sintered neodymiumiron-boron (NdFeB) magnets, used in clean energy technologies. Sintered NdFeB magnets are the strongest magnets commercially available and provide a host of benefits to wide-ranging applications in consumer and industrial electronics, especially in advanced motor and drive systems. Within the Energy Sector Industrial Base, and clean energy in particular, NdFeB magnets are key intermediate components of permanent magnet synchronous (direct drive) generators in wind turbines (especially for offshore turbines) and electric synchronous traction motors for propulsion systems in battery and hybrid electric vehicles.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2024

Formation of field-induced breakdown precursors on metallic electrode surfaces

Understanding the underlying factors responsible for higher-than-anticipated local field enhancements required to trigger vacuum breakdown on pristine metal surfaces is crucial for the development of devices capable of withstanding intense operational fields. In this study, we investigate the behavior of nominally flat copper electrode surfaces exposed to electric fields of hundreds of MV/m. Our novel approach considers curvature-driven diffusion processes to elucidate the formation of sharp breakdown precursors. To do so, we develop a mesoscale finite element model that accounts for driving forces arising from both electrostatic and surface-tension-induced contributions to the free energy. Our findings reveal a dual influence: surface tension tends to mitigate local curvature, while the electric field drives mass transport toward regions of high local field density. This phenomenon can trigger the growth of sharper protrusions, ultimately leading to a rapid enhancement of local fields and, consequently, to a runaway growth instability. We delineate supercritical and subcritical regimes across a range of initial surface roughness. Our numerical results are in qualitative agreement with experimentally reported data, indicating the potential practical relevance of field-driven diffusion in the formation of breakdown precursors.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

DOE OSTI2024

Improving the Freight Productivity of a Heavy-Duty, Battery Electric Truck by Intelligent Energy Management

This project aimed to enhance the range and reduce the operating costs of battery electric Class 8 trucks traveling over 250 miles daily. This was achieved through the development and implementation of an intelligent-Energy Management System (i-EMS) that leverages vehicle and operations data, physics-aware machine learning algorithms, and vehicle-to-cloud (V2C) connectivity. The project hypothesized that advanced machine learning algorithms and real-time data analytics could significantly improve the energy efficiency and range of these trucks. Key objectives included developing a physics-aware machine learning algorithm, implementing an i-EMS with V2C connectivity and physics-aware spatial data analytics (PSDA), and validating the system’s effectiveness with fleet partners HEB Companies and Murphy Logistics. Extensive data collection from vehicle operations, including vehicle characteristics, road conditions, and payload, was conducted. A machine learning algorithm was developed to predict energy consumption and enable proactive decision-making. The i-EMS was implemented on two Volvo VNR BEVs, with operators receiving charging and routing recommendations. Charging stations were installed at depot locations in Texas and Minnesota, with an additional on-route charger in Minnesota. Significant findings included a 14% range improvement for Murphy Logistics on a highway-driving eco-route and a 22% range improvement for HEB Companies on a city-driving eco-route. The i-EMS utilized rule-based methods and physics-based algorithms to predict and reduce energy consumption, with real-time monitoring and analysis through V2C connectivity enabling proactive decision-making. The project demonstrated the feasibility and economic viability of battery electric Class 8 trucks for long-haul operations, showcasing the potential of physics-aware machine learning in optimizing energy management. The successful implementation of the i-EMS in real-world scenarios validates its practical application and effectiveness, paving the way for the widespread adoption of battery electric vehicles in the freight transportation industry.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2022

Magnetic Field Amplification by a Plasma Cavitation Instability in Relativistic Shock Precursors

Abstract Plasma streaming instabilities play an important role in magnetic field amplification and particle acceleration in relativistic shocks and their environments. However, in the far shock precursor region where accelerated particles constitute a highly relativistic and dilute beam, streaming instabilities typically become inefficient and operate at very small scales when compared to the gyroradii of the beam particles. We report on a plasma cavitation instability that is driven by dilute relativistic beams and can increase both the magnetic field strength and coherence scale by orders of magnitude to reach near-equipartition values with the beam energy density. This instability grows after the development of the Weibel instability and is associated with the asymmetric response of background leptons and ions to the beam current. The resulting net inductive electric field drives a strong energy asymmetry between positively and negatively charged beam species. Large-scale particle-in-cell simulations are used to verify analytical predictions for the growth and saturation level of the instability and indicate that it is robust over a wide range of conditions, including those associated with pair-loaded plasmas. These results can have important implications for the magnetization and structure of shocks in gamma-ray bursts, and more generally for magnetic field amplification and asymmetric scattering of relativistic charged particles in plasma astrophysical environments.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2021

Energy Analysis: Ways to Save Energy and Reduce the Emissions in Wastewater Treatment Plants

The key of this study is to explore the primary energy consumers in wastewater treatment plants, which is considered as one of the major energy consumers, and introduces the best solution to save energy and reduce emissions in these facilities. This study is based on the energy assessment and analyses of eleven wastewater treatment plants. Through the investigation, it was found that plants can save up to 44,158 MWh of the energy consumption which is 47% from the total electricity consumption with a 17% reduction in the total utility bills and that about 2.5 million dollars cost savings after reviewing the currently facilitated energy system. Additionally, an average of five years' payback period resulted in most energy-saving recommendations. A vast potential of greenhouse gas emissions can be reduced with a total range reduction between 13 to 35 million kg of CO 2 based on the speed reduction percentage.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗