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Conical Euler analysis and active roll suppression for unsteady vortical flows about rolling delta wings
A conical Euler code was developed to study unsteady vortex-dominated flows about rolling, highly swept delta wings undergoing either forced motions or free-to-roll motions that include active roll suppression. The flow solver of the code involves a multistage, Runge-Kutta time-stepping scheme that uses a cell-centered, finite-volume, spatial discretization of the Euler equations on an unstructured grid of triangles. The code allows for the additional analysis of the free to-roll case by simultaneously integrating in time the rigid-body equation of motion with the governing flow equations. Results are presented for a delta wing with a 75 deg swept, sharp leading edge at a free-stream Mach number of 1.2 and at 10 deg, 20 deg, and 30 deg angle of attack alpha. At the lower angles of attack (10 and 20 deg), forced-harmonic analyses indicate that the rolling-moment coefficients provide a positive damping, which is verified by free-to-roll calculations. In contrast, at the higher angle of attack (30 deg), a forced-harmonic analysis indicates that the rolling-moment coefficient provides negative damping at the small roll amplitudes. A free-to-roll calculation for this case produces an initially divergent response, but as the amplitude of motion grows with time, the response transitions to a wing-rock type of limit cycle oscillation, which is characteristic of highly swept delta wings. This limit cycle oscillation may be actively suppressed through the use of a rate-feedback control law and antisymmetrically deflected leading-edge flaps. Descriptions of the conical Euler flow solver and the free-to roll analysis are included in this report. Results are presented that demonstrate how the systematic analysis of the forced response of the delta wing can be used to predict the stable, neutrally stable, and unstable free response of the delta wing. These results also give insight into the flow physics associated with unsteady vortical flows about delta wings undergoing forced motions and free-to-roll motions, including the active suppression of the wing-rock type phenomenon. The conical Euler methodology developed is directly extend able to three-dimensional calculations.
Rapid scalable fabrication of roll-to-roll slot-die coated flexible perovskite solar cells using intense pulse light annealing
Perovskite solar cells have achieved high efficiencies at the lab scale using batch processes that often may not be scalable. Processes that can be integrated into a continuous manufacturing platform, such as roll-to-roll, where several processes can be carried out sequentially are necessary to develop a new cost-competitive solar technology. In this work, intense pulsed light thermal post-processing is coupled with scalable slot-die coating and air knife evaporation in a high-speed roll-to-roll process of up to 2 m min –1 . The optimization of IPL energy parameters, web speeds, solution flow rates, and concentration of precursor inks yielded a champion power conversion efficiency of 11.24% for a 1 cm 2 roll-to-roll coated device. The overall processing time for a single layer in this process is reduced from minutes to seconds and the overall footprint of the manufacturing process is decreased. Furthermore, this demonstrates the promising capabilities for intensed pulsed light to reduce manufacturing costs and paves a roadmap for scalable and efficient PSCs on a roll-to-roll platform.
A Flight Investigation of the Damping in Roll and Rolling Effectiveness Including Aeroelastic Effects of Rocket Propelled Missile Models Having Cruciform, Triangular, Interdigitated Wings and Tails
The damping in roll and rolling effectiveness of two models of a missile having cruciform, triangular, interdigitated wings and tails have been determined through a Mach number range of 0.8 to 1.8 by utilizing rocket-propelled test vehicles. Results indicate that the damping in roll was relatively constant over the Mach umber range investigated. The rolling effectiveness was essentially constant at low supersonic speeds and increased with increasing mach numbers in excess of 1.4 over the Mach number range investigated. Aeroelastic effects increase the rolling-effectiveness parameters pb/2V divided by delta and decrease both the rolling-moment coefficient due to wing deflection and the damping-in-roll coefficient.
Computer-aided roll pass design in rolling of airfoil shapes
This paper describes two computer-aided design (CAD) programs developed for modeling the shape rolling process for airfoil sections. The first program, SHPROL, uses a modular upper-bound method of analysis and predicts the lateral spread, elongation, and roll torque. The second program, ROLPAS, predicts the stresses, roll separating force, the roll torque and the details of metal flow by simulating the rolling process, using the slab method of analysis. ROLPAS is an interactive program; it offers graphic display capabilities and allows the user to interact with the computer via a keyboard, CRT, and a light pen. The accuracy of the computerized models was evaluated by (a) rolling a selected airfoil shape at room temperature from 1018 steel and isothermally at high temperature from Ti-6Al-4V, and (b) comparing the experimental results with computer predictions. The comparisons indicated that the CAD systems, described here, are useful for practical engineering purposes and can be utilized in roll pass design and analysis for airfoil and similar shapes.
Computational Analysis of Ares I Roll Control System Jet Interaction Effects on Rolling Moment
The computational flow solver USM3D was used to investigate the jet interaction effects from the roll control system on the rolling moment of the Ares I full protuberance configuration at wind tunnel Reynolds numbers. Solutions were computed at freestream Mach numbers from M = 0.5 to M = 5 at the angle of attack 0deg, at the angle of attack 3.5deg for a roll angle of 120deg, and at the angle of attack 7deg for roll angles of 120deg and 210deg. Results indicate that the RoCS housing provided a beneficial jet interaction effect on vehicle rolling moment for M > or = 0.9. Most of the components downstream of the roll control system housing contributed to jet interaction penalties on vehicle rolling moment.
Predicting Low Toxicity and Scalable Solvent Systems for High–Speed Roll–to–Roll Perovskite Manufacturing
Printed lead-based perovskite photovoltaics (PV) have gained interest due to their potential to be manufactured with scalable roll-to-roll techniques. In industrial scale-up, toxicity of inks can constrain roll-to-roll manufacturing due to the added cost of managing toxic effluents. Due to solvent toxicity, few perovskite solution chemistries in published works are scalable to gigawatt production capacity at low cost. Herein, it is shown that for scalable PV production, the use of aprotic polar solvents should be avoided due to their overall toxicity. Compliance with worldwide worker safety regulations for solvent exposure limits could require additional air handling requirements for some solvents, which in turn would affect cost-effectiveness. It is shown that costs associated with handling of hazardous substances can be significant and estimate an added cost of ¢3.7/W for dimethylformamide (DMF)-based inks. To solve this problem, a new perovskite ink solvent system is developed that is composed entirely of ether and alcohol, which has an effective exposure limit 14× higher than DMF, making it suitable for industrial coating processes. Here, it is shown that the new ink solvent system is capable of fabricating high-efficiency perovskite solar cells processed in 1 min on a standard roll-to-roll system.
Rolling Moments Due to Rolling and Yaw for Four Wing Models in Rotation
This report presents the results of a series of autorotation and torque tests on four different rotating wing systems at various rates of roll and at several angles of yaw. The investigation covered an angle of attack range up to 90 degrees and angles of yaw of 0 degree, 5 degrees, 10 degrees, and 20 degrees. The tests were made in a 5-foot, closed-throat atmospheric wind tunnel. The object of the tests was primarily to determine the effects of various angles of yaw on the rolling moments of the rotating wings up to large angles of attack. It was found that at angles of attack above that of maximum lift the rolling moments on the wings due to yaw (or side slip) from 5 degrees to 20 degrees were roughly of the same magnitude as those due to rolling. There was a wide variation in magnitude of the rolling moment due to yaw angle. The rates and ranges of stable autorotation for the monoplane models were considerably increased by yaw, whereas for an unstaggered biplane they were little affected. The immediate cause of the rolling moment due to yaw is apparently the building up of large loads on the forward wing tip and the reduction of loads on the rearward wing tip.
Techno-economic analysis of roll-to-roll production of perovskite modules using radiation thermal processes
Perovskite solar technology can produce economically viable photovoltaic devices due to low cost of materials and scalable manufacturing. Solution phase deposition of all active layers lends itself to roll-to-roll fabrication methods which are well-established and have production rates of several hundred square meters per minute. In this techno-economic analysis, the opportunity to scale at this production throughput is considered with manufacturing rates exceeding one gigawatt per year in a single plant. Intense pulsed light is used for the post deposition process to minimize costs associated with the footprint, equipment, and operation. The analysis is limited to the operation of a roll-to-roll manufacturing facility producing a perovskite solar film that can be incorporated into photovoltaic modules. Costs associated with materials, labor, and equipment are considered along with utilities determined from the fundamental engineering calculations. Furthermore, the results show that at very large-scale operations of several gigawatts, the costs to produce the solar films range between $0.04-$0.10 per watt.
Human Ocular Counter-Rolling and Roll Tilt Perception during Off-Vertical Axis Rotation after Spaceflight
Ocular counter-rolling (OCR) induced by whole body tilt in roll has been explored after spaceflight as an indicator of the adaptation of the otolith function to microgravity. It has been claimed that the overall pattern of OCR responses during static body tilt after spaceflight is indicative of a decreased role of the otolith function, but the results of these studies have not been consistent, mostly due to large variations in the OCR within and across individuals. By contrast with static head tilt, off-vertical axis rotation (OVAR) presents the advantage of generating a sinusoidal modulation of OCR, allowing averaged measurements over several cycles, thus improving measurement accuracy. Accordingly, OCR and the sense of roll tilt were evaluated in seven astronauts before and after spaceflight during OVAR at 45 /s in darkness at two angles of tilt (10 and 20 ). There was no significant difference in OCR during OVAR immediately after landing compared to preflight. However, the amplitude of the perceived roll tilt during OVAR was significantly larger immediately postflight, and then returned to control values in the following days. Since the OCR response is predominantly attributed to the shearing force exerted on the utricular macula, the absence of change in OCR postflight suggests that the peripheral otolith organs function normally after short-term spaceflight. However, the increased sense of roll tilt indicates an adaptation in the central processing of gravitational input, presumably related to a re-weigthing of the internal representation of gravitational vertical as a result of adaptation to microgravity.
Model support roll balance and roll coupling
The design concepts of two specialized wind tunnel model support mechanisms are described. The forced oscillation roll balance mechanism was designed to meet the specific requirement to measure aerodynamic forces and moments to permit determination of the damping-in-roll parameters of winged configurations. A variable speed motor is used to oscillate the model by means of an offset crank. The oscillating motion is resisted by a torsion spring to provide a restoring torque and is attached to the section forward of the strain-gage balance. This spring action allows the model to be oscillated at a frequency for velocity resonance, whereby the mechanical spring and any aerodynamic spring balance. This spring action allows the model to be oscillated at a frequency for velocity resonance, whereby the mechanical spring and any aerodynamic spring balance out the model inertia. The only torque then required to oscillate the model at that particular frequency is equal to that due to aerodynamic damping. The second mechanism, a roll coupling for remotely rotating a model, was designed to invert or roll a model about its longitudinal axis when mounted for testing.
Rolling-element fatigue life with traction fluids and automatic transmission fluid in a high-speed rolling-contact rig
Rolling-element fatigue tests were run in standard and high-speed rolling-contact rigs at bar speeds from 5000 to 50,000 rpm to determine the effects of speed and lubricant film parameter on rolling-element fatigue life. AISI 52100 test bars were tested at a maximum Hertz stress of 4.83 GPa (700,000 psi) with three traction fluids and an automatic transmission fluid. Rolling-element fatigue life increased with speed, with the greatest increases occurring from 10,000 to 50,000 rpm. The life data tended to follow published life-versus-lubricant-film-parameter data up to a film parameter of approximately 3.
Demonstration of and future perspective on scaling ultrafast-laser-ablation microstructuring of Li-ion battery electrodes to roll-to-roll production and large-format cells
This work demonstrates integration of an ultrafast laser onto a roll-to-roll machine, the laser structuring of a double-sided, 700 m long roll of graphite battery anode and its subsequent manufacture into 27 Ah prismatic cells. The electrode was ablated with a novel hybrid-microstructure composed of both hexagonally arranged pores for enhanced rate performance and channels for fast electrolyte wetting. Subsequently, this anode and a non-ablated baseline anode are paired with an NMC111 cathode for cell building and electrochemical characterization. Compared to the baseline, laser ablated cells demonstrated a reduction in soaking time of at least 60%, an improvement in fast charge capability with >30% more capacity accepted during 6C charging, and an extension of cycle life of >40% during 0.5C cycling. Further, a perspective is provided on scaling ultrafast laser ablation of battery electrodes to industrial throughputs. Additionally, lessons learned from this pilot-scale demonstration are provided in regards to optical architecture, debris removal, and system control. A techno-economic analysis is used to demonstrate that laser ablation can be integrated into existing electrode manufacturing facilities with only ≈$\$$1.3 per kWh increase (≈2%) in manufacturing cost. Preemptive electrode design for laser ablation is discussed as a further method for enhancing performance. Finally, an analysis of available laser systems and beam-scanning architectures is used to determine design requirements to scale process throughput to a state-of-the-art speed of 50 m min −1 . This analysis demonstrates that laser ablating Li-ion battery electrodes has multiple benefits to manufacturing and battery performance, that the technology already exists to achieve high laser-ablation throughputs, and that integrating ultrafast laser ablation to electrode manufacturing will not create a cost or processing bottleneck.
Roll-to-roll SOFC manufacturing method and system
A method of making a solid oxide fuel cell (SOFC) includes the steps of providing a first SOFC layer laminate tape comprising a first SOFC layer composition attached to a flexible carrier film layer, providing a second SOFC laminate tape comprising a second SOFC layer composition attached to a flexible carrier film layer, and providing a third SOFC layer laminate tape comprising a third SOFC layer composition attached to a flexible carrier film layer. The first SOFC layer laminate tape, the second SOFC layer laminate tape, and the third SOFC layer laminate tape are assembled on rolls positioned along a roll-to-roll assembly line. The laminate tapes are sequentially laminated and calendered and the flexible carrier films removed to provide a composite SOFC precursor laminate that can be sintered and combined with a cathode to provide a completed SOFC. An assembly for making composite SOFC precursor laminates is also disclosed.
Robust constrained tension control for high-precision roll-to-roll processes
Tension control is critical for maintaining good product quality in most roll-to-roll (R2R) production systems. Previous work has primarily focused on improving the disturbance rejection performance of tension controllers. Here, a robust linear parameter-varying model predictive control (LPV-MPC) scheme is designed to enhance the tension tracking performance of a pilot R2R system for deposition of materials used in flexible thin film applications. The performance of a tension controller may degrade due to disturbances associated with model uncertainties and the slowly-changing dynamics in R2R systems. We introduce a method that separately treats these two sources of disturbance. The controller utilizes an incremental model to eliminate the errors caused by the mismatch between the nominal model and the actual system. A tube-based MPC formulation combined with scheduled parameters adequately updates models and corrects for the time-varying dynamics. Constraints on the rated motor torque are incorporated in the MPC to maintain the controller reliability and avoid machine failures. We illustrate the operation of our control algorithm through simulation of an actual R2R system. The controller outperforms the benchmarks in terms of fast transient response and offset-free tension tracking. Furthermore, it also demonstrates immunity from variations due to parametric uncertainties.
Scalable aqueous-phase fabrication of reduced graphene oxide nanofiltration membranes by an integrated roll-to-roll (R2R) process
Economic fractionation of multicomponent biomass-derived streams is a key challenge in biobased fuels and chemicals production. Kraft black liquor (BL) is generated at ~1 billion tons/yr globally from biomass pulping and contains ~15wt% total solids including lignin, hemicellulose fragments, and inorganics. Membrane-based BL concentration is attractive but challenged by low solute rejections and poor stability in BL, which combines alkaline pH (~13), high dissolved solids content (15+ wt%) and high temperature (70–85°C). Here we discuss the scaled fabrication and characterization of reduced graphene oxide (rGO) nanofiltration membranes by slot die coating on a roll-to-roll (R2R) with integrated vacuum filtration. Here, we obtain high-quality 90×30 cm rGO membranes (referred to as “R2R-rGO membranes” in this work) with ~100 nm average thickness supported on porous poly(ethersulfone) (PES) sheets, and an effective area of 2700cm 2 . We present characterizations of their microstructure and uniformity as mapped over large areas by scanning electron microscopy (SEM), ellipsometry, adhesion test and X-ray photoelectron spectroscopy (XPS). The constructed ellipsometry model for the rGO membrane/PES substrate composite was successfully applied to 48 different locations of the R2R-rGO membranes. The R2R-rGO membranes showed >98% lignin rejection with a steady state flux of ~12 LMH at 50bar in a 15.7wt% total solids (TS) kraft BL stream at 72°C and 2–3 gal/min crossflow rates. Slot die coating on a R2R platform with integrated vacuum filtration can enable rapid fabrication of high-quality GO membranes at scale without organic solvents or volatile organic compounds.
Roll-to-Roll, Dual-Layer Slot Die Coating of Chitin and Cellulose Oxygen Barrier Films for Renewable Packaging
Cellulose and chitin are the two most abundant naturally produced biopolymers and are being extensively studied as candidates for renewable oxygen barrier films used in packaging. It has been shown that bilayers formed from cellulose nanocrystals (CNCs) and chitin nanofibers (ChNFs) exhibit oxygen barrier properties similar to polyethylene terephthalate (PET). However, this prior work explored only coating each layer individually in sequence through techniques such as spray coating. Here, we demonstrate the viability of dual-layer slot die coating of CNC/ChNF bilayers onto cellulose acetate (CA) substrates. The dual-layer slot die method enables significantly lower oxygen permeability versus spray coating while using a roll-to-roll system that applies the bilayer in a single pass. This work discusses suspension properties, wetting, and drying conditions required to achieve well-controlled ChNF/CNC bilayers. Spray-coated bilayer films were on average 25% thinner than the dual-layer bilayer film; however, the thickness-normalized oxygen permeability (OP) of the dual-layer-coated ChNF/CNC bilayer film on CA was 20 times better than that of the spray-coated bilayers. Additionally, it has been shown that ChNF contributes to the wetting and barrier properties. Values of OP for the slot die-coated bilayers under optimized drying conditions were as low as 1.2 cm 3 ∙μm∙m -2 ∙d -1 ∙kPa -1 , corresponding to a normalized oxygen transmission rate of 0.32 cm 3 ∙m -2 ∙d -1 at 23 °C and 50% relative humidity. It is also noted that the adhesive properties of the dual-layer coating are also improved when films are air-dried and that ChNF contributes to the wetting and barrier properties.
Cost Estimates of Roll-to-Roll Production of Organic Light Emitting Devices for Lighting
White organic light emitting devices (WOLEDs) offerdistinct advantages as solid state lighting sources, including high energy efficiency, superior color quality,and a flexible, thin profile that can accommodate a vast array of possible fixture designs. Recent advances in device lifetime and high speed deposition suggest that mass production of WOLED panels is approaching an inflection point. To understand the tradeoffs in the volume manufacturing of WOLED lighting panels, in this work, we estimate the cost of white WOLED panel production based on vacuum and vapor phase deposition in a roll-to-roll production line envisioned to yield an annual capacity of at least 6 × 10 6 m 2 . Assuming a WOLED operating luminance at 10 klm/m 2 , we anticipate a $\$12.5$ /klm cost of a WOLED light engine that includes the cost of the current driverand packaging. With incremental reduction in material and driver costs and improved luminance, the costof WOLED lighting can be reduced to $\$6.3$ /klm in thenear term, potentially positioning WOLEDs for use innumerous premium lighting applications.