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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 19 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2013

Progress of the Computer-Aided Engineering of Electric Drive Vehicle Batteries (CAEBAT) (Presentation)

This presentation, Progress of Computer-Aided Engineering of Electric Drive Vehicle Batteries (CAEBAT) is about simulation and computer-aided engineering (CAE) tools that are widely used to speed up the research and development cycle and reduce the number of build-and-break steps, particularly in the automotive industry. Realizing this, DOE?s Vehicle Technologies Program initiated the CAEBAT project in April 2010 to develop a suite of software tools for designing batteries.

25 ENERGY STORAGE↗
DOE OSTI2013

New Structural-Dynamics Module for Offshore Multimember Substructures within the Wind Turbine Computer-Aided Engineering Tool FAST: Preprint

FAST, developed by the National Renewable Energy Laboratory (NREL), is a computer-aided engineering (CAE) tool for aero-hydro-servo-elastic analysis of land-based and offshore wind turbines. This paper discusses recent upgrades made to FAST to enable loads simulations of offshore wind turbines with fixed-bottom, multimember support structures (e.g., jackets and tripods, which are commonly used in transitional-depth waters). The main theory and strategies for the implementation of the multimember substructure dynamics module (SubDyn) within the new FAST modularization framework are introduced. SubDyn relies on two main engineering schematizations: 1) a linear frame finite-element beam (LFEB) model and 2) a dynamics system reduction via Craig-Bampton's method. A jacket support structure and an offshore system consisting of a turbine atop a jacket substructure were simulated to test the SubDyn module and to preliminarily assess results against results from a commercial finite-element code.

17 WIND ENERGY↗
DOE OSTI2014

Coupling of Mechanical Behavior of Cell Components to Electrochemical-Thermal Models for Computer-Aided Engineering of Batteries under Abuse (Presentation)

The EV Everywhere Grand Challenge aims to produce plug-in electric vehicles as affordable and convenient for the American family as gasoline-powered vehicles by 2022. Among the requirements set by the challenge, electric vehicles must be as safe as conventional vehicles, and EV batteries must not lead to unsafe situations under abuse conditions. NREL's project started in October 2013, based on a proposal in response to the January 2013 DOE VTO FOA, with the goal of developing computer aided engineering tools to accelerate the development of safer lithium ion batteries.

25 ENERGY STORAGE↗
DOE OSTI2013

Application of Robust Design and Advanced Computer Aided Engineering Technologies: Cooperative Research and Development (Final Report)

Oshkosh Corporation (OSK) is taking an aggressive approach to implementing advanced technologies, including hybrid electric vehicle (HEV) technology, throughout their commercial and military product lines. These technologies have important implications for OSK's commercial and military customers, including fleet fuel efficiency, quiet operational modes, additional on-board electric capabilities, and lower thermal signature operation. However, technical challenges exist with selecting the optimal HEV components and design to work within the performance and packaging constraints of specific vehicle applications. SK desires to use unique expertise developed at the Department of Energy?s (DOE) National Renewable Energy Laboratory (NREL), including HEV modeling and simulation. These tools will be used to overcome technical hurdles to implementing advanced heavy vehicle technology that meet performance requirements while improving fuel efficiency.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2025

Processing behavior evolution of recycled polypropylene: An integrated experimental and Computer-Aided engineering simulation study

Polypropylene (PP) comprises 21% of global plastics production and 18% of plastics waste, yet less than 1% of solid-waste PP is recycled in the United States (U.S.), representing significant environmental and economic challenges. Mechanical recycling, the most prevalent recycling method, subject's materials to thermomechanical stresses, which typically degrade polymer properties, affecting the quality of polymer products. This study replicates the impact of mechanical recycling through multiple extrusion cycles to examine the effects on PP's processing behavior. Dynamic scanning calorimetry (DSC) measurements showed stable melting behavior across all processing conditions, while crystallization analysis exhibited consistent shifts in kinetic parameters. Rheological characterization demonstrated progressive viscosity reductions through successive cycles, particularly pronounced at elevated reprocessing temperatures. Here, the integration of this experimental data into injection molding simulations showed that recycled PP maintains viable processing characteristics. Our findings establish quantitative correlations between processing history and material behavior, enabling optimization of processing parameters directly rather than relying on trial-and-error approaches. While these results reflect idealized recycling conditions with minimal contamination, they provide a framework for understanding fundamental property evolution during mechanical recycling.

42 ENGINEERING↗
DOE OSTI2018

Advanced Tool for Computer Aided Battery Engineering (SNL)

This project aims to provide experimental support, including support for validation and parameterization, for mechanical failure modeling work as part of DOE's Computer Aided Engineering for Electric-Drive Vehicle Batteries (CAEBAT) program. This work involves mechanical deformation testing on both charged and discharged cells, including abusive mechanical testing leading to battery failure. The mechanical data generated is provided to the modeling teams to provide empirical parameterization as well as validation for newly developed models. Testing fully charged cells and packs (abusive battery testing) also allows for a better understanding of what conditions are most likely to lead to a potentially hazardous thermal runaway event.

25 ENERGY STORAGE↗
DOE OSTI2022

U-splines: Splines over unstructured meshes

U-splines are a novel approach to the construction of a spline basis for representing smooth objects in Computer-Aided Design (CAD) and Computer-Aided Engineering (CAE). A spline is a piecewise-defined function that satisfies continuity constraints between adjacent cells in a mesh. U-splines differ from existing spline constructions, such as Non-Uniform Rational B-splines (NURBS), subdivision surfaces, T-splines, and hierarchical B-splines, in that they can accommodate local variation in cell size, polynomial degree, and smoothness simultaneously over more varied mesh configurations. Mixed cell types (e.g., triangle and quadrilateral cells in the same mesh) and T-junctions are also supported, although the continuity of interfaces with triangle and tetrahedral cells is limited in the present work. The U-spline algorithm introduces a new technique for using local null space solutions to construct basis functions for the global spline null space problem. The U-spline construction is presented for curves, surfaces, and volumes with higher dimensional generalizations possible. Lastly, a set of requirements are given to ensure that the U-spline basis is positive, forms a partition of unity, is complete, and is locally linearly independent.

42 ENGINEERING↗
DOE OSTI2016

Computer Aided Battery Engineering Consortium

A multi-national lab collaborative team was assembled that includes experts from academia and industry to enhance recently developed Computer-Aided Battery Engineering for Electric Drive Vehicles (CAEBAT)-II battery crush modeling tools and to develop microstructure models for electrode design - both computationally efficient. Task 1. The new Multi-Scale Multi-Domain model framework (GH-MSMD) provides 100x to 1,000x computation speed-up in battery electrochemical/thermal simulation while retaining modularity of particles and electrode-, cell-, and pack-level domains. The increased speed enables direct use of the full model in parameter identification. Task 2. Mechanical-electrochemical-thermal (MECT) models for mechanical abuse simulation were simultaneously coupled, enabling simultaneous modeling of electrochemical reactions during the short circuit, when necessary. The interactions between mechanical failure and battery cell performance were studied, and the flexibility of the model for various batteries structures and loading conditions was improved. Model validation is ongoing to compare with test data from Sandia National Laboratories. The ABDT tool was established in ANSYS. Task 3. Microstructural modeling was conducted to enhance next-generation electrode designs. This 3- year project will validate models for a variety of electrodes, complementing Advanced Battery Research programs. Prototype tools have been developed for electrochemical simulation and geometric reconstruction.

25 ENERGY STORAGE↗
DOE OSTI2021

Cabin Thermal Management Analysis for SuperTruck II Next-Generation Hybrid Electric Truck Design

In this article, we present a multistage, coupled thermal management simulation approach, informed by physical testing where available, to aid design decisions for PACCAR's SuperTruck II hybrid truck cabin concept. Focus areas include cabin insulation, battery sizing, and sleeper curtain position, as well as heating, ventilating, and air-conditioning (HVAC) component and accessory configurations, to maintain or improve thermal comfort while saving energy. The authors analyzed weather data and determined the national vehicle miles traveled weighted temperature and solar conditions for long-haul trucks. Example weather day profiles were selected to approximate the 5th and 95th percentile weighted conditions. A daylong drive cycle was developed to impose appropriate external wind conditions during rest and driving periods. Using the National Renewable Energy Laboratory's vehicle HVAC modeling and simulation tool VTCab, HVAC load design trade-off studies for the new truck geometry concept were completed. Parameters analyzed included effects of paint color, insulation, glass transmissivity, and curtain location. Simulation results helped with early design material selections for efficient cabin climate control. A detailed three-dimensional computer-aided engineering (CAE), computational fluid dynamics (CFD), radiation, and human physiology co-simulation, referred to in this article as CAE Thermal-CFD, was used to evaluate thermal comfort and energy impacts of diffuser configurations and air supply settings in driving and hoteling modes. Analysis revealed that it is more difficult to heat the cabin in hoteling mode during the winter than to cool the space in the summer. This seasonal load profile drives the requirement of additional energy storage for heating comfort. To determine the battery capacity requirement, multiday HVAC operation drive cycle simulations were then completed, showing that a 15-kWh battery would be required for HVAC operation during hoteling. Results helped reduce cabin thermal loads, determine component sizing requirements, and improve occupant comfort to save fuel and contribute to the economic viability of the hybrid system.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2014

Comparison of Hydrodynamic Load Predictions Between Engineering Models and Computational Fluid Dynamics for the OC4-DeepCwind Semi-Submersible: Preprint

Hydrodynamic loads on the platforms of floating offshore wind turbines are often predicted with computer-aided engineering tools that employ Morison's equation and/or potential-flow theory. This work compares results from one such tool, FAST, NREL's wind turbine computer-aided engineering tool, and the computational fluid dynamics package, OpenFOAM, for the OC4-DeepCwind semi-submersible analyzed in the International Energy Agency Wind Task 30 project. Load predictions from HydroDyn, the offshore hydrodynamics module of FAST, are compared with high-fidelity results from OpenFOAM. HydroDyn uses a combination of Morison's equations and potential flow to predict the hydrodynamic forces on the structure. The implications of the assumptions in HydroDyn are evaluated based on this code-to-code comparison.

17 WIND ENERGY↗
DOE OSTI2014

Effects of Second-Order Hydrodynamic Forces on Floating Offshore Wind Turbines

Relative to first-order, second-order wave-excitation loads are known to cause significant motions and additional loads in offshore oil and gas platforms. The design of floating offshore wind turbines was partially inherited from the offshore oil and gas industry. Floating offshore wind concepts have been studied with powerful aero-hydro-servo-elastic tools; however, most of the existing work on floating offshore wind turbines has neglected the contribution of second-order wave-excitation loads. As a result, this paper presents a computationally efficient methodology to consider these loads within FAST, a wind turbine computer-aided engineering tool developed by the National Renewable Energy Laboratory. The method implemented was verified against the commercial OrcaFlex tool, with good agreement, and low computational time. A reference floating offshore wind turbine was studied under several wind and wave load conditions, including the effects of second-order slow-drift and sum-frequency loads. Preliminary results revealed that these loads excite the turbine's natural frequencies, namely the surge and pitch natural frequencies.

13 HYDRO ENERGY↗
DOE OSTI2015

SubDyn User's Guide and Theory Manual

SubDyn is a time-domain structural-dynamics module for multimember fixed-bottom substructures created by the National Renewable Energy Laboratory (NREL) through U.S. Department of Energy Wind and Water Power Program support. The module has been coupled into the FAST aero-hydro-servo-elastic computer-aided engineering (CAE) tool. Substructure types supported by SubDyn include monopiles, tripods, jackets, and other lattice-type substructures common for offshore wind installations in shallow and transitional water depths. SubDyn can also be used to model lattice support structures for land-based wind turbines. This document is organized as follows. Section 1 details how to obtain the SubDyn and FAST software archives and run both the stand-alone SubDyn or SubDyn coupled to FAST. Section 2 describes the SubDyn input files. Section 3 discusses the output files generated by SubDyn; these include echo files, a summary file, and the results file. Section 4 provides modeling guidance when using SubDyn. The SubDyn theory is covered in Section 5. Section 6 outlines future work, and Section 7 contains a list of references. Example input files are shown in Appendixes A and B. A summary of available output channels are found in Appendix C. Instructions for compiling the stand-alone SubDyn program are detailed in Appendix D. Appendix E tracks the major changes we have made to SubDyn for each public release.

17 WIND ENERGY↗
DOE OSTI2014

Extending the Capabilities of the Mooring Analysis Program: A Survey of Dynamic Mooring Line Theories for Integration into FAST: Preprint

Techniques to model dynamic mooring lines come in various forms. The most widely used models include either a heuristic representation of the physics (such as a Lumped-Mass, LM, system), a Finite-Element Analysis (FEA) discretization of the lines (discretized in space), or a Finite-Difference (FD) model (which is discretized in both space and time). In this paper, we explore the features of the various models, weigh the advantages of each, and propose a plan for implementing one dynamic mooring line model into the open-source Mooring Analysis Program (MAP). MAP is currently used as a module for the FAST offshore wind turbine computer-aided engineering (CAE) tool to model mooring systems quasi-statically, although dynamic mooring capabilities are desired. Based on the exploration in this manuscript, the lumped-mass representation is selected for implementation in MAP based on its simplicity, computational cost, and ability to provide similar physics captured by higher-order models.

17 WIND ENERGY↗
DOE OSTI2014

Development and Analysis of a Swept Blade Aeroelastic Model for a Small Wind Turbine (Presentation)

As part of the U.S. Department-of-Energy-funded Competitiveness Improvement Project, the National Renewable Energy Laboratory (NREL) developed new capabilities for aeroelastic modeling of precurved and preswept blades for small wind turbines. This presentation covers the quest for optimized rotors, computer-aided engineering tools, a case study, and summary of the results.

17 WIND ENERGY↗