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Results for “on-board performance processing”

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 OSTI2018

Modal Frequency Identification of a Cylindrical Object from Noisy Vibrational Response Measurements

The investigation of the vibrational response of a cylindrical object in a noisy environment (a pipe in air) to impact excitations provided by a cam-driven, hammer-like surface, randomly excited by an electric motor is of high interest—especially when potential anomalies can occur. This project encompasses all of the components from modeling to validation to controlled testing and signal processing in order develop a real-time system capable of on-board performance and monitoring.

42 ENGINEERING↗
DOE OSTI2019

PERFORMANCE CHARACTERISTICS OF A VECTOR SENSOR ARRAY IN AN ENERGETIC TIDAL CHANNEL

A compact three-dimensional vector sensor array (termed the NoiseSpotter) was recently developed with the goal of characterizing and localizing sources of sound in energetic environments such as those where marine renewable energy devices are likely to be located. The three vector sensors on the NoiseSpotter are mounted on a bottom platform with each sensor suspended inside an optional flow noise removal shield. The multiple pressure and particle velocity channels on the NoiseSpotter are simultaneously sampled and stored on-board to enable coherent array processing of vector sensor array data. A series of field trials were conducted where the NoiseSpotter was deployed on a bottom platform in an 8 m deep tidal channel in Sequim Bay, Washington. Pure tones were transmitted from a drifting vessel whose distance from the bottom platform varied between 50 m and 500 m. The effect of flow noise on vector sensor array performance is quantified along with the detectability of low intensity sound in an energetic environment. Flow noise removal efficiency for each channel of every vector sensor is demonstrated using multiple metrics derived from the active and reactive intensities computed using the pressure-velocity cross-spectral density matrix. A flow noise removal shield is shown to improve the detectability of low intensity sound such as those that are expected to be emitted by marine renewable energy devices.

Raghukumar, Kaustubha↗
DOE OSTI2017

Advancements and Opportunities for On-board 700 bar Compressed Hydrogen Tanks in the Progression towards the Commercialization of Fuel Cell Vehicles

Fuel cell vehicles are entering the automotive market with significant potential to reduce harmful greenhouse emissions, facilitate energy security, and increase efficiency while providing expected driving range and fill times. One of the challenges for successful commercialization is transitioning the on-board fuel system from liquid gasoline to compressed hydrogen gas. Storing high pressurized hydrogen requires a specialized structural pressure vessel, significantly different in function from a gasoline container. In addition, the lower hydrogen energy combined with highly efficient fuel cell still requires a storage vessel that is four times the volume of a gasoline tank. In the late 1990s, the industry first developed hydrogen tanks based on traditional type 3 and 4 compressed natural gas (CNG) tanks designed for 250 bar service. As fuel cell vehicles developed along with the need for greater driving range, the OEMs increased the hydrogen storage pressure to 350 bar and then to 700 bar, which is currently the industry norm. However, the 700 bar pressure vessels continued to be manufactured using the materials and the design approach from the CNG tank technologies. In 2012 the U.S. Department of Energy, Office of Fuel Cell Technologies initiated a project to develop Enhanced Materials and Design Parameters for Reducing the Cost of Hydrogen Storage Tanks. The project took a holistic approach to improving performance by investigating: 1) the cost tradeoff of reduced composite mass at 500 bar versus the added insulation cost for cold gas operation at 200K, 2) using hybrid fiber layups to refine the tank composite design, 3) increasing the composite translation efficiency by adding nano-reinforcing particles to the resin, and 4) substituting a lower cost alternate resin in the filament winding process. This paper summarizes the effectiveness of these design modifications and considers the outlook for on-board 700 bar compressed hydrogen tank systems to achieve the commercialization goals for fuel cell vehicles.

Hydrogen storage, carbon fiber composite, compo, a↗
DOE OSTI2020

Application and Certification of Comparative Vacuum Monitoring Sensors for Structural Health Monitoring of 737 Wing Box Fittings

Multi-site fatigue damage, hidden cracks in hard-to-reach locations, disbonded joints, erosion, impact, and corrosion are among the major flaws encountered in today's extensive fleet of aging aircraft and space vehicles. The use of in-situ sensors for real-time health monitoring of aircraft structures are a viable option to overcome inspection impediments stemming from accessibility limitations, complex geometries, and the location and depth of hidden damage. Reliable, structural health monitoring systems can automatically process data, assess structural condition, and signal the need for human intervention. Prevention of unexpected flaw growth and structural failure can be improved if on-board health monitoring systems are used to continuously assess structural integrity. Such systems are able to detect incipient damage before catastrophic failures occurs. Condition-based maintenance practices could be substituted for the current time-based maintenance approach. Other advantages of on-board distributed sensor systems are that they can eliminate costly, and potentially damaging, disassembly, improve sensitivity by producing optimum placement of sensors and decrease maintenance costs by eliminating more time- consuming manual inspections. This report presents a Sandia Labs-aviation industry effort to move SHM into routine use for aircraft maintenance. This program addressed formal SHM technology validation and certification issues so that the full spectrum of concerns, including design, deployment, performance and certification were appropriately considered. The Airworthiness Assurance NDI Validation Center (AANC) at Sandia Labs, in conjunction with Boeing, Delta Air Lines, Structural Monitoring Systems Ltd., Anodyne Electronics Manufacturing Corp. and the Federal Aviation Administration (FAA) carried out a certification program to formally introduce Comparative Vacuum Monitoring (CVM) as a structural health monitoring solution to a specific aircraft wing box application. Validation tasks were designed to address the SHM equipment, the health monitoring task, the resolution required, the sensor interrogation procedures, the conditions under which the monitoring will occur, the potential inspector population, adoption of CVM into an airline maintenance program and the document revisions necessary to allow for routine use of CVM as an alternate means of performing periodic structural inspects. To carry out the validation process, knowledge of aircraft maintenance practices was coupled with an unbiased, independent evaluation. Sandia Labs designed, implemented, and analyzed the results from a focused and statistically-relevant experimental effort to quantify the reliability of the CVM system applied to the Boeing 737 Wing Box fitting application. All factors that affect SHM sensitivity were included in this program: flaw size, shape, orientation and location relative to the sensors, as well as operational and environmental variables. Statistical methods were applied to performance data to derive Probability of Detection (POD) values for CVM sensors in a manner that agrees with current nondestructive inspection (NDI) validation requirements and also is acceptable to both the aviation industry and regulatory bodies. This report presents the use of several different statistical methods, some of them adapted from NDI performance assessments and some proposed to address the unique nature of damage detection via SHM systems, and discusses how they can converge to produce a confident quantification of SHM performance An important element in developing SHM validation processes is a clear understanding of the regulatory measures needed to adopt SHM solutions along with the knowledge of the structural and maintenance characteristics that may impact the operational performance of an SHM system. This report describes the major elements of an SHM validation approach and differentiates the SHM elements from those found in NDI validation. The activities conducted in this program demonstrated the feasibility of routine SHM usage in general and CVM in particular for the application selected. They also helped establish an optimum OEM-airline-regulator process and determined how to safely adopt SHM solutions. This formal SHM validation will allow aircraft manufacturers and airlines to confidently make informed decisions about the proper utilization of CVM technology. It will also streamline the regulatory actions and formal certification measures needed to assure the safe application of SHM solutions.

42 ENGINEERING↗
DOE OSTI2017

Fast-Neutron Multiplicity Counter for the Detection of Diversion Scenarios

We demonstrated the application of a fast-neutron multiplicity counter (FNMC) to detect small variations in an assembly of uranium-oxide pins. The current version of the FNMC includes eight liquid organic scintillators (EJ-309 7.62 cm diameter x 7.62 cm) and eight crystal organic scintillators (stilbene 5.08 cm diameter x 5.08 cm) in a checkerboard assembly. We measured time-correlated fast neutrons, emitted by an assembly of 32 uranium-oxide pins, using two AmLi sources to induce fissions in the sample. Each pin is a cylinder of approximately 1 cm diameter and 10 cm length, with a mass of 75.52 g and 16.37 wt% enrichment. We removed up to 16 pins from a sample consisting of 32 pins, and determined the minimum number of pins that resulted in a statistically significant decrease of neutron coincidence counts. All the measurements were performed at the Zero Power Physics Reactor facility of Idaho National Laboratory. We found that a diversion of the four innermost pins could be detected by the system in 5 minutes. The detection of time-correlated neutrons requires their discrimination from gamma-ray events. This is an especially challenging task when measuring uranium isotopes, because of the intense gamma-ray flux generated by the radioactive decay of uranium daughters. We will describe the on-board pulse shape discrimination and post processing techniques that we applied to effectively distinguish neutrons from gamma-rays. Fast-neutron measurements have several potential advantages compared to thermal and epithermal neutron counters, the most important being a shorter die-away time and therefore reduced spurious coincidences due to accidental counts. This advantage may result in a higher sensitivity in timely detecting diversion of nuclear material from peaceful uses.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2023

Evaluation of a Wave Powered Water Pump Performance by Ocean Field Testing and WEC-Sim Modeling

This submission from AMEC (the Atlantic Marine Energy Center) includes data from an ocean field deployment of a wave powered water pump in March 2023. The wave pump is an upweller device, designed to enhance macroalgal aquaculture. The wave pump device was deployed off the coast of Isles of Shoals Appledore Island in Maine, USA. The data were collected using a custom-built DAQ module comprised of Arduino Unos. GPS time stamp accompanies the data. The data are volumetric flow rate from the wave pump, and relative motion of the device between float and spar buoys. Flow rate is measured by flow meter, and relative motion is measured by lidar. Calibration data for the lidar and flow meter sensors are included. This data set also includes synchronous Sofar Spotter buoy data from a mooring approximately 300 feet away from the wave pump mooring. Video data from the deployment are included from both on-board the device sporadically throughout the deployment, and from a webcam for a short duration of the deployment. Hydrophone data were also taken co-currently, and are available by contacting Martin Wosnik at the University of New Hampshire. The Matlab code used to process the field data is incorporated. A biological assessment is included which aided the NEPA consultation process, prior to conducting the field deployment. A WEC-Sim numerical model of the wave pump, and a re-design effort are part of this work. Code used to validate the WEC-Sim model from the field data are also included.

16 TIDAL AND WAVE POWER↗
DOE OSTI2021

Performance Evaluation of Comparative Vacuum Monitoring and Piezoelectric Sensors for Structural Health Monitoring of Rotorcraft Components

The costs associated with the increasing maintenance and surveillance needs of aging structures are rising at an unexpected rate. Multi-site fatigue damage, hidden cracks in hard-to-reach locations, disbonded joints, erosion, impact, and corrosion are among the major flaws encountered in today’s extensive fleet of aging aircraft and space vehicles. Aircraft maintenance and repairs represent about a quarter of a commercial fleet’s operating costs. The application of Structural Health Monitoring (SHM) systems using distributed sensor networks can reduce these costs by facilitating rapid and global assessments of structural integrity. The use of in-situ sensors for real-time health monitoring can overcome inspection impediments stemming from accessibility limitations, complex geometries, and the location and depth of hidden damage. Reliable, structural health monitoring systems can automatically process data, assess structural condition, and signal the need for human intervention. The ease of monitoring an entire on-board network of distributed sensors means that structural health assessments can occur more often, allowing operators to be even more vigilant with respect to flaw onset. SHM systems also allow for condition-based maintenance practices to be substituted for the current time-based or cycle-based maintenance approach thus optimizing maintenance labor. The Federal Aviation Administration has conducted a series of SHM validation and certification programs intended to comprehensively support the evolution and adoption of SHM practices into routine aircraft maintenance practices. This report presents one of those programs involving a Sandia Labs-aviation industry effort to move SHM into routine use for aircraft maintenance. The Airworthiness Assurance NDI Validation Center (AANC) at Sandia Labs, in conjunction with Sikorsky, Structural Monitoring Systems Ltd., Anodyne Electronics Manufacturing Corp., Acellent Technologies Inc., and the Federal Aviation Administration (FAA) carried out a trial validation and certification program to evaluate Comparative Vacuum Monitoring (CVM) and Piezoelectric Transducers (PZT) as a structural health monitoring solution to specific rotorcraft applications. Validation tasks were designed to address the SHM equipment, the health monitoring task, the resolution required, the sensor interrogation procedures, the conditions under which the monitoring will occur, the potential inspector population, adoption of CVM and PZT systems into rotorcraft maintenance programs and the document revisions necessary to allow for their routine use as an alternate means of performing periodic structural inspections. This program addressed formal SHM technology validation and certification issues so that the full spectrum of concerns, including design, deployment, performance and certification were appropriately considered. Sandia Labs designed, implemented, and analyzed the results from a focused and statistically relevant experimental effort to quantify the reliability of a CVM system applied to Sikorsky S-92 fuselage frame application and a PZT system applied to an S-92 main gearbox mount beam application. The applications included both local and global damage detection assessments. All factors that affect SHM sensitivity were included in this program: flaw size, shape, orientation and location relative to the sensors, as well as operational and environmental variables. Statistical methods were applied to performance data to derive Probability of Detection (POD) values for SHM sensors in a manner that agrees with current nondestructive inspection (NDI) validation requirements and is acceptable to both the aviation industry and regulatory bodies. The validation work completed in this program demonstrated the ability of both CVM and PZT SHM systems to detect cracks in rotorcraft components. It proved the ability to use final system response parameters to provide a Green Light/Red Light (“GO” – “NO GO”) decision on the presence of damage. In additional to quantifying the performance of each SHM system for the trial applications on the S-92 platform, this study also identified specific methods that can be used to optimize damage detection, guidance on deployment scenarios that can affect performance and considerations that must be made to properly apply CVM and PZT sensors. These results support the main goal of safely integrating SHM sensors into rotorcraft maintenance programs. Additional benefits from deploying rotorcraft Health and Usage Monitoring Systems (HUMS) may be realized when structural assessment data, collected by an SHM system, is also used to detect structural damage to compliment the operational environment monitoring. The use of in-situ sensors for health monitoring of rotorcraft structures can be a viable option for both flaw detection and maintenance planning activities. This formal SHM validation will allow aircraft manufacturers and airlines to confidently make informed decisions about the proper utilization of CVM and PZT technology. It will also streamline future regulatory actions and formal certification measures needed to assure the safe application of SHM solutions.

42 ENGINEERING↗
DOE OSTI2017

Using EMIS to Identify Top Opportunities for Commercial Building Efficiency

Energy Management and Information Systems (EMIS) comprise a broad family of tools and services to manage commercial building energy use. These technologies offer a mix of capabilities to store, display, and analyze energy use and system data, and in some cases, provide control. EMIS technologies enable 10–20 percent site energy savings in best practice implementations. Energy Information System (EIS) and Fault Detection and Diagnosis (FDD) systems are two key technologies in the EMIS family. Energy Information Systems are broadly defined as the web-based software, data acquisition hardware, and communication systems used to analyze and display building energy performance. At a minimum, an EIS provides daily, hourly or sub-hourly interval meter data at the whole-building level, with graphical and analytical capability. Fault Detection and Diagnosis systems automatically identify heating, ventilation, and air-conditioning (HVAC) system or equipment-level performances issues, and in some cases are able to isolate the root causes of the problem. They use computer algorithms to continuously analyze system-level operational data to detect faults and diagnose their causes. Many FDD tools integrate the trend log data from a Building Automation System (BAS) but otherwise are stand-alone software packages; other types of FDD tools are implemented as “on-board” equipment-embedded diagnostics. (This document focuses on the former.) Analysis approaches adopted in FDD technologies span a variety of techniques from rule-based methods to process history-based approaches. FDD tools automate investigations that can be conducted via manual data inspection by someone with expert knowledge, thereby expanding accessibility and breath of analysis opportunity, and also reducing complexity.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2015

Eddy current sensor for in-situ monitoring of swelling of Li-ion prismatic cells

In-situ monitoring an on-board rechargeable battery in hybrid cars can be used to ensure a long operating life of the battery and safe operation of the vehicle. Intercalations of ions in the electrode material during charge and discharge of a Lithium Ion battery cause periodic stress and strain of the electrode materials that can ultimately lead to fatigue resulting in capacity loss and potential battery failure. Currently this process is not monitored directly on the cells. This work is focused on development technologies that would quantify battery swelling and provide in-situ monitoring for onboard vehicle applications. Several rounds of tests have been performed to spatially characterize cell expansion of a 5 Ah cell with a nickel/manganese/cobalt-oxide cathode (Sanyo, Japan) used by Ford in their Fusion HEV battery pack. A collaborative team of researchers from GE and the University of Michigan has characterized the free expansion of these cells to be in the range of 100×125 microns (1% of total cell thickness) at the center point of the cell. GE proposed to use a thin eddy current (EC) coil to monitor these expansions on the cells while inside the package. The photolithography manufacturing process previously developed for EC arrays for detecting cracks in aircraft engine components was used to build test coils for gap monitoring. These sensors are thin enough to be placed safely between neighboring cells and capable of monitoring small variations in the gap between the cells. Preliminary investigations showed that these coils can be less than 100 micron thick and have sufficient sensitivity in a range from 0 to 2 mm. Laboratory tests revealed good correlation between EC and optical gap measurements in the desired range. Further technology development could lead to establishing a sensor network for a low cost solution for the in-situ monitoring of cell swelling during battery operation.

42 ENGINEERING↗
DOE OSTI2025

Initial in-orbit operation of the soft X-ray spectrometer Resolve onboard the X-ray imaging and spectroscopy mission satellite

The X-Ray Imaging and Spectroscopy Mission satellite was launched on September 6, 2023 (UT). Its Resolve instrument is a high-resolution X-ray spectrometer enabled by a microcalorimeter array thermally anchored to a 50-mK heat sink. Many sensitive, critical sub-systems comprise Resolve, including a multistage cryogenic cooling system, thin-film aperture filters, low-noise electronics, on-board signal processing, and several sources of X-rays for calibration. We summarize the initial on-orbit power-on and checkout of Resolve that commenced immediately after launch. Soon after launch, the cryocoolers were activated, and their operation was successfully established. On October 9, 2023, the first cycle of the adiabatic demagnetization refrigerator was carried out, bringing the sensors to their steady-state operational temperatures. Following this, the energy resolution at 5.9 keV was successfully measured. The energy scale of the system is highly sensitive to the thermal environment surrounding both the sensors and their analog electronics. Gain correction was performed using reference X-ray lines from onboard calibration sources. To optimize cooler frequency settings, noise spectra were collected across a range of frequencies, and the most suitable frequency pair was selected based on the in-orbit environment. During the final phase of the checkout, an attempt was made to open the gate valve, which is designed to protect the Dewar’s interior from external pressure during ground operations and launch. Unfortunately, this attempt was unsuccessful. As a result, the checkout process was temporarily paused, and a stable operational strategy was subsequently developed to enable Resolve to function effectively with the gate valve remaining closed.

X-ray micro-calorimeter↗
DOE OSTI2018

3D Measurement Simulation and Relative Pointing Error Verification of the Telescope Mount Assembly Subsystem for the Large Synoptic Survey Telescope

An engineering validation of a large optical telescope consists of executing major performing tests at the subsystem level to verify the overall engineering performance of the observatory. Thus, the relative pointing error verification of the telescope mount assembly subsystem is of special interest to guarantee the absolute pointing performance of the large synoptic survey telescope. This paper presents a new verification method for the relative pointing error assessment of the telescope mount assembly, based on laser tracker technology and several fiducial points fixed to the floor. Monte-Carlo-based simulation results show that the presented methodology is fit for purpose, even if floor movement occurs due to temperature variation during the measurement acquisition process. A further research about laser tracker technology integration into the telescope structure may suggest that such laser tracker technology could be permanently installed in the telescope in order to provide an active alignment system that aims to detect and correct possible misalignment between mirrors or to provide the required mirror positioning verification accuracy after maintenance activities. The obtained results show that two on-board laser tracker systems combined with eight measurement targets could result in measurement uncertainties that are better than 1 arcsec, which would provide a reliable built-in metrology tool for large telescopes.

47 OTHER INSTRUMENTATION↗
DOE OSTI2020

On the elastocaloric effect in CuAlBe shape memory alloys: A quantitative phase-field modeling approach

We report the reversible stress-induced phase transformation in shape memory alloys (SMAs) is a dissipative process during which heat is absorbed or released. The inherent temperature variations inside the material has an elastocaloric effect (eCE) with appealing applications in solid-state cooling technology such as compact and efficient on-board refrigeration system for eletronic devices. In this manuscript, we conduct the first study of eCE of CuAlBe SMAs utilizing phase-field modeling. For an applied stress of 500 MPa, the results for polycrystalline Cu-Al11-2Be (at. %) show a minimum adiabatic unloading temperature change of -10 K over a pseudoelastic window of 40 K. In the absence of plastic deformation, the material demonstrates good reproducibility of the eCE over a few loading–unloading cycles. The presence of plastic deformation is found to cause functional fatigue that deteriorates the cooling capacity; however, the coefficient of performance only decreases from 9.04 to 8.03, which is still a very good value. These results place CuAlBe as a frontrunner SMA for solid-state cooling compared to the expensive NiTi.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Methods for Estimating Hydrogen Fuel Tank Characteristics

The pressure vessels needed to store hydrogen for next-generation hydrogen fuel cell vehicles are expected to be a substantial portion of the total system mass, volume, and cost. Gravimetric capacity, volumetric capacity, and cost per kilogram of usable hydrogen are key performance metrics that the U.S. Department of Energy (DOE) uses to determine the viability of hydrogen fuel cell systems. Research and development related to hydrogen storage systems covers a wide range of potential operating conditions, from cryogenic temperatures to high temperatures (above ambient) and low pressure to high pressure. Researchers at PNNL have developed methods for estimating these key pressure vessel characteristics to support on-board hydrogen storage system design and performance evaluation and to support decision-making about DOE hydrogen storage system research investments. This article describes the pressure tank estimation methodology that has been used as a stand-alone calculation and has been incorporated into larger system evaluation tools. The methodology estimates the geometry, mass, and material cost of type I, type III, and type IV pressure vessels based on operating pressure and material strength at the system's operating temperature, using classical thin-wall and thick-wall pressure vessel stress calculations. The geometry, mass, and material cost requirements of the pressure vessel have significant impacts on the total system performance. For example, hydrogen storage materials that can separately achieve a very high hydrogen density can be deemed impractical for use in fuel cell vehicle hydrogen storage systems because the pressure tank containing them is too large, heavy, or expensive. This article describes the design philosophy and analytical process of the tank characteristic estimation methodology, which has been implemented in spreadsheet calculation tools and system-level analysis tools used by DOE researchers. Each of the three tank types (type I, type III, and type IV) uses a different analysis methodology with some common elements. This article also provides examples of implementing the methodology to perform parametric studies of all three pressure vessel types. The goal of this article is to present the methodology in sufficient detail so it can be implemented in other hydrogen fuel cell vehicle design and analysis tools.

42 ENGINEERING↗
DOE OSTI2023

GAHLS: an optimized graph analytics based high level synthesis framework

The urgent need for low latency, high-compute and low power on-board intelligence in autonomous systems, cyber-physical systems, robotics, edge computing, evolvable computing, and complex data science calls for determining the optimal amount and type of specialized hardware together with reconfigurability capabilities. With these goals in mind, we propose a novel comprehensive graph analytics based high level synthesis (GAHLS) framework that efficiently analyzes complex high level programs through a combined compiler-based approach and graph theoretic optimization and synthesizes them into message passing domain-specific accelerators. This GAHLS framework first constructs a compiler-assisted dependency graph (CaDG) from low level virtual machine (LLVM) intermediate representation (IR) of high level programs and converts it into a hardware friendly description representation. Next, the GAHLS framework performs a memory design space exploration while account for the identified computational properties from the CaDG and optimizing the system performance for higher bandwidth. The GAHLS framework also performs a robust optimization to identify the CaDG subgraphs with similar computational structures and aggregate them into intelligent processing clusters in order to optimize the usage of underlying hardware resources. Finally, the GAHLS framework synthesizes this compressed specialized CaDG into processing elements while optimizing the system performance and area metrics. Evaluations of the GAHLS framework on several real-life applications (e.g., deep learning, brain machine interfaces) demonstrate that it provides 14.27× performance improvements compared to state-of-the-art approaches such as LegUp 6.2.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2016

Supply Chain-Based Solution to Prevent Fuel Tax Evasion: Final Report

The primary source of funding for the United States transportation system is derived from motor fuel and other highway use taxes. Loss of revenue attributed to fuel-tax evasion has been assessed to be somewhere between 1 billion and 3 billion per year. Any solution that addresses this problem needs to include not only the tax-collection agencies and auditors, but also the carriers transporting oil products and the carriers customers. This report presents a system developed by the Oak Ridge National Laboratory (ORNL) for the Federal Highway Administration which has the potential to reduce or eliminate many fuel-tax evasion schemes. The solution balances the needs of tax-auditors and those of the fuel-hauling companies and their customers. The system has three main components. The on-board subsystem combined sensors, tracking and communication devices, and software (the on-board Evidential Reasoning System, or obERS) to detect, monitor, and geo-locate the transfer of fuel among different locations. The back office sub-system (boERS) used self-learning algorithms to determine the legitimacy of the fuel loading and offloading (important for tax auditors) and detect potential illicit operations such as fuel theft (important for carriers and their customers, and may justify the deployment costs). The third sub-system, the Fuel Distribution and Auditing System or FDAS, is a centralized database, which together with a user interface allows tax auditors to query the data submitted by the fuel-hauling companies and correlate different parameters to quickly identify any anomalies. Industry partners included Barger Transport of Weber City, Virginia (fleet); Air-Weigh, of Eugene, Oregon (and their wires and harnesses); Liquid Bulk Tank (LBT) of Omaha, Nebraska (three five-compartment trailers); and Innovative Software Engineering (ISE) of Coralville, Iowa(on-board telematics device and back-office system). ORNL conducted a pilot test with the three instrumented vehicles collecting real-world data during an eight-month period (October 2014 to June 2015). The vehicles logged a total of 375,000 miles and transported more than 7.5 million gallons of fuel. The drivers entered information on the telematics device about 77% of the time, with about 15% (10%) of the data showing at least one compartment with loading (offloading) valve activity, but not driver information entry for that compartment. Seven events (or about 0.7% of the trips) were identified by the boERS as having a missing fuel diversion number. The solution developed and tested in the pilot test had federal- and state-level tax auditors as its main audience. Nonetheless, the technology has to be adopted by the fuel carriers and therefore the solution had to address the needs of fuel-hauling companies and their customers (i.e., fuel theft and cocktailing). Sensors in the hatches allowed the obERS recognize when one of those were opened (always a suspicious activity, unless it happens at locations where maintenance is performed on the vehicle). The fuel-theft issue was addressed by a self-learning algorithm deployed on the boERS that continuously processed the data from the field to construct probability distributions of measures such as elapsed time of fuel loading and offloading by driver, vehicle, and compartment, valve actuation sequence, elapsed time between the first two valve actuations (by driver, compartment, and location), and other parameters. Probability thresholds, which can be set up by the carrier, determined how to classify the observed events. The boERS also kept track of valve sequencing at a given location and analyzed these actuations to help identify any suspicious activities. Technical and economic recommendations include: a) simplification of the driver data-entry task; b) reduction of system deployment cost; c) addition of capabilities that make the system more appealing to industry (i.e., identify and avoid fuel misdelivery); and d) incorporation of additional capabilities to the FDAS. Path to commercialization recommendations include: a) identify a company willing to further develop, test, and certify a hardened system with a price point the market will bear; b).transfer ERS to licensee; c) establish a fleet or fleets who want this technology for carrier benefits or trailer manufacturer who wants to offer it as optional technology; and d) identify a location for the deployment of FDAS.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
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↗
DOE OSTI2015

From Fundamental Understanding To Predicting New Nanomaterials For High Capacity Hydrogen/Methane Storage and Carbon Capture

On-board hydrogen/methane storage in fuel cell-powered vehicles is a major component of the national need to achieve energy independence and protect the environment. The main obstacles in hydrogen storage are slow kinetics, poor reversibility and high dehydrogenation temperatures for the chemical hydrides; and very low desorption temperatures/energies for the physisorption materials (MOF’s, porous carbons). Similarly, the current methane storage technologies are mainly based on physisorption in porous materials but the gravimetric and volumetric storage capacities are below the target values. Finally, carbon capture, a critical component of the mitigation of CO 2 emissions from industrial plants, also suffers from similar problems. The solid-absorbers such as MOFs are either not stable against real flue-gas conditions and/or do not have large enough CO 2 capture capacity to be practical and cost effective. In this project, we addressed these challenges using a unique combination of computational, synthetic and experimental methods. The main scope of our research was to achieve fundamental understanding of the chemical and structural interactions governing the storage and release of hydrogen/methane and carbon capture in a wide spectrum of candidate materials. We studied the effect of scaffolding and doping of the candidate materials on their storage and dynamics properties. We reviewed current progress, challenges and prospect in closely related fields of hydrogen/methane storage and carbon capture. For example, for physisorption based storage materials, we show that tap-densities or simply pressing MOFs into pellet forms reduce the uptake capacities by half and therefore packing MOFs is one of the most important challenges going forward. For room temperature hydrogen storage application of MOFs, we argue that MOFs are the most promising scaffold materials for Ammonia-Borane (AB) because of their unique interior active metal-centers for AB binding and well defined and ordered pores. Here the main challenge is to find a chemically stable MOF required for regeneration of the AB-spent fuel. Finally, for carbon capture application of MOFs, we investigate the performance of a number of metal–organic frameworks with particular focus on their behavior at the low pressures commonly used in swing adsorption. This comparison clearly shows that it is the process that determines which MOF is optimal rather than there being one best MOF, though MOFs that possess enhanced binding at open metal sites generally perform better than those with high surface area.

03 NATURAL GAS↗
DOE OSTI2016

An integrated model-driven method for in-treatment upper airway motion tracking using cine MRI in head and neck radiation therapy

Purpose: For the first time, MRI-guided radiation therapy systems can acquire cine images to dynamically monitor in-treatment internal organ motion. However, the complex head and neck (H&N) structures and low-contrast/resolution of on-board cine MRI images make automatic motion tracking a very challenging task. In this study, the authors proposed an integrated model-driven method to automatically track the in-treatment motion of the H&N upper airway, a complex and highly deformable region wherein internal motion often occurs in an either voluntary or involuntary manner, from cine MRI images for the analysis of H&N motion patterns. Methods: Considering the complex H&N structures and ensuring automatic and robust upper airway motion tracking, the authors firstly built a set of linked statistical shapes (including face, face-jaw, and face-jaw-palate) using principal component analysis from clinically approved contours delineated on a set of training data. The linked statistical shapes integrate explicit landmarks and implicit shape representation. Then, a hierarchical model-fitting algorithm was developed to align the linked shapes on the first image frame of a to-be-tracked cine sequence and to localize the upper airway region. Finally, a multifeature level set contour propagation scheme was performed to identify the upper airway shape change, frame-by-frame, on the entire image sequence. The multifeature fitting energy, including the information of intensity variations, edge saliency, curve geometry, and temporal shape continuity, was minimized to capture the details of moving airway boundaries. Sagittal cine MR image sequences acquired from three H&N cancer patients were utilized to demonstrate the performance of the proposed motion tracking method. Results: The tracking accuracy was validated by comparing the results to the average of two manual delineations in 50 randomly selected cine image frames from each patient. The resulting average dice similarity coefficient (93.28% ± 1.46%) and margin error (0.49 ± 0.12 mm) showed good agreement between the automatic and manual results. The comparison with three other deformable model-based segmentation methods illustrated the superior shape tracking performance of the proposed method. Large interpatient variations of swallowing frequency, swallowing duration, and upper airway cross-sectional area were observed from the testing cine image sequences. Conclusions: The proposed motion tracking method can provide accurate upper airway motion tracking results, and enable automatic and quantitative identification and analysis of in-treatment H&N upper airway motion. By integrating explicit and implicit linked-shape representations within a hierarchical model-fitting process, the proposed tracking method can process complex H&N structures and low-contrast/resolution cine MRI images. Future research will focus on the improvement of method reliability, patient motion pattern analysis for providing more information on patient-specific prediction of structure displacements, and motion effects on dosimetry for better H&N motion management in radiation therapy.

60 APPLIED LIFE SCIENCES↗