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At least 19 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

On the use of Graphs for Test Sequence Selection

This report demonstrates that applying graph theory techniques provides a way to obtain sufficient statistics in finding errors when testing complex state machines. It discusses how to define the tests, then demonstrates how to automatically generate test suites that diversify test cases, subject to constraints. If included within a continuous integration approach, these constructs provide an unbiased means to systematically check for errors within the latest controller software release.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2026

Lessons from the IEC Durability of Adhesion Accelerated Test Sequence

The IEC 62788-1-1 and IEC 63209-2 standards use aging sequences for durability of adhesion in photovoltaic (PV) modules, which may be evaluated using the single cantilever beam (SCB) test. Because the encapsulant forms critical interfaces with the front glass and solar cells, degradation at those interfaces under ultraviolet (UV) exposure, elevated temperature, and humidity can lead to interfacial delamination - compromising the long-term reliability. In this work, adhesion durability of UV-transmitting poly(ethylene-co-vinyl acetate) (EVA) encapsulant to glass and to silicon solar cells is evaluated after sequenced UV and damp heat aging (85C/85%RH). Laminates were prepared using StarPhire solar front glass with thin glass or PERC cells, and two EVA formulations with different concentrations of siloxane coupling agent. Adhesion was quantified by measuring critical debond energy using the SCB method. Both formulations exhibit similar qualitative trends, while different adhesion is observed at the periphery despite the use of low-shrink manufacturing. The results show that while glass/EVA adhesion remains stable or increases after UV exposure and shows only moderate changes after damp heat, the EVA/cell interface exhibits an irreversible loss of adhesion following UV and then damp heat exposure. Although glass/EVA interfaces generally exhibit lower debond energies, the EVA/cell interface is significantly more vulnerable to UV-driven degradation, identifying it as the dominant reliability risk location through early- and intermediate-module life. These results demonstrate that accelerated aging sequences can expose large, interface-specific losses in adhesion durability and underscore the importance of interface engineering for long-term PV module reliability.

14 SOLAR ENERGY↗
DOE OSTI2022

UAE6 - Wind Tunnel Tests Data - UAE6 - Sequence 4 - Raw Data

Sequence 4: Static Pressure Calibration (P) This test sequence used a downwind, teetered turbine with a 3.4° cone angle. The wind speed ranged from 5 m/s to 25 m/s. Yaw angles of 0° to 30° were achieved. The blade tip pitch was 3°. The rotor rotated at 72 RPM. Blade and probe pressure measurements were collected. A static pitot probe was installed on a boom 2.3 m upwind of the nacelle at hub height and connected to the reference side of the Mensor digital differential pressure transducer through the pneumatic rotary coupling. This provided the reference pressure for all blade-mounted pressure transducers, as opposed to the NASA atmospheric pressure reference that was used for all other test sequences. This simulates the pressure system connections used in field measurements where the static pressure was unknown.

17 WIND ENERGY↗
DOE OSTI2021

Improving solar panel durability through novel panel designs and advanced manufacturing equipment

Work in the project was spread across 4 main themes:1) Improved Understanding of Why Cracks Form and Cause Degradation in Solar Cells: We developed a finite element model which correlated well with experimental determined deflection vs load profiles and which predicted stress profiles vs load level and temperature. These profiles helped to guide brace designs and showed the high stress levels seen in the silicon near the interconnect wire locations as the temperature is cooled below -30C, likely forming "invisible" microcracks. Experiments showed how for polymer backsheet modules, a brief exposure to such low temperatures made modules extremely sensitive to propagation of these microcracks at relatively low load levels, and how thicker and softer encapsulant helped to reduce this crack sensitivity. We showed for some modules that most cracks that are seen under loading had their origin at short, hard to see, V-cracks from soldering damage, and how the shunting from cells with high densities of cracks reduces energy delivery more than Pmax. 2) Improved Durability Testing Methods With Respect to Cracked Cells: We lobbied the PV community throughout the project that IEC 61215 was insufficient to probe the sensitivity of module Pmax degradation due to cracks in that in did not have a test leg that included a crack creation step (static loading) followed by a crack opening step (cyclic loading and/or thermal cycling). We published extensively on how pre- existing cracks opened up with cyclic loading. The new IEC TS 63209-1 ED1 test sequence now include our recommendations, and this should lead to improved module designs and reduced risk for investors. We also published recommendations for a new "Cold Climate Test" sequence to probe the sensitivity of modules to degradation from short microcracks formed when modules see temperatures below -30C followed by front side loading. We participated in several USTAG meetings related to cracked cells, EL testing, and mechanical load testing and provided input to the group to improve new standards under consideration. We also showed how the act of performing an EL test can affect the test results due to heating from the injected current. 3) New Module Designs and Related Manufacturing Methods & Equipment: We demonstrated reduced crack sensitivity on encapsulated cell coupons the benefits of building protective compressive stress into the cells by laminating them in a bent state and then allowing the coupon to flatten out after lamination. Our attempts to scale this to the module level with a more manufacturable sequence did not demonstrate the same positive effects, but we hope that others will follow up with other variations on this bent lamination or bent cooling concept to make more durable modules. 4) New Module Mounting Designs: We explored a range of bracing concepts which pressed on the backsheet to slightly bow the glass outward and place cells in a state of protective compressive stress and to reduce the deflection under front side loads. These successfully reduced cell cracking and crack opening, but high static loads permanently deformed cost-effective braces, after which they provided little benefit. We settled on an elegant & effective solution – the RailPad, where lightweight bracing elements are placed between the mounting rail(s) and the backsheet, and the existing strength of the rails is used to prevent module deflection under load. New construction and retrofit designs were made, and test sites were implemented in FL and MA. We applied for RailPad patent protection.

14 SOLAR ENERGY↗
DOE OSTI2022

UAE6 - Wind Tunnel Tests Data - UAE6 - Sequence G - Raw Data

Sequence G: Upwind Teetered (F) Test sequence G used an upwind, teetered turbine with a 0° cone angle. The wind speeds ranged from 5 m/s to 25 m/s. Yaw angles of ±180° were achieved at low wind speeds and angles of ±10° were achieved at the high wind speeds. The blade tip pitch was 3°. The rotor rotated at 72 RPM. Blade and probe pressure measurements were collected.

17 WIND ENERGY↗
DOE OSTI2022

UAE6 - Wind Tunnel Tests Data - UAE6 - Sequence M - Raw Data

Sequence M: Transition Fixed (P) Test sequence M used an upwind, rigid turbine with a 0° cone angle. The wind speed ranged from 5 m/s to 15 m/s. Yaw angles ranged from 0° to 90°. The blade tip pitch was 3°. The rotor rotated at 72 RPM. Blade pressure measurements were collected. The five-hole probes were removed and the plugs were installed. Plastic tape 0.03-mm-thick was used to smooth the interface between the plugs and the blade. The teeter dampers were replaced with rigid links, and these two channels were flagged as not applicable by setting the measured values in the data file to –99999.99 Nm. The teeter link load cell was pre-tensioned to 40,000 N. During post-processing, the probe channels were set to read –99999.99. Zigzag tape was installed near the leading edge of the instrumented blade on both the upper and lower surfaces as described in Appendix K. In addition to the standard 30-second campaigns, yaw sweeps were done at 7 m/s and 10 m/s. These 90-second campaigns were collected while the yaw drive rotated the turbine 90° at a rate of 1°/s. The file names for these campaigns use the letter designation, followed by two digits for wind speed, followed by YSU, followed by 00.

17 WIND ENERGY↗
DOE OSTI2025

Fuel Property Effects on Stochastic Preignition Events During Engine Load Transitions

Stochastic preignition (SPI) is an abnormal combustion phenomenon that can cause catastrophic engine damage. There have been several proposed mechanisms of SPI, where a uniform source is still not certain, however, SPI tendencies have been shown to be influenced by engine operating conditions, oil composition, engine age, and fuel chemical and physical properties. Laboratory research and testing for SPI propensity is challenging given the stochastic nature of events, as well as the potential for significant degradation of the engine platform and measuring equipment over time. Thus, SPI specific experiments are generally conducted under either sustained or cyclic patterning of steady-state operating conditions to avoid the influence of transient engine boundary conditions on test parameters of interest (e.g. oil additive package, fuel properties, engine speed/load, etc.). In this work a cyclically varying SPI test sequence involves a 5 min engine warmup period at a low engine load of around 4 bar gross indicated mean effective pressure (IMEPg), followed by a transition to high load (~20 bar IMEPg) at a constant 2000 rev/min engine speed for a total of 25 min. This individual test sequence load schedule is then sequentially repeated 10 times to generate significant statistical data for analysis. This work examines the influence of fuel chemical and physical properties on SPI tendency during the unsteady portion of the 10-cycle sequence (the first 5 min of the high load operation in each sequence of the loading cycle) which has been discarded from previous analyses due to the uncertainty in engine operating and thermal boundary conditions. Results from this analysis suggest an increasing trend in the ratio of SPI events during the unsteady test period relative to the steady test period with increasing fuel Reid Vapor Pressure (RVP), implying differences in uncontrolled ignition source terms, possibly from, fuel wall interactions and retention during the load transition phase of the test.

Splitter, Derek [ORNL] (ORCID:0000000174044047)↗
DOE OSTI2022

UAE6 - Wind Tunnel Tests Data - UAE6 - Sequence E - Raw Data

Sequence E: Yaw Releases (P) This test sequence used a downwind, rigid turbine with a 3.4° cone angle. The wind speeds ranged from 7 m/s to 17 m/s. Initial yaw angles of ±90° were achieved. The blade tip pitch was 3°. The rotor rotated at 72 RPM. Blade and probe pressure measurements were collected. The teeter dampers were replaced with rigid links, and these two channels were flagged as not applicable by setting the measured values in the data file to –99999.99 Nm. The teeter link load cell was pre-tensioned to 40,000 N. The turbine was positioned at each specified yaw angle. A 30- second data set was collected with the yaw brake engaged. These points used a letter for the last digit beginning with A and proceeding through the alphabet as repeat points were needed. These points were plotted and compared to ascertain the functionality of the instrumentation. The files ending in numbers beginning with 0 and increasing with each repetition represent yaw release points. Once the fixed-position yaw test was complete, the yaw drive was engaged to hold the turbine. The yaw brake was released, and the yaw drive was disabled allowing the turbine to yaw freely. The yaw drive was disabled about 5 seconds into the campaign, and the turbine was allowed to yaw freely for the rest of the 30-second duration. When the yaw drive is disabled, no torque is applied to the motor, and the inertia and yawing force of the nacelle and rotor overcomes the friction and inertia of the yaw gear and motor. The yaw releases were repeated five times at each condition. Four additional campaigns were collected to determine the turbine’s natural yaw error by releasing the brake at 0° yaw error. These file names use the E designation, followed by two digits for wind speed, followed by XXXX, followed by the repetition digit.

17 WIND ENERGY↗
DOE OSTI2022

UAE6 - Wind Tunnel Tests Data - UAE6 - Sequence W - Raw Data

Sequence W: Extended Blade (F) This test sequence used an upwind, rigid turbine with a 0° cone angle. The wind speed ranged from 5 m/s to 21 m/s, and the yaw angle was held at 0°. The blade pitch angle was 3°. The rotor rotated at 72 RPM. Blade pressure measurements were collected. The five-hole probes were removed and the plugs were installed. Plastic tape 0.03-mm thick was used to smooth the interface between the plugs and the blade. The teeter dampers were replaced with rigid links, and these two channels were flagged as not applicable by setting the measured values in the data file to –99999.99 Nm. The teeter link load cell was pretensioned to 40,000 N. During postprocessing, the probe channels were set to read –99999.99. The standard tip blocks were replaced with blade extensions that created a 5.532-m radius rotor as shown in Appendix A. The extension used the S809 airfoil throughout, and the linear taper of the blade continued along the extension. Note that the blade radius was not changed during post-processing so the pressure tap locations are at the same radial location, but the reference to 30% represents 30% of 5.029 m, not 5.532 m. Throughout this report, references to the blade span are made for the 5.029-m radius, not the 5.532-m radius.

17 WIND ENERGY↗
DOE OSTI2022

UAE6 - Wind Tunnel Tests Data - UAE6 - Sequence 7 - Raw Data

Sequence 7: Shroud Operating (P) This test sequence used a downwind, rigid turbine with a 3.4° cone angle. The wind speed ranged from 5 m/s to 25 m/s. Turntable angles from 0° to 30° were achieved, but the yaw error angle was maintained at 0° by adjusting the nacelle yaw. The blade tip pitch was 3°. The rotor rotated at 72 RPM. Blade and probe pressure measurements were collected. The teeter dampers were replaced with rigid links, and these two channels were flagged as not applicable by setting the measured values in the data file to –99999.99 Nm. The teeter link load cell was pre-tensioned to 40,000 N. An airfoil-shaped aluminum shroud was placed on the tower below the 34% span five-hole probe. It extended below the 91% span five-hole probe. The turntable angle was adjusted to position the shroud at various angles relative to the flow, but the turbine yaw error angle was maintained at 0°. Two additional points were collected where the turntable angle was 0°, and the turbine yaw angle was 20° (71000200) or -20° (710M0200).

17 WIND ENERGY↗
DOE OSTI2022

UAE6 - Wind Tunnel Tests Data - UAE6 - Sequence V - Raw Data

Sequence V: Tip Plate (F) This test sequence used an upwind, rigid turbine with a 0° cone angle. The wind speed ranged from 5 m/s to 25 m/s, and the yaw angle was held at 0°. The blade pitch angle was 3°. The rotor rotated at 72 RPM. Blade pressure measurements were collected. The five-hole probes were removed and the plugs were installed. Plastic tape 0.03-mm-thick was used to smooth the interface between the plugs and the blade. The teeter dampers were replaced with rigid links, and these two channels were flagged as not applicable by setting the measured values in the data file to –99999.99 Nm. The teeter link load cell was pre-tensioned to 40,000 N. During post-processing, the probe channels were set to read -99999.99. The standard tip blocks were replaced with a tip plate to simulate the effect of an undeployed tip-mounted aerodynamic brake as shown in Appendix A. Note that the blade radius was not changed during post-processing so the pressure tap locations are at the same radial location, but the reference to 30% represents 30% of 5.029 m, not 4.943 m. Throughout this report, references to the blade span are made for the 5.029- m radius, not the 4.943-m radius.

17 WIND ENERGY↗
DOE OSTI2022

UAE6 - Wind Tunnel Tests Data - UAE6 - Sequence X - Raw Data

Sequence X: Elevated RPM (F) This test sequence used an upwind, rigid turbine with a 0° cone angle. The wind speed ranged from 5 m/s to 12 m/s, and yaw angles of ±30° were obtained. The blade pitch angle was 3°. The rotor rotated at 90 RPM. Blade pressure measurements were collected. The five-hole probes were removed and the plugs were installed. Plastic tape 0.03-mm-thick was used to smooth the interface between the plugs and the blade. The teeter dampers were replaced with rigid links, and these two channels were flagged as not applicable by setting the measured values in the data file to –99999.99 Nm. The teeter link load cell was pre-tensioned to 40,000 N. During post-processing, the probe channels were set to read -99999.99. As described in Appendix F, the hydrostatic correction derived for operation at 72 RPM was applied to these data.

17 WIND ENERGY↗
DOE OSTI2022

UAE6 - Wind Tunnel Tests Data - UAE6 - Sequence F - Raw Data

Sequence F: Downwind High Cone (F) This test sequence used a downwind, rigid turbine with an 18° cone angle. The wind speed ranged from 10 m/s to 20 m/s. Excessive inertial loading due to the high cone angle prevented operation at lower wind speeds. Yaw angles of ±20° were achieved. The blade tip pitch was 3°. The rotor rotated at 72 RPM. Blade and probe pressure measurements were collected. The teeter dampers were replaced with rigid links, and these two channels were flagged as not applicable by setting the measured values in the data file to –99999.99 Nm. The teeter link was replaced with a shorter bar so the load cell was not installed during this test. However, the teeter link load cell channel was flagged as not applicable by setting the measured values in the data file to -99999.99 N.

17 WIND ENERGY↗
DOE OSTI2022

UAE6 - Wind Tunnel Tests Data - UAE6 - Sequence P - Raw Data

Sequence P: Wake Flow Visualization, Upwind (P) This test sequence used an upwind, rigid turbine with a 0° cone angle. The wind speed ranged from 5 m/s to 15 m/s. Yaw angles of 0° to –60° were achieved. The blade tip pitch was 3°. The rotor rotated at 72 RPM. Blade and probe pressure measurements were collected. The teeter dampers were replaced with rigid links, and these two channels were flagged as not applicable by setting the measured values in the data file to –99999.99 Nm. The teeter link load cell was pre-tensioned to 40,000 N. The aluminum blade tip designed to contain a smoke generator was installed, and counterweights were installed in the non-instrumented blade tip to compensate. The turbine was positioned at the appropriate yaw angle, and the smoke generator was ignited remotely. The campaign duration was 3 minutes for all tests except P1000000, which was 2 minutes. The file name convention was the standard format except for P10000A0, which indicated a 3° pitch angle. File P1000000 used a 12° pitch angle. After these two campaigns were collected, it was determined that all subsequent data should be collected with a 3° pitch angle. Pressure data were not acquired during this sequence, so all associated data values were flagged as not applicable by setting the measured values in the data file to 0.000 Pa. Corresponding pressure data are available from Sequence H for the 3° pitch angle test points. Flow visualization data obtained from wall- and ceiling-mounted video cameras were recorded to videotape. The camera locations and calibration procedures are described in Appendix J.

17 WIND ENERGY↗
DOE OSTI2022

UAE6 - Wind Tunnel Tests Data - UAE6 - Sequence 6 - Raw Data

Sequence 6: Shroud Wake Measure (P) This test sequence used a downwind, rigid turbine with a 3.4° cone angle. The wind speeds for this sequence corresponded to subcritical [7 m/s], transitional [15 m/s], and supercritical [20 m/s] Reynolds number regimes for the circular cross-section tower. The yaw angle and blade tip pitch angles were selected to traverse the probe tip across the tower wake while keeping the probe axis approximately parallel to the tunnel centerline. The rotor was parked with the instrumented blade at 180° azimuth. Blade and probe pressure measurements were collected. An airfoil-shaped aluminum shroud was placed on the tower below the 34% span five-hole probe. It extended below the 91% span five-hole probe. The turntable angle was adjusted to position the shroud at various angles relative to the flow.

17 WIND ENERGY↗
DOE OSTI2022

UAE6 - Wind Tunnel Tests Data - UAE6 - Sequence 5 - Raw Data

Sequence 5: Sweep Wind Speed (F,P) This test sequence used an upwind, rigid turbine with a 0° cone angle. The wind speed was ramped from 5 m/s to 25 m/s by the wind tunnel operator. This was repeated with a decreasing ramp. The yaw angle was maintained at 0°. The blade tip pitch was 3° or 6°. The rotor rotated at 72 RPM. Blade pressure and probe measurements were collected for both pitch angles. The five-hole probes were removed and the plugs were installed for another 3° pitch case. Plastic tape 0.03 mm thick was used to smooth the interface between the plugs and the blade. The teeter dampers were replaced with rigid links, and these two channels were flagged as not applicable by setting the measured values in the data file to –99999.99 Nm. The teeter link load cell was pre-tensioned to 40,000 N. During post-processing, the probe channels were set to read -99999.99. The 6- minute campaigns were named using the sequence designation 5, followed by DN or UP, which indicates the wind speed ramp direction. The next four digits are 0000, and the sequence digit is at the end.

17 WIND ENERGY↗
DOE OSTI2022

UAE6 - Wind Tunnel Tests Data - UAE6 - Sequence R - Raw Data

Sequence R: Step AOA, No Probes (P) This sequence was designed to quantify the effect of the five-hole probes on the 3-D blade static angle-of-attack response in the presence of rotational influences by repeating Sequence K without five-hole probes. This test sequence used an upwind, rigid turbine with a 0° cone angle. The wind speeds ranged from 6 m/s to 20 m/s, and data were collected at yaw angles of 0° and 30°. The rotor rotated at 72 RPM. Blade pressure measurements were collected. The five-hole probes were removed and the plugs were installed. Plastic tape 0.03-mm-thick was used to smooth the interface between the plugs and the blade. The teeter dampers were replaced with rigid links, and these two channels were flagged as not applicable by setting the measured values in the data file to –99999.99 Nm. The teeter link load cell was pre-tensioned to 40,000 N. During post-processing, the probe channels were set to read –99999.99. The blade pitch angle ramped continuously at 0.18°/s over a wide range of increasing and decreasing pitch angles. A step sequence was also performed. The blade pitch was stepped 5°; the flow was allowed to stabilize; and the pitch angle was held for 5 seconds. Then the pitch angle step was repeated. Again, a wide range of pitch angles was obtained, both increasing and decreasing. The file lengths for this sequence varied from 96 seconds to 6 minutes, depending on the pitch angle range. Some short points were collected at 0° yaw and 3° pitch to ascertain the functionality of the instrumentation and repeatability over time. The file name convention used the initial letter R, followed by two digits specifying wind speed, followed by two digits for yaw angle, followed by RU, RD, or ST, followed by the repetition digit. The angle of attack motion was differentiated by RU (ramp up), RD (ramp down), and ST (step down, then step up). This sequence is related to Sequences K and L.

17 WIND ENERGY↗
DOE OSTI2022

UAE6 - Wind Tunnel Tests Data - UAE6 - Sequence B - Raw Data

Sequences B, C, and D: Downwind Baseline (F), Downwind Low Pitch (F), Downwind High Pitch (F) This test sequence used a downwind, teetered turbine with a 3.4° cone angle. The wind speed ranged from 5 m/s to 25 m/s. Yaw angles of ±180° were achieved at low wind speeds, and yaw angles of -20° to 10° were achieved for high wind speeds. The blade tip pitch was 3° for sequence B, 0° for sequence C, and 6° for sequence D. These three sequences were interleaved during testing because the pitch angle change was easily made by the turbine operator. The rotor rotated at 72 RPM. Blade and probe pressure measurements were collected.

17 WIND ENERGY↗