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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 OSTI2021

TriFrame Mount Structural Performance - Period A

Long-Term TriFrame Monitoring System (LTTFMS) data collected during Period A (13 days - 10/22/20 - 11/4/20). The central component of the Verdant Power Free Flow System is a three-bladed horizontal-axis turbine. The turbine is equipped with a composite rotor with three fixed-pitch blades that rotate at a slow and regular rate (approx. 32 rpm), well below normal water vessel propeller speeds and conventional hydropower turbine blade speeds. The TriFrame mount is the structural mount that holds the three Verdant Power three-bladed horizontal-axis turbines.

16 TIDAL AND WAVE POWER↗
DOE OSTI2023

Stellarator Simplification using Permanent Magnets (PM4Stell)

This Report describes the design and prototyping of an array of rare-Earth permanent magnets to form a stellarator. This effort was motivated by the hypothesis that the usage of permanent magnets, rather than electromagnetic coils with complex geometry, could reduce the cost of stellarator construction and thereby make increase the feasibility of the stellarator as a technology for a fusion-based power plant. In this project, we have developed novel methods for specifying the positions, shapes, and polarizations of the magnets in the array, and have developed designs for mounting structures and tooling for assembly. We have also performed detailed finite-element modeling to qualify the accuracy of the magnetic field produced by the magnet array as designed, and to confirm that the structure can withstand the forces between the magnets. We have also developed techniques for measuring the magnetic field produced by the array once constructed, as well as for correcting errors in the field arising from misalignments and offsets within the tolerances for mounting and fabrication. Finally, we have constructed a tabletop prototype of a section of the array to qualify the concept for assembling and mounting magnets within the array.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2023

Stellarator Simplification using Permanent Magnets (PM4Stell)

This Report describes the design and prototyping of an array of rare-Earth permanent magnets to form a stellarator. This effort was motivated by the hypothesis that the usage of permanent magnets, rather than electromagnetic coils with complex geometry, could reduce the cost of stellarator construction and thereby make increase the feasibility of the stellarator as a technology for a fusion-based power plant. In this project, we have developed novel methods for specifying the positions, shapes, and polarizations of the magnets in the array, and have developed designs for mounting structures and tooling for assembly. We have also performed detailed finite-element modeling to qualify the accuracy of the magnetic field produced by the magnet array as designed, and to confirm that the structure can withstand the forces between the magnets. We have also developed techniques for measuring the magnetic field produced by the array once constructed, as well as for correcting errors in the field arising from misalignments and offsets within the tolerances for mounting and fabrication. Finally, we have constructed a tabletop prototype of a section of the array to qualify the concept for assembling and mounting magnets within the array.

47 OTHER INSTRUMENTATION↗
DOE OSTI2024

Close roof-mounted system temperature estimation for compliance to IEC TS 63126

When photovoltaic (PV) modules are installed on rooftops, the module temperature depends primarily on the geographic location and the mounting configuration. If the mounting structure does not provide sufficient airflow in a hot environment, the 98th percentile temperature will exceed 70°C, which according to IEC TS 63126 ED. 1, requires higher levels of thermal stability testing. However, there is no clear way to determine the temperature level needed for a particular location and system design. Here, in this work, we identify a relationship between the module standoff to the rooftop and the module temperature and propose methods to describe a minimum standoff for typical PV modules in a simple mounting configuration installed in a given location. For more complex system designs, we show how to determine an equivalent “effective standoff” that can be applied to generic calculations. Lastly, we show measurements and calculations from several systems to demonstrate how this method could work.

14 SOLAR ENERGY↗
DOE OSTI2021

Spatio-Temporal Modeling of Field Surveyed Backsheet Degradation

Assessing photovoltaic module backsheet durability is critical to increasing module lifetime. Lab based accelerating testing has recently failed to predict large scale failures of widely adopted polymeric materials. Field surveyed data is critical to assess the performance of component lifetime. Using a documented field survey protocol, 13 field surveys where conducted. Each measurement is encoded with it's spatial location in respect to the other modules. By combining field survey data on degradation predictors with real time satellite weather data, data-driven predictive models of backsheet degradation were trained. LOESS models were constructed to investigate the spatial dependence of measurements. It was found that micro-climatic effects like tree-lines, ground surface changes, and elevation changes effected the magnitude and variance of the measurements. A GAM model was created to predict the value of degradation based on measured predictors. The model includes variables on the climate of the system and the location of each measurement in the PV mounting structure. The model performed well with an adj.R 2 of 0.95 for yellowness index prediction. The model was cross-validated using k-folds.

backsheet↗
DOE OSTI2022

Spatiotemporal Modeling of Real World Backsheets Field Survey Data: Hierarchical (Multilevel) Generalized Additive Models

Assessing photovoltaic module backsheet durability is critical to increasing module lifetime. Laboratory-based accelerating testing has recently failed to predict large scale failures of widely adopted polymeric materials. Additionally, there is a growing concern on characterizing the non-uniformity of field exposure. Therefore, data from field surveys are critical to assess the performance of component lifetimes. Using a documented field survey protocol, 19 field surveys were conducted. The focus of this survey strategy is to investigate spatial continuity in degradation modes. By combining field survey data with real-time satellite weather data, stressor / response models have been trained. Generalized additive Models (GAM) model was created to predict the value of degradation based on measured predictors. Two different GAM constructions were testing using different implementations of basis splines. The model includes variables on the environmental stressors of the system and the location of each measurement in the PV mounting structure. The incorporation of hierarchical structure into the models allowed for material specific degradation rates, while maintaining the assumption of a global trend. The model performed well with an adjusted R2 of 0.975 for yellowness index prediction.

backsheet↗
DOE OSTI2022

Solar Photovoltaics: Supply Chain Deep Dive Assessment

This is one of a series of reports and deep dive assessments produced in response to Executive Order 14017 “America’s Supply Chains,” which directs the Secretary of Energy to submit a report on supply chains for the energy sector industrial base. The Executive Order is helping the federal government to build more secure and diverse U.S. supply chains, including energy supply chains. Over the past decade, solar power has gone from an emerging, niche technology to a mature energy industry. By 2035, solar power could supply 40% or more of U.S. electricity demand, dramatically accelerating the decarbonization of buildings, transportation, and industry; and, if current technology trends continue, it could do so without increasing the price of electricity. The rapid expansion of solar energy has the potential to yield broad benefits in the form of economic activity and workforce development. The solar industry already employs roughly 230,000 people in the United States, at an average wage that is higher than the national average for most comparable positions. By decarbonizing the electricity sector by 2035, the U.S. solar industry could employ 500,000–1,500,000 people by 2030. The components that are assembled to install a photovoltaic power system are produced by a global supply chain. Photovoltaic (PV) modules (also called panels) are made of cells that use a variety of technologies. There are two leading types of solar modules used in the United States, with crystalline silicon (c-Si) modules representing 84% of the market and cadmium telluride (CdTe) modules representing 16% of the market. Modules of either type require mounting structures to provide mechanical support (racking), which may be configured to follow the sun (tracking). The output of any PV module is direct current (dc), which is almost always converted to alternating current (ac) by an inverter.

14 SOLAR ENERGY↗
DOE OSTI2025

Q1-2024 Solar Cost Benchmarks

Each year, the U.S. Department of Energy’s (DOE) Solar Energy Technologies Office (SETO) and its national laboratory partners develop cost benchmarks for U.S. solar photovoltaic (PV) systems. These benchmarks track progress toward reducing solar costs and guide R&D priorities. Unlike typical studies that report only $/W, SETO uses intrinsic units (e.g., $/m² for mounting structures) to better capture how technology improvements such as module efficiency would impact system costs. This allows flexible modeling where inputs can vary significantly to assess cost sensitivity. Costs are reported in two ways: Minimum Sustainable Price (MSP): Long term, financially viable price under stable market conditions. Modeled Market Price (MMP): Actual market price, influenced by short term distortions such as tariffs or subsidies. Three national labs collect cost data from industry stakeholders, ensuring no duplication in outreach to stakeholders. Data reflects real transactions (primarily from Q1) and is weighted based on the number of sources per cost element. The PV System Cost Model (PVSCM) divides total installed system cost into eight categories: 1. Module (PV) 2. Inverter 3. Energy Storage System (ESS) 4. Structural BOS (SBOS) 5. Electrical BOS (EBOS) 6. Fieldwork 7. Office work 8. Other (developer/EPC costs) The first five are hardware costs, while the last three are soft costs. Each category includes fixed and variable cost components, where “size” depends on context (e.g., manufacturing capacity for modules vs. system capacity for installation costs). Variable costs are expressed using appropriate intrinsic units. The model reflects the owner’s upfront overnight capital cost, excluding tax credits. Tariffs and subsidies are treated as temporary market distortions affecting MMP but not MSP. PVSCM is implemented in Excel, where cost elements are aggregated into total system cost. Additional sheets handle unit conversions and operation & maintenance (O&M), with O&M costs levelized over the system’s lifetime.

14 SOLAR ENERGY↗
DOE OSTI2022

Spatiotemporal Modeling of Real World Backsheets Field Survey Data: Hierarchical (Multilevel) Generalized Additive Models: Preprint

Assessing photovoltaic module backsheet durability is critical to increasing module lifetime. Lab based accelerating testing has recently failed to predict large scale failures of widely adopted polymeric materials. Field surveyed data is critical to assess the performance of component lifetime. Using a documented field survey protocol, 13 field surveys where conducted. Each measurement is encoded with it's spatial location in respect to the other modules. By combining field survey data on degradation predictors with real time satellite weather data, data-driven predictive models of backsheet degradation were trained. LOESS models were constructed to investigate the spatial dependence of measurements. It was found that micro-climatic effects like treelines, ground surface changes, and elevation changes effected the magnitude and variance of the measurements. A GAM model was created to predict the value of degradation based on measured predictors. The model includes variables on the climate of the system and the location of each measurement in the PV mounting structure. The model performed well with an adj:R2 of 0:95 for yellowness index prediction. The model was cross-validated using k-folds.

backsheet↗
DOE OSTI2023

Close Roof Mounted System Temperature Estimation for Compliance to IEC TS 63126

When photovoltaic modules are installed on rooftops the temperature is dependent on both the geographic location and the mounting configuration. If the mounting structure does not provide sufficient air flow in a hot environment, the 98th percential temperature will exceed 70 degrees C which according to IEC TS 63126 requires higher levels of thermal stability testing. However, a simple there is not a clear way to determe which temperature level is needed for a particular location and system design. In this work we identify a relationship between the gap between the rooftop and a module and propose methods to describe minimum gaps for a given location. Because system designs vary in more ways than just the gap, we show how to determine an effective gap which can be simply applied to generic calculations. Lastly, we show measurements and calculations from several systems to demonstrate how this method could work.

IEC 63126↗
DOE OSTI2021

Peripheral end face attachment of exposed copper layers of a first printed circuit board to the surface of a second printed circuit board by surface mount assembly

A printed circuit board (PCB) structure and mounting assembly for joining two PCBs. A first PCB has a top and bottom surface faces and a peripheral end face separating the top and bottom surface. The first PCB has one or more conductive wire ends exposed at a surface of the peripheral end face; the exposed conductive wire ends forming multiple separate electrical contacts across the thickness and length of the PEF surface. A second PCB has a top surface face and one or more conductive pads exposed at the top surface at locations corresponding to locations of the multiple electrical contacts. A surface mount solder material is disposed on one or more exposed conductive pads for electrically connecting with corresponding the multiple electrical contacts. The disposed solder material stably joins the PEF surface of the first PCB to the top surface of the second PCB in a relative perpendicular orientation.

Takken, Todd E.↗
DOE OSTI2025

Flat TBPS Integration Testing for the CMS Outer Tracker Upgrade

The upcoming High-Luminosity (HL) LHC will significantly increase luminosity, introducing more demanding operating conditions for the CMS detector. To meet these challenges, CMS is undergoing major upgrades, including a complete replacement of its tracking detector. This poster presents recent integration testing efforts conducted at Fermilab on the Flat Tracker Barrel with pixel-strip (PS) modules integration test stand, a subcomponent of the outer tracker located in the central barrel region. In this region, PS modules are mounted on structures that provide mechanical support and cooling, called planks. The testing focuses on validating the integrated system’s thermal and electrical performance. Results from these tests will be discussed, highlighting their importance for ensuring reliable tracker operation in the HL-LHC era.

Salazar Segovia, Itzelli [UC, Davis]↗
DOE OSTI2023

Mount pad

According to one implementation a mount pad is provided that includes a plurality of arcuate flexure members disposed between and connected to top and bottom plates. According to some implementations a majority or all of the arcuate flexure members have a semi-circular cross-section and are arranged to form a plurality of radially spaced-apart concentric rings. Concave surfaces of the arcuate flexure members face radially inward toward a center of the concentric rings. Circumferential adjacent arcuate flexure members in each of the concentric rings are circumferentially spaced apart from one another so that a gap exists between them. According to some implementations the mount pad further includes a coupling unit prolonging from one of the top and bottom plates, the coupling unit facilitating a connection of the mount pad to a support structure. According to some implementations the mount pad is a monolithic structure. According to some implementations the monolithic structure is made using an additive manufacturing method.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Measurement of Magnetic Field using Doppler-Free Saturation Spectroscopy (DFSS) in C-2W FRC Plasma

The Cooperative Research and Development Agreement (CRADA) between Oak Ridge National Laboratory (ORNL) and TAE Technologies (TAE) focused on implementing an existing mobile Doppler-free saturation spectroscopy (DFSS) diagnostic to determine the direction of the equilibrium magnetic field within TAE’s C-2W field-reversed configuration (FRC) fusion device. Non-perturbative measurements of magnetic fields in the core of FRCs can provide critical information needed to constrain equilibrium models and for the continued advancement of the fusion research program at TAE. DFSS is a well-established, laser-based absorption spectroscopy technique used to suppress inhomogeneous (Doppler) broadening and reveal the Zeeman fine structure of the target emission lines. The collaboration involved the use of ORNL’s recently constructed mobile DFSS diagnostic. The DFSS diagnostic was shipped and installed on C- 2W in February 2023. TAE’s expertise was used to design and construct the mechanic support structures required to mount the optical hardware on C-2W. Additionally TAE provide critical input to minimize the noise imposed on the DFSS signal by vibrations of the mechanic support structure during operations. DFSS data was obtained for over 500 C-2W shots and will continue until the expiration of this CRADA on September 30 th 2023. Over the course of this work, significant progress was made to maximize the signal to noise (SNR) ratio. Analysis of recently acquired data is on-going, however, initial indications are highly suggestive that a DFSS signal above background has been successfully acquired in C-2W.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2021

Load-decoupling attachment system

A load-decoupling attachment system is configured to secure a component to a primary structure. The load-decoupling system includes a fore end coupling bracket that is configured to attach to a fore end of the component. A first tie rod is coupled to the fore end coupling bracket. The first tie rod is configured to couple to a first portion of the primary structure. A second tie rod is coupled to the fore end coupling bracket. The second tie rod configured to couple to a second portion of the primary structure. A universal joint mount assembly is configured to couple to an aft end of the component and a third portion of the primary structure.

Weathers, Jeffrey W.↗
DOE OSTI2022

Influence on Structural Loading of a Wave Energy Converter by Controlling Variable-Geometry Components and the Power Take-Off: Preprint

Oceans are a harsh environment and can impose significant loads on deployed structures. Deployment of wave energy converters (WECs) faces a design challenge with apparently contradictory goals. A WEC should be designed to maximize the energy absorbed while ensuring the operating wave condition does not exceed the failure limits of the device itself. Therefore, the loads endured by the support structure are a design constraint for the system. Adaptability to different sea states is, therefore, highly desirable. This work uses a WEC-Sim model of a Variable Geometry Oscillating Wave Energy Converter (VGOSWEC) mounted on a support structure simulated under different wave scenarios. A VGOSWEC resembles a paddle pitching about a fixed hinge perpendicular to the incoming waves-fronts. Therefore, the hinge experiences loads perpendicular to its axis as it maintains its position. The geometry of the VGOSWEC was varied by opening a series of controllable flaps on the pitching paddle when the structure experiences threshold loads. Since opening the flaps lets the waves transmit through the paddle, it is hypothesized that opening the flaps should result in load shedding at the base of the support structure. This load shedding is achieved by reducing the moments about the hinge axis. This work compares the hydrodynamic coefficients, natural periods, and Response Amplitude Operators (RAOs) from completely closed to completely open configurations of the controllable flaps. These comparisons quantify the effects of letting the waves transmit through the VGOSWEC. This work shows that the completely open configuration can reduce the pitch and surge loads on the base of the support structure by as much as 80%. It was observed that at the paddle's resonance frequency, the loads on the structure increased substantially. This increase in loads can be mitigated by a rotational Power Take-off (PTO) damping about the hinge axis. Changing the rotational PTO damping was identified as an additional design parameter that can be used to control the loads experienced by the WEC's support structure.

fixed and floating structures↗
DOE OSTI2022

Influence on Structural Loading of a Wave Energy Converter by Controlling Variable-Geometry Components and the Power Take-Off

Oceans are harsh environments and can impose significant loads on deployed structures. The deployment of wave energy converters (WECs) faces a design challenge with apparently contradictory goals. A WEC should be designed to maximize the energy absorbed while ensuring the operating wave condition does not exceed the failure limits of the device itself. Therefore, the loads endured by the support structure are a design constraint for the system. Adaptability to different sea states is, therefore, highly desirable. This work uses a WEC-Sim model of a variable-geometry oscillating wave energy converter (VGOSWEC) mounted on a support structure simulated under different wave scenarios. A VGOSWEC resembles a paddle pitching about a fixed hinge perpendicular to the incoming wave fronts. Therefore, the hinge experiences loads perpendicular to its axis as it maintains its position. The geometry of the VGOSWEC is varied by opening a series of controllable flaps on the pitching paddle when the structure experiences threshold loads. Because opening the flaps lets the waves transmit through the paddle, it is hypothesized that opening the flaps should result in load shedding at the base of the support structure. The load shedding is achieved by reducing the moments about the hinge axis. This work compares the hydrodynamic coefficients, natural periods, and response amplitude operators from completely closed to completely open configurations of the controllable flaps. The comparisons quantify the effects of letting the waves transmit through the VGOSWEC. This work shows that the completely open configuration can reduce the pitch and surge loads on the base of the support structure by as much as 80%. It was observed that at the paddle's resonance frequency, the loads on the structure increased substantially. This increase in loads can be mitigated by a rotational power take-off damping about the hinge axis. Changing the rotational power take-off damping was identified as an additional design parameter that can be used to control the loads experienced by the WEC's support structure.

fixed and floating structures↗