Impacts of Operating Hardware on Window Thermal Performance
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29 ENERGY PLANNING, POLICY, AND ECONOMY↗
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Nuclear Thermal Rocket Emulator for a Hardware-in-the-Loop Test Bed
To support NASA’s mission to use nuclear thermal rockets for future Mars missions, an instrumentation and control test bed has been built at Oak Ridge National Laboratory. The system is designed as a hardware-in-the-loop test bed for testing control elements and autonomous control algorithms for nuclear thermal propulsion rockets. The mock reactor system consists of a modular and scalable framework, using inexpensive components and open-source software. The hardware system consists of a two-phase flow loop and a mock reactor with six control drums. A single-board computer (NVIDIA Jetson) handles reactor core emulation and hosts a message queuing telemetry transport broker that allows user-deployed control algorithms to interact with the system hardware. The reactor emulator receives sensor data from the hardware and provides the simulated performance of the reactor under steady-state, transient, and fault conditions. The emulator uses a reactivity lookup table and the point kinetics equations to solve for the reactor dynamics in real time. Emulated reactor dynamics and sensor input inform the autonomous control algorithm’s decision-making in a closed-loop manner. The current system is capable of operating at 10 Hz, but faster cycle rates are an area of ongoing research. This test bed will enable NASA and other space vendors to rigorously test their autonomous control systems for NTP rockets under transient (reactor startup and shutdown), steady-state, and fault conditions to reduce development time and risk for autonomous control systems in future missions.
autonomous control↗
Assessment of Electrode Contamination Mitigation at 0.5 MA Scale
The Z Machine at Sandia National Laboratories uses current pulses with peaks up to 27 MA to drive target implosions and generate high energy density conditions of interest for stockpile stewardship programs pertinent to the NNSA program portfolio . Physical processes in the region near the Z Machine target create electrode plasmas which seed parasitic current loss that reduce the performance and output of a Z experiment. Electrode surface contaminants (hydrogen, water, hydrocarbons) are thought to be the primary constituent of electrode plasmas which contribute to loss mechanisms. The Sandia team explore d in situ heating and plasma discharge techniques by integrating requisite infrastructure into Sandia's Mykonos LTD accelerator, addressing potential impacts to accelerator operation, and reporting on the impact of these techniques on electrode plasma formation and shot performance. The in situ discharge cleaning utilizes the electrodes of the accelerator to excite an argon-oxygen plasma to sputter and chemically react contaminants from electrode surfaces. Insulating breaks are required to isolate the plasma in electrode regions where loss processes are most likely to occur. The shots on Mykonos validate that these breaks do not perturb experiment performance, reducing the uncertainty on the largest unknown about the in situ cleaning system. Preliminary observations with electrical and optical diagnostics suggest that electrode plasma formation is delayed, and overall inventory has been substantively reduced. In situ heating embeds cartridge heaters into accelerator electrodes and employs a thermal bakeout to rapidly desorb contaminants from electrode surfaces. For the first time, additively manufactured (AM) electrode assemblies were used on a low impedance accelerator to integrate cooling channels and manage thermal gradients. Challenges with poor supplier fabrication to specifications, load alignment, thermal expansion and hardware movement and warpage appears to have introduced large variability in observed loss, though, preventing strong assertions of loss reduction via in situ heating. At this time, an in situ discharge cleaning process offers the lowest risk path to reduce electrode contaminant inventories on Z, though we recommend continuing to develop both approaches. Additional engineering and testing are required to improve the implementation of both systems. .
70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
Operating Hardware Impact on the Heat Transfer Properties of Windows
Despite significant advancements in fenestration technology in the last two decades, the thermal transmittance of fenestration products is still significantly higher than that of walls. This corresponds to 60% of the total energy loss of a modern building envelope through the windows. Hence, further development and improvements of fenestration products are necessary. Increasingly stringent codes and standards for fenestration stimulate industry to work on improved solutions. Thus, it is crucial that assessment techniques are able to account for innovations accurately. The thermal effects of non-continuous hardware in window frames are currently ignored by international rating procedures. A preliminary investigation conducted by our team showed significant performance degradation in two of the three out-opening casement profiles caused by the presence of operating hardware. Frames with the structure made of vinyl and fiberglass consist of many air cavities that are penetrated by operating hardware made of highly conductive materials. In these frames, in order to have an accurate assessment, it may be required to employ three-dimensional modeling due to the convective nature of heat transfer within the cavities. However, in this study, we demonstrate that the three-dimensional (3D) effects of non-continuous hardware can be approximated accurately with simpler two-dimensional (2D) simulations. We then develop a simplified model based on weighted average capable of replacing the time- and computation-intensive 3D simulations with 2D simulations and validate it against market available frames and their corresponding hardware. Validation results show that our approximation technique results in discrepancies lower than 0.05 W/(m2K), or 3% of the total thermal transmittance. Thus, we conclude that simplified 2D simulation models may be used for predicting hardware impact in window frames with reasonable accuracy. As windows and glazing structures are becoming ever better thermally insulated, it is becoming even more important to be able to model the impact of the operating hardware on the total thermal performance in order to design the best windows possible and not let the operating hardware ruin an otherwise well-proven design, which is hence addressed in this study.
32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
Reconstructing thermal quantum quench dynamics from pure states
Simulating the nonequilibrium dynamics of thermal states is a fundamental problem across scales from high-energy to condensed-matter physics. Quantum computers may provide a way to solve this problem efficiently. Preparing a thermal state on a quantum computer is challenging, but there exist methods to circumvent this by computing a weighted sum of time-dependent matrix elements in a convenient basis. Further, while the number of basis states can be large, in this paper we show that it can be reduced by simulating only the largest density matrix elements by weight, capturing the density matrix to a specified precision. Leveraging Hamiltonian symmetries enables further reductions. This approach paves the way to more accurate thermal-state dynamics simulations on near-term quantum hardware.
75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
MO-AB-BRA-08: A Modular Multi-Source X-Ray Tube for Novel Computed Tomography Applications
Purpose: To develop and build a practical implementation of an x-ray line source for the rapidly increasing number of multi-source imaging applications in CT. Methods: An innovative x-ray tube was designed using CST Particle Studio, ANSYS, and SolidWorks. A slowly varying magnetic field is synchronized with microsecond gating of multiple thermionic electron sources. Electrostatic simulations were run to optimize the geometry of the optics and prevent electrode arcing. Magnetostatic simulations were used for beam deflection studies and solenoid design. Particle beam trajectories were explored with an emphasis on focusing, acceleration, deflection, and space charge effects. Thermal constraints were analyzed for both transient and steady-state regimes. Electromagnetic simulations informed the design of a prototype unit under construction. Results: Particle tracking simulations for a benchtop system demonstrate that three 80 keV electron beams are able to be finely controlled and laterally swept a combined distance of 15 cm over a stationary target with an oscillating magnetic field in the hundreds of gauss. The beams are pulsed according to scanning sequences developed for implementation in a mock stationary CT scanner capable of a 30 ms temporal resolution. Beam spot diameters are approximately 1 mm for 30 mA beams and the stationary target stays well within thermal limits. The relevant hardware and control circuits were developed for incorporation into a physical prototype. Conclusion: A new multi-source x-ray tube was designed in a modular form factor to push the barriers of high-speed CT and spur growth in emerging imaging applications. This technology can be used as the basis for a stationary high-speed CT scanner, a system for generating a virtual fan-beam for dose reduction, or for reducing scatter radiation in cone-beam CT utilizing a tetrahedron beam CT geometry. A 2.4 kW benchtop system is currently being built to show proof of concept for the tube. Support for this research was provided by the University of Wisconsin Madison, Office of the Vice Chancellor for Research and Graduate Education with funding from the Wisconsin Alumni Research Foundation.
60 APPLIED LIFE SCIENCES↗
CFD simulations of electric motor end ring cooling for improved thermal management
Proper thermal management of an electric motor for vehicle applications extends its operating range. One cooling approach is to impinge Automatic Transmission Fluid (ATF) onto the rotor end ring. Increased ATF coverage correlates to enhanced heat transfer. Computational Fluid Dynamics (CFD) analytical tools provide a mechanism to assess motor thermal management prior to hardware fabrication. The complexity of the fluid flow (e.g., jet atomization, interface tracking, wall impingement) and heat transfer makes these simulations challenging. Computational costs are high when solving these flows on high-speed rotating meshes. Typically, a Volume-of Fluid (VOF) technique (i.e., two-fluid system) is used to resolve ATF dynamics within this rotating framework. Suitable numerical resolution of the relevant physics for thin films under strong inertial forces at high rotor speeds is computationally expensive, further increasing the run times. In this work, a numerical study of rotor-ring cooling by ATF is presented using a patent automated Cartesian cut-cell based method coupled with Automatic Mesh Refinement (AMR). This approach automatically creates the Cartesian mesh on-the-fly and can effectively handle complex rotating geometries by adaptively refining the mesh based on local gradients in the flow field which results in better resolution of the air-ATF interface. A Single non-inertial Reference Frame (SRF) approach is used to account for the rotating geometry and to further improve the overall computational efficiency. Quasi-steady state conditions are targeted in the analysis of the results. Important physics such as ATF jet structure, velocity detail near the air-jet interface, ATF coverage/accumulation on the ring surface, and cooling capacity are presented for a low-resolution Reynolds averaged Navier-Stokes (RANS), high-resolution RANS, and high-resolution Large-Eddy Simulation (LES) models. Computations are scaled over hundreds of cores on a supercomputer to maximize turnaround time. Each numerical approach is shown to capture the general trajectory of the oil jet prior to surface impingement. The high-resolution LES simulation, however, is superior in capturing small scale details and heat transfer between the free jet and surrounding air.
42 ENGINEERING↗
Experimentally Measured Thermal Masses of Adsorption Heat Exchangers
The thermal masses of components influence the performance of many adsorption heat pump systems. However, typically when experimental adsorption systems are reported, data on thermal mass are missing or incomplete. This work provides original measurements of the thermal masses for experimental sorption heat exchanger hardware. Much of this hardware was previously reported in the literature, but without detailed thermal mass data. The data reported in this work are the first values reported in the literature to thoroughly account for all thermal masses, including heat transfer fluid. The impact of thermal mass on system performance is also discussed, with detailed calculation left for future work. The degree to which heat transfer fluid contributes to overall effective thermal mass is also discussed, with detailed calculation left for future work. This work provides a framework for future reporting of experimental thermal masses. The utilization of this framework will enrich the data available for model validation and provide a more thorough accounting of adsorption heat pumps.
30 DIRECT ENERGY CONVERSION↗
Final Report: Utilizing Alternative Fuel Ignition Properties to Improve SI and CI Engine Efficiency
Experimental and modeling studies were completed to explore leveraging physical and chemical fuel properties for improved thermal efficiency of internal combustion engines. Fundamental studies of the ignition chemistry of ethanol and iso-octane blends and constant volume spray chamber studies of gasoline and diesel sprays supported the core research effort which used several reciprocating engine platforms. Single cylinder spark ignition (SI) engine studies were carried out to characterize the impact of ethanol/gasoline, syngas (H 2 and CO)/gasoline and other oxygenate/gasoline blends on engine performance. The results of the single-cylinder engine experiments and other data from the literature were used to train a GT Power model and to develop a knock criteria based on reaction chemistry. The models were used to interpret the experimental results and project future performance. Studies were also carried out using a state of the art, direct injection (DI) turbocharged multi- cylinder engine with piezo-actuated fuel injectors to demonstrate the promising spray and spark timing strategies from single-cylinder engine studies on the multi-cylinder engine. Key outcomes and conclusions of the studies were: 1. Efficiency benefits of ethanol and gasoline fuel blends were consistent and substantial (e.g. 5-8% absolute improvement in gross indicated thermal efficiency (GITE)). 2. The best ethanol/gasoline blend (based on maximum thermal efficiency) was determined by the engine hardware and limits based on component protection (e.g. peak in-cylinder pressure or maximum turbocharger inlet temperature) – and not by knock limits. Blends with <50% ethanol delivered significant thermal efficiency gains with conventional SI hardware while maintain good safety integrity to the engine hardware. 3. Other compositions of fuel blends including syngas (H 2 and CO) and other dilution strategies provided significant efficiency gains as well (e.g. 5% absolute improvement in ITE). 4. When the combination of engine and fuel system is not knock limited, multiple fuel injection events maintain thermal efficiency while improving engine-out emissions (e.g. CO, UHC, and particulate number).
33 ADVANCED PROPULSION SYSTEMS↗
Evaluating the Effects of Transient Purge Flow on Stator-Rotor Seal Performance
Abstract As modern engine designs target higher efficiencies through increased turbine inlet temperatures, critical turbine components are at increased risk of damage from conditions exceeding material melting temperatures. In particular, improperly designed underplatform hardware components are susceptible to damage when hot main gas path flow is ingested into the stator-rotor cavity. While all turbines inherently experience transients during operation, a majority of publicly available turbine studies have been executed using steady operating conditions or inherently transient “blowdown” rigs. For this reason, routine transient events are not well understood. To address this need, the present study utilized a combined experimental and computational approach. The test article is a continuous-duration, one-stage test turbine operating with true-scale engine hardware and seal geometries at engine-representative flow conditions. The nature of the continuous-duration facility uniquely supports the direct assessment of transient events through its ability to transition between steady-state operating conditions. The effects of a transient purge flow were investigated in this study to identify general trends for transient events in a full-scale engine. Results from multiple measurement techniques in the wheelspace region show an interdependence of transient purge flow with a thermal lag of the underplatform hardware. Through experiments conducted at different coolant-to-main gas path temperature ratios, the use of pressure measurements as an indicator of fully purged behavior was introduced, and a thermally driven influence on rim seal performance was quantified. The computational results show good agreement with experimental pressure measurements and provide insight into the physical mechanisms that drive the relationship between pressure and sealing effectiveness measurements observed for the tested geometry.
Engineering↗
Material‐Driven Neuronal Oscillators and Filters via Active Reactance in CC‐NDR and VC‐NDR Electro‐Thermal Memristors
The continued scaling of artificial intelligence and telecommunications hardware is increasingly constrained by the power, bandwidth, and area limitations of transistor-based circuits. Neuromorphic processor units, analog oscillators, and active inductors and capacitors rely on complex multi-transistor architectures restricting material choices and incurring energy and footprint overhead. Here, we show that active reactance in electro-thermal memristors provides an intrinsic, material driven route to neuronal oscillator dynamics and signal processing. Using a physics-based compact modeling framework, we bridge negative differential resistance (NDR) and bias-tunable reactance, which underlies spiking dynamics in electro-thermal memristors. Memristors with negative temperature coefficients of resistance (TCR) manifest current-controlled (CC-) NDR and act as active inductors, thus generating spiking above a critical circuit capacitance; whereas memristors with positive TCR manifest voltage-controlled (VC-) NDR and active capacitance, leading to spiking above a critical inductance. By creating a compact model for La 0.7 Ca 0.3 MnO 3 as a representative VC-NDR material and comparing it with LaCoO 3 manifesting CC-NDR, we explain the physical origins of their distinct current-voltage characteristics, reactive phase shifts and consequent spiking behaviors. Finally, we demonstrate tunable filtering enabled by the active reactance of electro-thermal memristors, establishing them as a compact hardware platform for neuronal oscillator functionality and integrated filtering beyond conventional CMOS.
active reactance↗
Hardware Design of a 1.7 kV SiC MOSFET Based MMC for Medium Voltage Motor Drives
Abstract—This paper presents the hardware design of a 7 kV dc bus,1 MVA, 0-1,000 Hz, 1.7 kV SiC MOSFET based medium voltage variable speed drive (MVVSD)1. The system is based on a 7-level three-phase modular multilevel converter (MMC). The full in-depth design, development, and testing of this prototype are provided, including MMC submodule development, arm inductor design, control hardware realization, system integration and thermal analysis. Finally, experimental results demonstrate the excellent performance of the 1.7 kV SiC MOSFET based submodule and the 1 MW, 7 kV MVVSD as a unity in various operation modes
SiC MOSFET, Modular Multilevel Converter, Medium V↗
A hardware-in-the-loop approach for laboratory performance verification of flexible building equipment in a typical commercial building
The overall objective of the project is to develop datasets that measure the holistic load flexibility performance of a suite of commonly-used commercial building HVAC and thermal storage equipment using a hardware-in-the-loop test method. The development of the software side of the hardware-in-the-loop flexible load testbed is summarized in this paper.
Chen, Zhelun↗
Photovoltaic Inverter Reliability Assessment
As the price of PV modules drops, the price of power electronics become more important. Power electronics now constitute 8%-12% of the total lifetime PV cost. As of 2010, the inverter and associated power conditioning components accounted for $\$0.25$/W, well above the DOE benchmark of $\$0.12$/W by 2020. As efforts to reduce PV module costs yield diminishing returns, the importance of understanding and reducing inverter costs becomes an increasingly critical and cost-effective investment toward achieving the DOE SunShot goals. With this in view, this report showcases and describes an approach to help assess and predict the reliability of photovoltaic (PV) inverters. To predict the reliability, thermal cycling is considered as a prominent stressor in the inverter system. To evaluate the impacts of thermal cycling, a detailed linearized model of the PV inverter is developed along with controllers. This research also develops models and methods to compute the losses of the power electronics switches and other components in a PV inverter. The losses are then used to estimate the junction and heat sink temperature. The model is verified by developing an in-house inverter. Additionally, to assess the scalability of the research, the hardware inverter is placed inside a thermal chamber to verify the losses for different ambient temperatures. After the verification of the model, a reduced-order model of the inverter is implemented to translate the profile of ambient temperature and solar irradiance into the profile of junction temperatures of the switches. The estimated junction temperature data are used to identify inverter reliability indices and predict the useful lifetime of the inverter system. After developing the models to predict the useful lifetime of the system, the impact of reactive power on the overall reliability of the system will be studied. The first chapter involves the motivation behind the research on assessing the reliability of PV inverters. The inverter power stage and controller design of the power converter used in this research is also explained in detail in this chapter. The second chapter presents the various losses of the power converter system and the translation of power loss into temperature increase with thermal modeling. The results of the loss modeling and the thermal modeling are also explained in detail in this chapter. The third chapter involves implementing the reduced-order model to translate the mission profile of ambient temperature and solar irradiance into profile of the junction temperatures of the switches. The final chapter involves identifying reliability indices, which are of interest for this system to predict the remaining useful life of the system, and concludes with the impact of reactive power on the overall reliability of the inverter system.
14 SOLAR ENERGY↗
Numerical and Experimental Studies of Ultra Low Profile Three-dimensional Heat Sinks (3DHS) Made using a Novel Manufacturing Approach
The continued increase in electronic device packaging densities is placing ever more challenging performance requirements on air-cooled heat sinks. In cases where the state-of-the-art heat sink technology is unable of to meet these requirements, this often results in either a relaxation of design specifications, or the exploration of other thermal management technologies better able to handle high heat density applications, such as liquid cooling. Both of these approaches provide challenges to equipment designers, as relaxing requirements does not allow for a scale-able path to increased device densities and their associated functionality, while incorporating new thermal management technologies often requires major hardware redesigns, which has significant cost implications. In this work, we explore the use of air-cooled heat sinks incorporating three-dimensional features, so-called three-dimensional heat sinks (3DHS), that enhance heat transfer through a number of different physical mechanisms, as an approach to further extending the limits of air cooling. An ultra low profile (5.7 mm) heat sink application is targeted due to the significant thermal challenges associated with restrictions on heat sink height. We also present details on a novel manufacturing method that has significant cost advantages over other fabrication methods such as investment casting and direct metal printing. Experiments on 3DHS and conventional heat sink are conducted in a wind tunnel test apparatus as a function of inlet air mass flow rate and flow bypass above the heat sinks. The experimental results show a strong correlation between heat sink permeability and thermal performance, as measured by heat sink thermal resistance versus ideal pumping power. The results also illustrate the important effects of flow bypass on heat sink performance. The best performing 3DHS design is observed to have up to a 19% improvement in thermal performance relative to a conventional parallel fin heat sink of the same form factor. Comparison of the experimental results with finite-volume simulations of the laminar, steady equations for mass, momentum and energy transport shows good agreement for heat sink thermal resistance and pressure drop across the heat sink. For the case where the fluid flow is modeled as transitional and steady, there is a greater discrepancy between simulations and experiments, suggesting that the experimental flow conditions are predominantly laminar.
42 ENGINEERING↗
High photon-phonon pair generation rate in a two-dimensional optomechanical crystal
Integrated optomechanical systems are a leading platform for manipulating, sensing, and distributing quantum information, but are limited by residual optical heating. Here, we demonstrate a two-dimensional optomechanical crystal (OMC) geometry with increased thermal anchoring and a mechanical mode at 7.4 GHz, well aligned with the operation range of cryogenic microwave hardware and piezoelectric transducers. The eight times better thermalization than current one-dimensional OMCs, large optomechanical coupling rates, g 0 /2π ≈ 880 kHz, and high optical quality factors, Q opt = 2.4 × 10 5 , allow ground-state cooling (n m = 0.32) of the acoustic mode from 3 K and entering the optomechanical strong-coupling regime. In pulsed sideband asymmetry measurements, we show ground-state operation (n m < 0.45) at temperatures below 10 mK, with repetition rates up to 3 MHz, generating photon-phonon pairs at ≈ 147 kHz. Our results extend optomechanical system capabilities and establish a robust foundation for future microwave-to-optical transducers with entanglement rates exceeding state-of-the-art superconducting qubit decoherence rates.
72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗
COOLR: A New System for Dynamic Thermal-Aware Computing
Extreme-scale systems need to walk a fine line between the amount of cooling they receive and the thermal-induced performance and reliability degradation they can sustain. System managers are extremely motivated to battle cooling-energy cost: the largest line item in their total operating cost. On the other hand, pushing the nodes to peak performance in tightened cooling regimes places the burden on the dynamic thermal management (DTM) to protect the hardware. DTM schemes throttle performance to relieve heat accumulation within nodes when cooling cannot mitigate the problem. These interventions prevent fatal failures but introduce inevitable performance degradations and variations. Such variations can have drastic consequences on the performance of extreme-scale systems. Furthermore, distribution of heat across different system nodes depends not only on the amount of workload. Even if a strictly equal share of computational load is assigned to all nodes, there are physical attributes and topological features of each system that inherently cause uneven accumulation of heat. These can cause one subcomponent to trigger DTM prematurely and penalize the overall system. Our goal in this project is to create a holistic thermal-aware view of the system, capturing both inherent physical attributes and dynamic system state. We developed COOLR, a dynamic system with the ability to evaluate the interplay between management of computation, data, power dissipation, and thermal state. Thereby, COOLR will achieve higher overall performance at the same energy and cooling cost. First, we performed a systematic power and thermal modeling and of high performance computing architectures. Analytical and empirical techniques were blended to generate a light-weight thermal model of target systems. Second, we developed a thermal-aware OS and runtime system. Policies for managing resources and schedules for processes has been designed to co-optimize the thermal state and performance of the system. The main outcome of our proposed thermal-aware dynamic computing system are scheduling and allocation of processes and memory accesses leading to an appropriately “skewed” distribution of activity across the system. The ultimate result of this new arrangement resulted in reduced occurrences of hotspots and reduced episodes of DTM intervention, leading to improvements in performance. The overall thermal characterization and modeling methodology (thermal instrumentation techniques, model building, and systematic model reduction) resulting from this project can be applied to systems beyond our immediate scope and will be applicable to future scaling. The thermal-aware dynamic computing paradigm will impact the efficiency of extreme-scale systems. The gained “thermal slack” can be given back to further tighten the cooling budget, benefiting the management cost of next generation extreme-scale systems.
97 MATHEMATICS AND COMPUTING↗