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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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All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Real-Twin

Real-Twin is a unified, model-agnostic scenario generation tool designed to streamline and standardize the evaluation of emerging mobility technologies. It provides an end-to-end framework that includes robust workflows, integrated tools, and comprehensive metrics to generate, calibrate, and benchmark microscopic traffic simulation scenarios across multiple platforms. Key Features of Real-Twin include: - Unified Scenario Generation: generate transferable, simulation-ready scenarios from heterogeneous data sources using a consistent workflow. - Automated Calibration Workflow: bridges simulation and real-world data, minimizing manual effort and making traffic simulation more accessible to researchers and engineers. - Model-Agnostic Compatibility: supports SUMO, VISSIM, and AIMSUN for cross-platform scenario generation and benchmarking. Enables reliable comparisons and reproducibility across different simulation tools. - Consistent Scenarios across Different Simulators: generate comparable simulation scenarios across different microscopic traffic simulators, providing users the ability to conduct benchmarking and cross-validation that are crucial for ensuring the reliability and reproducibility of simulation results. - Emerging Technology Support: includes a scenario database and pipeline for studying autonomous vehicles (AVs), with planned extensions to CAVs, EVs, and other advanced technologies.

Wang, Chieh (Ross) [Oak Ridge National Laboratory ↗
DOE OSTI2024

Application of a Prize Mechanism to Address Data Utilization Challenges at Utilities

The electric industry sector is facing an “explosion” of data from a variety of sources. Electric sector stakeholders need to define how to capitalize on large datasets, both those they create and those from other sources (like data on weather, buildings, electric vehicles, etc.), to improve reliability and resilience and meet the changing system dynamics from renewable integration. For the electricity sector to fully utilize these vast new datasets, it must undergo a transformation in how it manages data quality, storage, and processing. The U.S. Department of Energy (DOE) Office of Electricity (OE) is committed to accelerating research, development, and demonstration of new technologies and tools within the electricity sector to advance reliability, resilience, and affordable operation of the power system. Through the prize mechanism, OE identified two widespread data-related challenges for utilities—load modeling and data analysis automation—and offered an opportunity for utilities and teams of software engineers to identify additional challenges faced by utilities. After completing one round of the American-Made Digitizing Utilities Prize, OE, the National Renewable Energy Laboratory (NREL) as the prize administrator, and Pacific Northwest National Laboratory (PNNL) as the domain experts have compiled the results and lessons learned to feed into the second round of the prize.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2022

Ecological Adaptive Cruise Control of Plug-In Hybrid Electric Vehicle With Connected Infrastructure and On-Road Experiments

Abstract This paper examines both mathematical formulation and practical implementation of an ecological adaptive cruise controller (ECO-ACC) with connected infrastructure. Human errors are typical sources of accidents in urban driving, which can be remedied by rigorous control theories. Designing an ECO-ACC is, therefore, a classical research problem to improve safety and energy efficiency. We add two main contributions to the literature. First, we propose a mathematical framework of an online ECO-ACC for plug-in hybrid electric vehicle (PHEV). Second, we demonstrate ECO-ACC in a real world, which includes other human drivers and uncertain traffic signals on a 2.6 (km) length of the corridor with eight signalized intersections in Southern California. The demonstration results show, on average, 30.98% of energy efficiency improvement and 8.51% additional travel time.

Automation & Control Systems↗
DOE OSTI2024

Energy Systems Integration Facility (ESIF): World-Class Systems Integration Capabilities and Research

The Energy Systems Integration Facility (ESIF), located at the National Renewable Energy Laboratory (NREL) South Table Mountain campus, is a world-renowned user facility for research and development of modern, advanced, and clean energy technologies. ESIF is distinguished by its continuously evolving, highly integrated systems that span throughout the building, connecting research capabilities across multiple laboratories and test areas. The primary ESIF research systems include: [1] data, cyber, and control networks, [2] research electrical distribution buses (REDB), [3] thermal integration infrastructure, and [4] hydrogen systems. The data, cyber, and control networks provide monitoring, control, communication, automation, visualization, and time series data storage and tagging capabilities for research projects and ESIF systems, including facility safety functions. The REDB system consists of four dedicated AC and DC electrical power networks that can connect devices located across the facility through versatile, automatic circuit configuration to support complex power electronics experiments up to the megawatt-scale. The thermal integration infrastructure consists of three temperature-conditioned water loops that provide heating and cooling interfaces and capabilities for thermal energy research. The hydrogen systems provide megawatt-scale hydrogen production, drying, compression, high-pressure storage, and delivery to laboratory end uses, including hydrogen fuel cell vehicle fueling. The ESIF research systems interconnect and extend throughout the various lab areas of the facility to create elaborate networks composed of diverse technologies for cutting-edge research. The ESIF capabilities are operated and stewarded by the ESIF Research Operations group, who also actively upgrade and advance the systems to ensure they remain ahead of anticipated research - enabling the success of many pioneering energy integration projects. The poster, created by members of the ESIF Research Operations team, highlights and summarizes the four core integrated systems at ESIF. The poster was first presented at the internal NREL Energize Forum on May 13th, 2024, and received the "Best Poster" award.

capabilities↗
DOE OSTI2023

Inaugural Technologist in Communities Scanning Tour: Automated and Electrified On-Demand Mobility (Follow-On Summary Report: April 24-25, 2023) [Slides]

In 2023, the Technologist in Communities (TIC) program hosted its inaugural scanning tour across the American Southwest, with a goal of investigating the region's leading public mobility systems and their integration with on-demand public mobility services. The scanning tour concept was inspired by and named after a U.S. Department of Transportation Federal Highway Administration practice of hosting "scanning tours," both domestically and abroad, to explore innovative transportation practices throughout the 1990s and early 2000s. Guided by the idea that "seeing is believing," scanning tours created opportunities for government and industry representatives to collectively experience new technologies and best practices firsthand. In 2023, the National Renewable Energy Laboratory (NREL) followed suit by leading the inaugural TIC scanning tour. TIC, part of the Technology Integration program within the U.S. Department of Energy's (DOE's) Vehicle Technologies Office, supports positive energy and mobility outcomes in communities across rural to urban contexts. TIC enables technical experts to work directly with leaders and stakeholders in communities and assist them in implementing promising new technologies. This first TIC scanning tour invited NREL, DOE, and industry experts to survey innovative public mobility practices and their integration into public transit systems across the Southwest. The tour's goals included examining the state of innovation in public mobility in cities, communities, and airports; facilitating collaboration between entities; and sparking potential new partnerships. The following report summarizes key findings from the scanning tour.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2025

Infrastructure-Based Cooperative Perception at a Traffic Intersection: Overview and Challenges

Traffic intersections are crucial and challenging nodes in transportation networks where multiple lanes of vehicles and pedestrians converge. About one-quarter of traffic fatalities and about one-half of all traffic injuries in the United States happen at traffic intersections . Effective management of these intersections is important to ensure safety and efficiency of all users - vehicles, pedestrians, cyclists, and vulnerable road users (VRUs). With advancements in sensor perception technologies such as radar, light detection and ranging (lidar), and cameras, traffic intersections are developing into dynamic and data-rich environments. By using these data to create a real-time digital twin, we can enable real-time data-driven decision making and a range of applications such as sharing perception information to connected vehicles (CVs) and connected autonomous vehicles (CAVs), safety affirmative signaling, and curb optimizing to improve efficiency and enhance safety.This paper presents an overview of the concept and examines the challenges involved in implementing an infrastructure-based cooperative perception engine at a traffic intersection. In addition to outlining the physical components, this study also addresses important challenges involved in a multi-sensor system. We present results from deploying the National Renewable Energy Laboratory's (NREL's) Infrastructure Perception and Control (IPC) mobile trailer at a traffic intersection in the city of Colorado Springs, Colorado, USA that employed multiple radars and lidars to capture the data. This study provides necessary practical learning for the Cooperative Driving Automation (CDA) and traffic engineering communities for next-generation infrastructure-based cooperative perception that promises improvements in signal control for optimized traffic flow, among other applications, and documents findings for ongoing research and development efforts in other areas.

ADVANCED PROPULSION SYSTEMS,MATHEMATICS AND COMPUT↗
DOE OSTI2026

Automatic Calibration and Health Monitoring of Infrastructure Sensors

Smart transportation infrastructure relies on networks of heterogeneous sensors - cameras, radars, and lidars - continuously monitoring traffic conditions. However, executing the initial spatial calibration of multiple sensors and the subsequent health monitoring presents significant operational challenges. Environmental factors, mechanical vibrations, and gradual drift cause spatial misalignment, degrading fusion performance and tracking accuracy. Traditional calibration approaches require manual intervention with specialized targets or survey equipment, resulting in service interruptions and high maintenance costs. This work presents an automated framework for initial calibration and continuous health monitoring without human intervention or service disruption. Our approach addresses two critical problems: (1) detecting when sensors become miscalibrated during operation, and (2) automatically re-establishing spatial alignment using only operational traffic data. The health monitoring component analyzes measurement innovations - differences between sensor observations and predicted object states - to detect systematic biases indicative of calibration drift. By computing bias magnitude, directional consistency, and rejection rates, the system identifies miscalibrations as small as 0.5 meters. Unlike traditional methods requiring known calibration targets, our diagnostic operates continuously on live traffic observations, enabling early detection before fusion quality degrades. The automatic recalibration algorithm leverages overlapping sensor fields-of-view and temporal correlation of vehicle observations. Using graph-based optimization, the system automatically discovers which sensor pairs observe common regions, estimates pairwise spatial transformations using RANSAC-based robust estimation, and jointly optimizes all sensor poses through bundle adjustment. The framework handles practical deployment challenges, including different sensor sampling rates (1-10 Hz), varying installation positions, unknown orientations, and limited overlap regions (>10%). When approximate sensor positions are available from installation surveys (+/-1m accuracy), the algorithm additionally estimates sensor orientations, refining both position and rotation to sub-meter and sub-degree accuracy. We validate the framework on multi-hour traffic datasets from six heterogeneous sensors with sampling rates ranging from 1 Hz to 10 Hz. Results demonstrate successful calibration even with sparse overlap (<20%) and automatic detection of miscalibrations exceeding 0.8 meters. This work enables a "deploy-and-forget" sensor infrastructure that maintains calibration autonomously, reducing maintenance costs while improving tracking accuracy. The techniques generalize beyond transportation to any multi-sensor monitoring application requiring robust spatial alignment, including smart cities, industrial monitoring, and surveillance systems.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2024

Anomaly Detection in Connected and Autonomous Vehicle Trajectories Using LSTM Autoencoder and Gaussian Mixture Model

Connected and Autonomous Vehicles (CAVs) technology has the potential to transform the transportation system. Although these new technologies have many advantages, the implementation raises significant concerns regarding safety, security, and privacy. Anomalies in sensor data caused by errors or cyberattacks can cause severe accidents. To address the issue, this study proposed an innovative anomaly detection algorithm, namely the LSTM Autoencoder with Gaussian Mixture Model (LAGMM). This model supports anomalous CAV trajectory detection in the real-time leveraging communication capabilities of CAV sensors. The LSTM Autoencoder is applied to generate low-rank representations and reconstruct errors for each input data point, while the Gaussian Mixture Model (GMM) is employed for its strength in density estimation. The proposed model was jointly optimized for the LSTM Autoencoder and GMM simultaneously. The study utilizes realistic CAV data from a platooning experiment conducted for Cooperative Automated Research Mobility Applications (CARMAs). The experiment findings indicate that the proposed LAGMM approach enhances detection accuracy by 3% and precision by 6.4% compared to the existing state-of-the-art methods, suggesting a significant improvement in the field.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2021

A Stochastic Multi-Criteria Decision-Making Algorithm for Dynamic Load Prioritization in Grid-Interactive Efficient Buildings

Increasing deployment of advanced sensing, controls, and communication infrastructure enables buildings to provide services to the power grid, leading to the concept of grid-interactive efficient buildings. Since occupant activities and preferences primarily drive the availability and operational flexibility of building devices, there is a critical need to develop occupant-centric approaches that prioritize devices for providing grid services, while maintaining the desired end-use quality of service. In this paper, we present a decision-making framework that facilitates a building owner/operator to effectively prioritize loads for curtailment service under uncertainties, while minimizing any adverse impact on the occupants. The proposed framework uses a stochastic (Markov) model to represent the probabilistic behavior of device usage from power consumption data, and a load prioritization algorithm that dynamically ranks building loads using a stochastic multi-criteria decision-making algorithm. The proposed load prioritization framework is illustrated via numerical simulations in a residential building use-case, including plug-loads, air-conditioners, and plug-in electric vehicle chargers, in the context of load curtailment as a grid service. Suitable metrics are proposed to evaluate the closed-loop performance of the proposed prioritization algorithm under various scenarios and design choices. Scalability of the proposed algorithm is established via computational analysis, while time-series plots are used for intuitive explanation of the ranking choices.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2022

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↗
DOE OSTI2025

Review on Preprocessing Strategies, Deactivation, Thermal Safety, and Future Perspectives in Lithium-Ion Battery Recycling

The rapid growth in the use of lithium-ion batteries (LIBs) in electric vehicles, consumer electronics, and renewable energy storage has made effective end-of-life management essential. Recycling LIBs is critical not only for resource recovery and environmental protection but also for ensuring safety and economic viability. This review focuses on the preprocessing technologies that precede typical recovery processes, including disassembly, sorting, discharging, electrolyte removal, dismantling, thermal treatment, separation, and flotation. These steps play a foundational role in determining the efficiency, safety, and environmental impact of LIB recycling. LIBs pose substantial fire and explosion risks due to residual charge, flammable electrolytes, and reactive materials. The conditions and successive progression of the exothermic reactions which lead to thermal runaway has been discussed. It also explores secure deactivation techniques such as external circuit discharge, saline immersion, and thermomechanical methods, alongside fire prevention strategies including the use of flame retardants, elimination of oxidants, and reduction of heat generation and accumulation. Challenges and future directions are outlined, highlighting the need for standardized designs, automation, and safer, more sustainable recycling infrastructure. Furthermore, this review is distinguished by its focused analysis of preprocessing and deactivation steps, with particular attention to the thermal safety engineering aspects of LIB recycling.

Battery deactivation↗
DOE OSTI2024

Connected and Learning Based Optimal Freight Management for Efficiency

The management of the future heterogenous fleet is a complex decision-making problem. The heterogenous fleet is emerging as decarbonization technologies are deployed by fleets toward lowering the freight operation emissions in Medium and Heavy-duty vehicles. Traditionally, in fleets characterized by a homogeneous Diesel Internal Combustion Engine (ICE) powertrain, the process of fleet planning and operational optimization unfolds sequentially without the necessity to account for powertrain and vehicle-specific characteristics during dispatch decisions. Fleets with trucks less than 5 years old tend to maintain stable vehicle efficiency with minimal operational reliability risks for fleet managers. However, the landscape changes with the incorporation of emerging powertrain technologies, which lack extensive operational data and service experiences. This includes technologies like hybrid, Electric, Fuel Cell, or alternative fuel ICE. Operational decisions for fleets featuring heterogeneous powertrain technologies and facing limited access to alternative fueling and charging stations become intricate, requiring careful consideration and optimization at each dispatch. The difference in efficiency characteristics of emerging technologies, their range limitations, and the restricted availability of charging/alternative fueling infrastructure, coupled with sensitivity to driving conditions (e.g., EV range reduction in low temperatures) and their impact on component aging (such as batteries), become pivotal factors influencing the reliable and efficient freight transportation. To make the path toward low emission freight transportation efficient and reliable, an AI-assisted fleet management software is developed in this project to help fleet managers in optimizing both adoption of emerging powertrain decarbonization, connected and automated technologies and also operating the fleet after such technologies are deployed as schematically. Freight transportation requirements are different depending on the cargos to be shipped, customer requirements and regions of operations. This further highlights the need for software and digital solutions to tailor deployment and operation of emerging powertrain, connectivity, and automation technologies toward the specific fleet operation requirements. The fleet management optimizer was also integrated with a model of the fleet to simulate the operation of the fleet over 1 year of the baseline fleet operation (250,000+ shipments) indicating the significance of day-to-day variations on emissions and energy consumption of a freight transportation fleet. The results demonstrate ≥20% improvement in freight efficiency in terms of WTW CO2 per ton-mile of cargo shipments while all fleet operation constraints are enforced, and the cost (CapEx and OpEx) is minimized.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2023

Spatio-Temporal Assessment of Heavy-Duty Truck Incident and Inspection Data

Vehicular incidents, especially those involving tractor trailers, are increasing in number every year. These events are extremely costly for fleets, in terms of damage or loss of property, loss of efficiency, and certainly in terms of loss of life. Although the U.S. Department of Transportation (DOT) is responsible for performing inspections, and fleet managers are encouraged to maintain their fleet and participate in regular inspections, it is uncertain whether these inspections are occurring at a frequency that is necessary to prevent incidents. The Federal Motor Carrier Safety Administration (FMCSA) of the DOT manages and maintains the Motor Carrier Management Information System (MCMIS) dataset, which contains all incident and inspection data regarding commercial vehicles in the U.S. The purpose of this preliminary analysis was to explore the MCMIS dataset through spatiotemporal analyses, to uncover findings that may hint at potential improvements in the DOT inspection process and highlight location-specific trends in the dataset. These analyses are novel, as previous research using the MCMIS dataset only examined the data at the state or county level, not at a national scale. The results from the analyses pinpointed specific major metropolitan areas, namely Harris County (Houston), Texas, and three of the New York boroughs (Kings, Queens, and the Bronx), which were found to have increasing incident rates during the study period (2016–2020). An overview of potential causal factors contributing to this increase are provided as well as an overview of the inspection process, and suggestions for improvement relative to the highlighted locations in Texas and New York are also provided. Ultimately, it is suggested that the incorporation of advanced technology and automation may prove beneficial in reducing the occurrence of events that lead to incidents and may also help in the inspection process.

99 GENERAL AND MISCELLANEOUS↗
DOE OSTI2023

Engineering Computational Practices (Rev. 1)

This manual will attempt to motivate the use of an automated build system for the purposes of computational science and engineering. As part of this motivation, the surrounding computational practices of version control, documen tation, compute environment management, and regression testing will also be addressed as applied to the practice of computational engineering. Specifically, this manual intends to motivate the adoption of these traditional software engineering practices for use in research and production engineering simulation projects. This manual is not the first such effort in the greater scientific computing community. In fact, the authors relied heavily on the lesson plans of the Software Carpentry, established to teach computing skills to researchers in 1998. As the intention for this manual is to lay out fundamental practices of engineering computing, it will not attempt to fully teach the underlying concepts and will instead reference the well designed lesson plans of the Software Carpentry. Where possible, this manual will explain to general computing practices and concepts and limit discussion of specific software implementations to examples or vehicles for practice in concrete application. The specific software taught by the Software Carpentry curriculum is an excellent starting point to learn the core concepts of computational engi neering. However, the authors have found that applications to engineering simulation and analysis require translation of these software development concepts into the language and workflows of computational engineers. Adopting these computational tools may require engineers to re-imagine their workflows in some combination of traditional engineer ing and software concepts. It has also been necessary to extend existing software build systems for engineering practices beyond the simple wrap ping of engineering software execution. Where necessary, examples of specific software and their method of extension to engineering simulations will be given, with reference to the User Manual for recommended practical use. Where this manual relies on specific implementation examples, it should be understood that the practicing engineer may find that different software is more amenable to their specific work. It is always the overall collection of computational practices is more important than any specific software implementation. The ability to recognize which concepts are implemented by a software package will make a practicing engineer agile to changing project needs, computing resources, numeric solvers, programming languages, and even available funding.

42 ENGINEERING↗
DOE OSTI2024

Evaluating the Effectiveness of a Detection and Deterrent System in Reducing Golden Eagle Fatalities at Operational Wind Facilities

The Renewable Energy Wildlife Institute (REWI) was appointed as the prime awardee of DOE award number DE-EE0007883 to lead a team of scientists, wind developers, and technology manufacturers toward the overarching goal of evaluating the effectiveness of the current DTBird system in minimizing the risk of golden eagles (Aquila chrysaetos) and other large soaring raptors from approaching the rotor-swept zone (RSZ) of operating wind turbines. As part of this goal, the team set out to 1) quantify the expected reduction in collision risk for golden eagles from operation of the detection and deterrence modules in a manner that supports the approach used by the U.S. Fish and Wildlife Service (USFWS) to assess and credit facility operators for their efforts to minimize predicted collision fatalities and 2) provide information to help improve the technology to maximize its effectiveness. DTBird is an automated detection and audio deterrent system created by the Spanish company Liquen, designed to discourage birds from entering the RSZ of spinning wind turbines. The system uses cameras to automatically detect airborne targets of interest, records each such event in an online database, and triggers a warning signal (loud sound) if the tracked object has moved close to the turbine. If the object moves even closer to the RSZ, a more aggressive dissuasion signal is broadcast. To meet our objectives, the team conducted a two-year experiment at the Goodnoe Hills wind facility in Washington state, in which 14 turbines were outfitted with DTBird units. Daily, each DTBird-equipped turbine was randomly assigned to a control or treatment group. Treatment turbines operated with DTBird running as intended—broadcasting warning or deterrent signals when DTBird detected a target within range. On control turbines, no sound signals were broadcast if a moving target triggered the DTBird system. The team also flew unmanned aerial vehicles (UAVs) designed to coarsely mimic the general size, weight, and coloration of golden eagles in programmed flight transects across DTBird detection ranges to quantify DTBird’s ability to detect intended targets and to evaluate factors that influence the probability of detection and DTBird’s response distances. Additionally, the team evaluated the behavioral responses of in situ eagles exposed to spinning turbines alone (visual and sound influences) versus spinning turbines plus broadcasted DTBird audio deterrents, to estimate the effectiveness of deterrence by the DTBird system. The data and results from these investigations were combined with those from a pilot study conducted at the Manzana Wind Power Project in California to better evaluate DTBird’s effectiveness across different landscapes.

17 WIND ENERGY↗
DOE OSTI2022

Low-Cost Preform and Molding Processes

The entry cost for prototyping a composite component for manufacture using automated, high rate processes is prohibitively expensive in many cases, especially for small business, where tooling costs may be several $100k. Discussions with industry also indicate that many small companies, tier 1 and 2 suppliers, have an interest to mold composite parts but do not want to deal with the capital cost, material handling issues, and labor associated with dry fiber preforming operations. While the molders may locate near the end user for logistics reasons, it may be more cost effective for the performer to remain regional and invest in capital equipment to support preform automation, thus keeping costs to a minimum. This project was designed to explore and demonstrate several options to meet these industry needs. Dry fiber preforming approaches were evaluated which allow for low pressure resin infusion, single sided tooling options such a vacuum assisted resin transfer molding (VARTM) or low pressure resin transfer molding (RTM-light). Unlike sheet molding compound, SMC compression molding where typical molding pressures of 1000 psi are required to push material into the desired location; positioning of a dry fiber preform into the desired location on the tool allows for low molding pressures of 10-50 psi. Lower molding pressures allow for use of low cost, additive fabrication of polymeric tooling. Polymeric tooling is suitable for rapid part prototyping and limited production. Dry fiber preforming approaches evaluated included use of commercial chopped strand mat, robotic chopper gun deposition, and continuous fiber preform augmentation using tailored fiber placement (TFP). Use of chopped strand mat does not require a robotic deposition method, however a cutting table is generally required and there is typically 20-30% scrap generation. While various fiber areal weights are available, the preform is not readily optimized for minimal fiber use or weight savings. In contrast, a robotic chopper gun approach allows for localized deposition where fiber is required to meet structural requirements. The robotic method is highly automated and minimizes fiber scrap, however the capital cost of the equipment and engineering labor for programming can result in higher preform cost compared to chopped strand mat in certain cases depending on preform complexity. Dry fiber preforming using the robotic chopper gun method allows for creation of three dimensional forms. This approach may be ideal for molding in-house, or if the preforms stack together densely to allow for efficient shipping. Applications evaluated for this program considered trade-off between fabrication of a fully 3D preform versus production of a flat preform which is designed to readily drape into the final desired shape. Such a preform design greatly simplifies robotic programming and requires no specialized tooling. The flat preforms are easily stacked and shipped to the final molding location. Flat preforms are much easier to augment with TFP continuous fiber to provide local reinforcement. The demonstration and evaluation of these preforming and tooling methods were completed on three component applications. The first application was a battery box cover for an electric vehicle which was highly three dimensional. The second demonstrator article was comprised of complex contours and was used to demonstrate the use of TFP and RTM-light molding process. The third demonstration article was the roof of an operator’s cab for large construction equipment. The roof is relatively flat however it is comprised of complex changes in thickness which clearly demonstrate the advantage of robotic chopper gun approach as compared to using numerous preform layers of chopped strand mat. The cost trades for the various preforming methods are summarized to help guide the reader as to preforming method considerations. Finally, these demonstrations all used glass fiber roving. A fourth, exploratory task was added to evaluate the ability to make preforms using Zoltek’s carbon fiber split tow roving. We were able to adapt the chopper gun to make flat preforms for laminate testing, but further development effort would be required to make suitable preforms.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Control Design for a Marine Hydrokinetic Cycloturbine Vehicle

Abstract Marine Hydrokinetic (MHK) cycloturbines generate sustainable power by exploiting tidal currents. By powering the turbines and using pitching foils for control, a vehicle comprised of MHK cycloturbines also has the ability to station keep and maneuver. The vehicle consists of four counter-rotating cycloturbines, with hydrofoils oriented perpendicular to the flow in a paddlewheel configuration. Lift and drag generated from these foils sum together to produce thrust. An experimentally tuned simulation model that solves the six-degrees-of-freedom rigid body equations of motion for the MHK vehicle subject to hydrodynamic, hydrostatic, and propulsive forces is used to aid the design of vehicle controllers. Global feedback controllers are initially designed by applying classical control methods to an approximate linear model of the system dynamics. A higher performing nonlinear controller is designed using the nonlinear dynamic inversion (NDI) method. NDI accounts for the nonlinearities of the MHK system and therefore is suitable for a wide range of operating conditions. The response of the classical and NDI controllers to speed, depth, roll, pitch, and yaw commands are evaluated and compared in simulation. The classical controller outperforms the NDI controller for small amplitude maneuvers, although the degradation with NDI is minor. However, in the nonlinear operating regime the NDI controller outperforms the classical controller and the classical controller exhibits instability.

Automation & Control Systems↗
DOE OSTI2025

EV Charging Infrastructure Energization An Overview of Approaches for Simplifying and Accelerating Timelines to Processing EV Charging Load Service Requests

The United States has seen significant growth in electric vehicle (EV) adoption, leading to increased demand for EV charging infrastructure. Over the past decade, EV charging infrastructure site developers, site hosts, and electric distribution utilities have navigated the process to integrate chargers onto the electric grid. Site developers and site hosts have raised the alarm that the integration process for high-powered EV charging projects does not meet the needs of the EV market for timeliness or cost. High-powered charging stations typically require a load service request or an agreement with the local utility to connect to the grid. The process of energizing a new high-powered charging site can be complex and time-consuming, often taking up to 2 years. This timeline is the result of current utility energization processes having been designed for construction projects that take longer to build (i.e., buildings). The specific challenges stem from various factors, including compartmentalization in application processes, the integration of EV charging process approvals with other distributed energy resources (DERs), and the need to ensure grid reliability. The energization process needs to evolve to meet the growing demand for high-powered EV charging. This white paper compiles information gathered through various conversations with key stakeholders, including utilities, utility regulators, EV charging operators, site developers, and authorities having jurisdiction (AHJ) as well as through an extensive literature review. This document identifies the challenges and provides potential solutions to streamline the process of connecting EV charging infrastructure to the power grid in the United States, serving as a starting point for future conversations around these solutions. The solutions noted in this white paper require collaborative efforts among utilities, regulators, and EV charging infrastructure developers to streamline the grid connection process for EV charging infrastructure. They are broadly organized into four areas: 1. Increase data access and transparency: Develop automated load service request tools, integrate hosting capacity and load service request analyses, incorporate EV adoption forecasts, and provide transparency on the processing queue. 2. Improve energization processes and timing: Create fast-track options based on prescreening criteria, provide flexibility or phased approvals in the load service request/interconnection process, build internal knowledge within utilities about EV charging technologies, and provide standardized workforce training. 3. Promote economic efficiency: Right size distribution components to accurately reflect the load requirements of EV charging infrastructure, make proactive investments in grid infrastructure based on EV adoption forecasts and growth projections, and consider energy equity and environmental justice factors such as equitable access to EV charging when planning infrastructure. 4. Improve grid reliability and resilience: Use load management/power control systems (PCS) at EV charging stations, adopt and implement harmonized standards for communication protocols and information models between the EV charging and grid control infrastructure, and address cybersecurity considerations by implementing robust security measures and standards for EV charging infrastructure—with particular emphasis on clarifying the security requirements for the interface to the grid. The objective of the solutions proposed in this white paper is to accelerate the timeline and decrease costs associated with connecting EV charging infrastructure to the grid. Electric utilities, utility regulators, EV charging infrastructure developers, and site hosts will first need to understand which solutions are available in their service territory, and if warranted, which combination of solutions would support their specific needs. Through the successful implementations of solutions at scale detailed here, industry will demonstrate a new and innovative ecosystem where timely deployment and energization of EV charging infrastructure with greater grid resiliency and reliability is a reality.

24 POWER TRANSMISSION AND DISTRIBUTION↗