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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 343 records · Page 19
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

A methodology to develop multi-physics dynamic fuel cell system models validated with vehicle realistic drive cycle data

Fuel cell (FC) technology has been identified as a technically attractive solution to decarbonize the transportation sector, especially for heavy-duty vehicles. In this context, the industry and the scientific community are in need of advanced fuel cell systems (FCS) models that are able to replicate real -world operating conditions. Due to the scarcity of said models in the open literature, this study aimed to develop a comprehensive methodology to calibrate and validate multi -physics dynamic FCS models. Therefore, the key contribution of this paper is the detailed description of the calibration process for each component and the calibration order. The specific focus here was to accurately describe the behavior of the FC stack as well as the cathode, anode, and cooling circuits of the balance of plant. The model was calibrated with the aid of experimental data from a Toyota Mirai FC electric vehicle, which was predominantly retrieved from the vehicle's Controller Area Network (CAN) bus system thereby negating the need for major intrusion into the powertrain system. The validation process was deemed successful with the model being able to truthfully replicate the characteristics of the FC vehicle operated on the World-wide harmonized Light duty Test Cycle (WLTC) 3b and US06 driving cycle. The time -resolved physical parameters such as the cathode pressure, mass flow, or the FC stack temperature were captured with high fidelity, while the overall performance parameters such as the H2 consumption in the stack and the system, and the compressor energy consumption were predicted accurately with a deviation lower than 0.47%, 1.75% and 1.89% with respect to the experimental data, respectively.

Lopez-Juarez, Marcos↗
DOE OSTI2020

Comparison of electro-thermal performance of advanced cooling techniques for electric vehicle motors

Permanent magnet synchronous motors are commonly used in the powertrain of electric vehicles because of their high power and torque densities. Attempts to increase power and torque densities beyond the state-of-the-art often suffer from thermal limitations of the adopted winding-wire insulation class. In this paper, overall effectiveness of four different cooling technologies, namely conventional stator jacket cooling, embedded circular and rectangular cooling channels within stator core, and direct winding heat exchangers have been studied numerically. Here, by realizing temperature dependent magnetic and material properties, winding and core losses, a two-way coupling algorithm has been utilized to study the detailed electro-magnetic and thermal performance of BMW i3 motor with aforementioned cooling techniques. The numerical results illustrated that the direct winding heat exchangers approach provides better electro-thermal performance in comparison to the other cooling techniques analyzed. On the contrary, embedded rectangular and circular channel in stator core adversely affect the electro-magnetic performance and overall efficiency of the motor, despite their superior thermal performance compared to the jacket cooling

42 ENGINEERING↗
DOE OSTI2022

Evaluating the current perceived cost of ownership for buses and trucks in China

Decarbonizing commercial vehicles, including buses, trucks, and special purpose vehicles, is essential for China to achieve its carbon neutrality target by 2060. However, understanding the adoption barriers of alternative fuel technologies for commercial vehicles has largely been limited to the total cost of ownership approach that mainly considers tangible costs. Additionally, this study proposes a perceived cost of ownership (PCO) model, which monetizes both tangible and implicit costs, including charging annoyance for buses and trucks by size and classification under different use scenarios. In the case study for China's current bus and truck market, the PCO of alternative fuel technologies, such as battery electric vehicles (BEVs) and fuel cell electric vehicles (FCEVs) are 27%–129% and 31%–86% higher than the most economically competitive powertrains – the compressed natural/liquefied petroleum gas technology and hybrid electric technology. BEVs could be cost-effective in the mini/midsize bus segment or in the daily short-distance driving scenario, and FCEVs could firstly be deployed in cities with a low hydrogen price. Though the implicit costs caused by range anxiety and charging annoyance account for at least 27% of BEV's PCO, making BEV uncompetitive, the battery swapping technique could reduce the implicit cost and overall cash outflow for BEV owners.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2026

Scenario-based analysis of electric vehicle adoption in the United States: Technology, infrastructure, and electricity pricing

This work investigates the impact of battery technology advancement, charging infrastructure development, and time-of-use (TOU) electricity pricing on vehicle adoption by 6 powertrain types in the United States through 2050. Using the Market Acceptance of Advanced Automotive Technologies (MA3T) model, we simulate 15 scenarios, examining individual cost factors and their combinations. We assess outcomes through market share, consumer surplus, and energy consumption. Results show that battery cost reductions are the strongest driver of EV adoption, increasing 2050 battery electric vehicle (BEV) share by 27 percentage points over baseline, raising annual consumer surplus by $511 per household, and reducing cumulative energy consumption by 16,610 trillion Btu. These gains are two to five times larger than those from other individual factors. Reducing home charging installation costs produces moderate impact, while TOU pricing alone yields only small gains, raising 2050 BEV market share by 1–2 percentage points. However, when cost factor improvements are combined, their effects are amplified beyond simple additivity. Pairing modest battery cost reductions with charging installation cost reductions and TOU pricing results in the largest 2050 BEV sales combined impact. The analysis demonstrates that moderate progress targeting multiple cost barriers may be more impactful than focusing on any single barrier.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2024

A real-time energy and cost efficient vehicle route assignment neural recommender system

Here, this paper presents a neural network recommender system algorithm for assigning vehicles to routes based on energy and cost criteria. In this work, we applied this new approach to efficiently identify the most cost-effective medium and heavy duty truck (MDHDT) powertrain technology, from a total cost of ownership (TCO) perspective, for given trips. We employ a machine learning based approach to efficiently estimate the energy consumption of various candidate vehicles over given routes, defined as sequences of links (road segments), with little information known about internal dynamics, i.e. using high level macroscopic route information. A complete recommendation logic is then developed to allow for real-time optimum assignment for each route, subject to the operational constraints of the fleet. We show how this framework can be used to (1) efficiently provide a single trip recommendation with a top-k vehicles star ranking system, and (2) engage in more general assignment problems where n vehicles need to be deployed over m (m ≤ n) trips. This new assignment system has been deployed and integrated into the POLARIS. Transportation System Simulation Tool for use in research conducted by the Department of Energy's Systems and Modeling for Accelerated Research in Transportation (SMART) Mobility Consortium (SMART, 2024).

Energy consumption↗
DOE OSTI2020

Quantifying the impacts of micro- and mild- hybrid vehicle technologies on fleetwide fuel economy and electrification

Micro- and mild-hybridization (jointly labeled as M-HEV) is gaining popularity as a cost-effective technology for fuel economy improvement, but whether and how M-HEV may compete against less efficient conventional internal combustion engine vehicles (ICEV), more efficient full hybrid electric vehicles (HEV), and plug-in electric vehicles (PEV) is not well understood. As such, this study aims at evaluating the impact of the market adoption of M-HEV on the average fuel economy of the new vehicle fleet and on the sales share of PEVs. The study reviews recent sales trends and market forecasts, and uses published estimates of manufacturing cost and fuel economy of M-HEV with an existing discrete choice model (Market Acceptance of Advanced Automotive Technologies or MA3T) to project the market penetration and impacts of M-HEV under different scenarios of M-HEV choice positions, designed to enhance conclusion robustness. It is found that among engine-based powertrain choices, micro-HEV appears to be the most cost-effective, followed by ICEVs, mild-HEV and finally full HEVs. M-HEV technologies are likely to improve fleetwide average fuel economy without significant adverse effects on sales of plug-in electric vehicles, and are likely to remain highly competitive outside PEVs through 2050.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2020

Information and Collaboration Levels in Vehicular Strings: A Comparative Study

The potential safety, productivity, and energy benefits of automated vehicles have driven a surge of research interest in their algorithms. Even within single-lane driving, control engineers now have a profusion of approaches available to them. Algorithm classes include classical controllers, receding horizon controllers, and constrained eco-driving formulae based on Pontryagin’s Minimum Principle. Differing connectivity architectures and collaboration levels further differentiate algorithms from one another. This study evaluated six controllers in two drive cycle-based scenarios using an electric powertrain model for energy analysis. Individual-vehicle and string performance were examined, including string stability and length. Algorithms with greater access to information generally performed best. Although collaboration affected energy use only slightly, it made a greater impact on string length.

Dollar, R. Austin↗
DOE OSTI2020

Automotive fuel cell stack and system efficiency and fuel consumption based on vehicle testing on a chassis dynamometer at minus 18 °C to positive 35 °C temperatures

In this work we present an in-depth laboratory technology assessment of a 2016 Toyota Mirai Fuel Cell (FC) vehicle based on chassis dynamometer testing. The 114.6 kW FC stack has a high dynamic response, which makes this powertrain a FC-dominant hybrid electric vehicle. The measured peak efficiency is 66.0% FC stack and 63.7% FC system with an idle hydrogen flow rate of 4.39 g/hr. The high FC system efficiencies at low loads match typical vehicle power spectrums, resulting in a high average vehicle efficiency of 62% compared to 45% and 23% for a hybrid electric vehicle and a conventional vehicle, respectively. An energy breakdown accounts for the FC stack losses, FC system losses, air compressor loads, and heater loads for different drive cycles and different thermal conditions. The cold-start North American city drive cycle (UDDS) energy consumption values are, respectively, 758, 581, 226, and 321 Wh/km at ambient conditions of -18 degrees C, -7 degrees C, -25 degrees C and 35 degrees C with 850 W/m 2 of solar loading. The FC system shutdown and startup processes at temperatures below the freezing point contribute to the increased hydrogen consumption. Additionally, the raw test data files are available for download, thus providing the research community with a public reference data on a modern production automotive FC system.

08 HYDROGEN↗
DOE OSTI2020

Biomass feedstock transport using fuel cell and battery electric trucks improves lifecycle metrics of biofuel sustainability and economy

We report the use of new vehicle technologies such as fuel cell hybrid electric and fully electric powertrains for biomass feedstock supply is an unexplored solution to reducing biofuel production cost, greenhouse gas emissions, and health impacts. These technologies have found success in light-duty vehicle applications and are in development for heavy-duty trucks. This study presents the first detailed stochastic techno-economic analysis and life-cycle assessment of biomass feedstock supply systems with diesel, fuel cell hybrid electric, and fully electric trucks and determines their impacts on biofuel production considering butanol as a representative biofuel. This study finds that fuel cell hybrid electric and fully electric trucks consume less energy relative to the diesel-powered truck regardless of the evaluated circumstances, including payloads of truck (loaded and empty), pavement types (gravel and paved), road conditions (normal and damaged), and road networks (local and highways). The use of fuel cell hybrid and fully electric trucks powered by H 2 -fuel and renewable sources of electricity, respectively, results in a large reduction in cost and carbon footprint, specifically for a long-distance hauling, and minimize other economic and environmental impacts. While the economic advantage of fuel cell hybrid electric vehicle is dependent on the price of H 2 -fuel and road conditions, use reduces the GHG emissions of biobutanol per 100 km-trucking-distance by 0.98-10.9 gCO 2e /MJ. Results show that converting to fully electric truck transport decreases the biobutanol production cost and GHG emissions per 100 km-trucking-distance by 0.4-7.3 cents/L and 0.78 to 9.1 gCO 2e /MJ, respectively. This study establishes the foundation for future investigations that will guide the development of economically, socially, and environmentally sustainable biomass feedstock supply system for cellulosic biorefineries or other goods transportation systems.

09 BIOMASS FUELS↗
DOE OSTI2018

In-situ investigation of incipient melting in a 319 type Al alloy using laser scanning confocal microscopy

Highlights: • In-situ analysis of incipient melting of ternary eutectic in Al alloy. • Incipient melting occurred in three distinct stages in the eutectic. • Increased heating rate increase rate of liquid film propagation. • Incipient melting transformed initial eutectic structure and caused oxidation. • Study determined incipient melting mechanism for eutectic structures. - Abstract: The modified 319 Al alloy system has been used extensively in precision sand casting of automotive powertrain applications such as engine blocks and cylinder heads, with significant improvement in vehicle fuel efficiency. However, a concern in elevated temperature processing of Al alloys, such as heat treatment and hot working processes, is incipient melting of secondary phases, which is deleterious to mechanical properties. In this study, the laser scanning confocal microscopy (LSCM) technique was used in the analysis of in-situ changes in microstructure as a result of incipient melting. Microstructural analysis was carried out prior to and following elevated temperature exposure in the LSCM using optical microscopy, SEM and EDX. The results suggest that incipient melting of the Al-Al{sub 2}Cu-Al{sub 5}Mg{sub 8}Cu{sub 2}Si{sub 6} ternary eutectic clusters was initiated by the formation of a liquid film which propagated rapidly from the eutectic clusters, coating the Al dendrites in regions adjacent to the eutectic clusters. Following film formation, the ternary eutectic clusters melted completely. Incipient melting also resulted in a localized change in composition in the interdendritic channels as supported by a change in cluster morphology from eutectic to a combination of coarse blocky Al-Cu-Ni and Si particles, and ultra-fine eutectic.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Full-scale validation gaps and opportunities for low-head hydropower: a review and perspective

Hydropower is undergoing technological innovation as future development increasingly targets low-head sites (<10 m), primarily through retrofits, rehabilitation, and upgrades of existing infrastructure. This shift toward smaller systems creates a timely opportunity: unlike conventional large projects, many emerging low-head technologies may be small enough for direct full-scale validation. Full-scale testing is particularly important for environmental mitigation technologies, including fish passage, sediment continuity, and water-quality improvements, whose performance is difficult to assess reliably using reduced-scale models. Yet adoption remains constrained by the limited risk-bearing capacity of small hydropower owners, discouraging manufacturers from bringing unvalidated technologies to market. This review and perspective paper examines hydropower trends driving innovation, selected emerging technologies, conventional testing methods, and current U.S. testing capabilities as a case study. We then evaluate the gap between existing capabilities and the needs of low-head powertrains and environmental mitigation measures. Many technologies exceed existing facility flow capacities; in the U.S., the highest combined head–flow capability is limited to 5.66 m3/s, compared with median and 90th-percentile low-head turbine-unit flows of 14.3 and 60 m3/s. To mitigate this gap, we advocate repurposing large, retired, or underused hydraulic infrastructure as full-scale testing facilities to reduce first-adoption risk and support sustainable low-head hydropower deployment.

Tseng, Chien-Yung [Colorado State University, Fort↗
DOE OSTI2014

An investigation on the fuel savings potential of hybrid hydraulic refuse collection vehicles

Highlights: • Driving cycle acquisition in a refuse collection vehicle. • Vehicle modeling and validation for numerical simulations based on the measured driving cycle. • Fuel consumption analysis for a conventional diesel vehicle and a hybrid hydraulic vehicle. - Abstract: Refuse trucks play an important role in the waste collection process. Due to their typical driving cycle, these vehicles are characterized by large fuel consumption, which strongly affects the overall waste disposal costs. Hybrid hydraulic refuse vehicles offer an interesting alternative to conventional diesel trucks, because they are able to recuperate, store and reuse braking energy. However, the expected fuel savings can vary strongly depending on the driving cycle and the operational mode. Therefore, in order to assess the possible fuel savings, a typical driving cycle was measured in a conventional vehicle run by the waste authority of the City of Stuttgart, and a dynamical model of the considered vehicle was built up. Based on the measured driving cycle and the vehicle model including the hybrid powertrain components, simulations for both the conventional and the hybrid vehicle were performed. Fuel consumption results that indicate savings of about 20% are presented and analyzed in order to evaluate the benefit of hybrid hydraulic vehicles used for refuse collection.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2016

Life Cycle Assessment of Vehicle Lightweighting: A Physics-Based Model To Estimate Use-Phase Fuel Consumption of Electrified Vehicles

Assessing the life-cycle benefits of vehicle lightweighting requires a quantitative description of mass-induced fuel consumption (MIF) and fuel reduction values (FRVs). We have extended our physics-based model of MIF and FRVs for internal combustion engine vehicles (ICEVs) to electrified vehicles (EVs) including hybrid electric vehicles (HEVs), plug-in hybrid electric vehicles (PHEVs), and battery electric vehicles (BEVs). We illustrate the utility of the model by calculating MIFs and FRVs for 37 EVs and 13 ICEVs. BEVs have much smaller MIF and FRVs, both in the range 0.04-0.07 L e /(100 km 100 kg), than those for ICEVs which are in the ranges 0.19-0.32 and 0.16-0.22 L/(100 km 100 kg), respectively. The MIF and FRVs for HEVs and PHEVs mostly lie between those for ICEVs and BEVs. Powertrain resizing increases the FRVs for ICEVs, HEVs and PHEVs. Lightweighting EVs is less effective in reducing greenhouse gas emissions than lightweighting ICEVs, however the benefits differ substantially for different vehicle models. The physics-based approach outlined here enables model specific assessments for ICEVs, HEVs, PHEVs, and BEVs required to determine the optimal strategy for maximizing the life-cycle benefits of lightweighting the light-duty vehicle fleet.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2018

Optimal velocity prediction for fuel economy improvement of connected vehicles

With the advancement of vehicle-to-vehicle and vehicle-to-infrastructure technologies, more and more real-time information regarding traffic and transportation system will be available to vehicles. This paper presents the development of a novel algorithm that uses available velocity bounds and powertrain information to generate an optimal velocity trajectory over a prediction horizon. When utilised by a vehicle, this optimal velocity trajectory reduces fuel consumption. The objective of this optimisation problem is to reduce dynamic losses, required tractive force, and completing trip distance with a given travel time. Sequential quadratic programming method is employed for this nonlinearly constrained optimisation problem. When applied to a GM Volt-2, the generated velocity trajectory saves fuel compared to a real-world drive cycle. The simulation results confirm the fuel consumption reduction with the rule-based mode selection and the energy management strategy of a GM Volt 2 model in Autonomie.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2022

Sustainability, Scalability, and Resiliency of the Town of Innisfil Mobility-on-Demand Experiment: Preliminary Results, Analyses, and Lessons Learned

In 2017, the town of Innisfil, Ontario, launched Innisfil Transit in partnership with Uber, a transportation network company, to provide a subsidized on-demand public mobility service as an alternative to investing in a new fixed-route bus service. The performance of Innisfil Transit is documented in a 2021 Ryerson University report by Sweet, Mitra, and Benaroya, which shows greater cost effectiveness of the mobility provided over the proposed bus alternative. This paper expands on those findings by assessing Innisfil Transit with respect to sustainability, scalability, and resiliency. First, we quantify the energy and emissions of this program relative to traditional transit and driving alone across varying powertrains. We then characterize a conservative first-order estimate of the percentage of US communities that fall within a similar spatial-demographic tier as Innisfil. Replicability also hinges on service cost and performance in comparison to average values for low-density transit in the US. Lastly, most transit agencies experienced a significant drop in demand (as much as 90%) with slowly rebounding ridership since the onset of the COVID-19 pandemic. The resiliency of the Innisfil program to the pressures induced by the pandemic is examined in comparison to other transit operations. The lessons learned across these three dimensions complement prior work to better understand the efficiency and sustainability of on-demand public mobility service for low-density communities like Innisfil.

ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2024

Analysis of Control Behavior in Eco-Driving Speed Optimization Using Pontryagin’s Minimum Principle

The energy efficiency of autonomous vehicles can be improved by selecting an optimized speed profile. Energy savings can be maximized by performing control optimization with knowledge of the powertrain characteristics and future driving conditions. Previous studies have shown that Pontryagin’s minimum principle (PMP) performs well in vehicle speed optimization problems. Building on the methods proposed in previous studies, the contribution of this study is to derive meaningful observations from the concepts and results of PMP to enhance the understanding of the control problem. In particular, the switching behavior of the control mode is analyzed with supportive variables, such as ξ and mv, which dictates the changes in the control modes. Additionally, the existence of the singular control is analyzed, which helps in understanding the cruise driving in the control problem. Finally, we obtain several solutions that satisfy various boundary conditions along with a map of the reachable states, and discuss the impact of cruise driving. This is helpful for designing practical control concepts for real-world applications based on this map. Previous studies have contributed significantly to this control problem; however, this study provides a better understanding of the issue and offers guidance and inspiration for future real-world applications based on these meaningful observations.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2019

Optimum Planning for Inductively Charged On-Demand Automated Electric Shuttles at Greenville, South Carolina

Wireless charging technology presents perfect fits for autonomous electric vehicles for realizing a fully automated system (vehicle and charger). This paper presents a planning optimization analysis for a pilot project of in-route wireless charging infrastructure serving fixed-route on-demand shared automated electric shuttles (SAESs) at Greenville, South Carolina, USA. A single-objective non-linear integer planning optimization problem is formulated. A comprehensive cost function representing the inductively charged SAESs is developed, considering road construction, power electronics and materials, traction battery, and installation costs. The optimization problem is solved to determine the best combination of the system key design parameters (number and allocations of wireless chargers, charging power level, track length and on-board battery capacity) that show the most cost-effective solution and allow the SAESs realizing charge sustaining operation. The planning platform incorporates representative simulated traffic data (drive cycles and routes) for four SAESs at Greenville project using the Simulation of Urban Mobility (SUMO) tool. These data are fed to a vehicle powertrain model and a wireless charger power model to predict the battery power, energy and state-of-charge (SOC) profiles, which are provided to the search algorithm to assess the design objectives under specific constraints. The results indicated that implementing wireless charging at a few designated stops for fixed-route SAESs with proper design allows the vehicles realizing charge sustaining operation, infinite range and zero recharge downtime, with a significant reduction in the on-board battery (36 % ) and road coverage (69%), at minimum cost.

33 ADVANCED PROPULSION SYSTEMS↗