Design and Test Validation of a Flat Flex Assembly Multi-Sensor Package
Explore the source record for details and available documents.
Engineering - Mechanical and civil engineering↗
SEARCH · Engineering Papers
Results for “sensor validation”
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.
Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.
Heterogeneous Integration Technologies for High-temperature, High-density, Low-profile Power Modules of Wide Bandgap Devices in Electric Drive Applications (Final Technical Report)
The goal of this project is to develop packaging technologies for making high-temperature, high-density, and low-profile wide-bandgap (WBG) power electronics modules for electric drives. These modules are aimed at enabling the DOE’s University Consortium to reach its 2025 inverter targets of ≥ 100 kW/L and ≤ 2.7 $/kW. The specific objectives are to: design and fabricate SiC half-bridge power modules with double-sided cooling and parasitic inductances < 5 nH, heat flux density > 400 W/cm 2 , and working junction temperature of 200 o C; design, fabricate, and deliver a gate driver with double-sided cooled modules for the construction of a 100 kW/L inverter at Oak Ridge National Lab; and design and prototype intelligent gate drivers with integrated current sensor and a low-profile DC-DC power supply with air-core transformer for testing power modules at 200 o C junction temperature. We followed an iterative technical approach of design, simulation, fabrication, and testing of various versions of modules, current sensors, and power supply. The state-of-the-art silicon carbide devices rated at 1.2 kV and 149 A were packaged by sintered-silver bonding on an aluminum nitride direct-bond-copper substrate for high thermal conductivity, high working temperature, and high joint reliability. Porous silver posts were used to interconnect the device’s source pads to the other direct-bond-copper substrate for low mechanical stresses, ease of manufacturing, and double-sided cooling. A current sensor based on package parasitic inductance was developed to measure switching current. A dynamic feedback scheme was developed to compensate the effect of parasitic resistance and temperature variation. A constant-current class-E dc-dc converter with air-core transformer was developed. Air-core transformer was used due to the unavailability of magnetic core at high temperatures. Gate driver and power supply were integrated with the double-side cooled, high temperature SiC power modules for testing the modules at 200 o C junction temperature. Double-pulse and continuous testing of the integrated technologies validated the design and fabrication of the three component technologies. Throughout the project, we overcame the challenge for design verification caused by low prototyping yield, which then helped train the graduate students, the future workforce, to learn the engineering know-how for low-cost manufacturing of reliable products. Below is a summary of the major accomplishments of this project: development of a prototyping process for fabricating double-side cooled (1200 V, 149 A) SiC phase-leg modules capable of working to 200 o C Tj; simulation and experimental verification of the improvement of thermo-mechanical reliability of the double-side cooled SiC phase-leg module by using rigid encapsulant; design and experimental validation of a current sensor based on package parasitic inductance and a compensation solution for eliminating the effect of parasitic resistance; design and experimental validation of a low-profile power supply with six-output air-core transformer for gate driver; functional demonstration of a SiC phase-leg module integrated with its gate driver, current sensor, and an air-core power supply at 200 o C Tj in a double-pulse switching test setup and Buck converter continuous test setup; successful completion of six PhD and two MS students who are or will work at Apple Inc., Tesla Inc., Wolfspeed Inc., Microchip Inc., Monolithic Power Systems Inc., and LG Magna Inc.
32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
Thermomagnetic generators for ultra-low-grade marine thermal energy harvesting
Low-grade thermal gradients in marine environments represent an underexploited energy source for autonomous sensing and monitoring. Converting such small temperature differences into usable electrical power remains a key challenge for ocean-deployed systems. We present a deployable thermomagnetic generator thoroughly characterized for marine-relevant energy harvesting. The device powers an internet-connected sensor and harvests ultra-low temperature differences akin to those at the ocean surface. It draws heat from water and rejects it to ambient air, operating optimally at a temperature difference (ΔT) of ~7.5 °C. Laboratory prototypes generated up to 6.7 mW at ΔT ~ 10 °C with gentle airflow (~1 m s -1 ). A separate controlled wave-tank demonstration validated stable operation and sensor powering under marine-like boundary conditions. Given its voltage and power margins, the generator could sustain multiple sensor nodes. Scalability and material assessments identify modular deployment and non-rare-earth alternatives as pathways toward practical marine energy harvesting and low-grade waste-heat recovery.
16 TIDAL AND WAVE POWER↗
Design optimization of MAPS-based detectors using a data-driven fast simulation approach
A parametric simulation tool for pixel sensors is presented. A realistic pixel response is simulated purely based on measurement input, without requiring detailed knowledge of the underlying manufacturing process. As such, it provides an efficient alternative to the use of Technology Computer-Aided Design simulations, which typically depend on proprietary process information. Due to its parametric approach, the package is fast and thus particularly useful for larger detector systems and high hit rate environments. This work presents measurements, simulation and its validation for the MALTA2 sensor. It is a small collection electrode monolithic active pixel sensor produced in the Tower 180 nm complementary metal-oxide-semiconductor imaging process. Modifications to the sensor’s periphery, mainly in the hit merger, are studied in order to optimize the performance for tracking and calorimetry. This optimization is of special interest as part of the MALTA3 sensor redesign in the 65 nm Tower Partners Semiconductor Co. process.
72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗
Steam generator model design parameter sensitivity study for small modular reactor system
Here, this study focuses on design parameter sensitivity studies pertaining to several Once-Through Steam Generator (OTSG) model cases both with and without a riser using python and advanced risk assessment and optimization tool, i.e. Risk Analysis Virtual Environment (RAVEN) developed at Idaho National Laboratory (INL), to support a Small Modular Reactor (SMR) system. The presented Steam Generator (SG) python-based model is a mathematical representation of a steam-generating unit for a Pressurized Water Reactor (PWR)-type SMR system, including fluid flow and heat transfer equations, models, and correlations. Design studies involve changing the model’s input design parameters (e.g., temperature, pressure, mass flow rate) to observe the resulting effects on the output of the system, such as the Heat Transfer Coefficient (HTC), Reynolds number, Nusselt number, and heat transfer performance. Sensitivity studies analyze the degree to which system output and/or desired parameters (e.g., HTC or heat transfer performance) are sensitive to changes in the input parameters. By using RAVEN, detailed design parametric sensitivity studies. Six input parameters—namely, the pressure, temperature, and mass flow rate for the inlet of the primary-side (hot fluid) and secondary-side (cold fluid) of the SG—were randomly perturbed via RAVEN’s Monte Carlo Sampler module, using uniform distributions (i.e., ±1%, ±5% and ±10 % relative changes) for 600 samples. The analysis results give valuable insights into SG system performance, and provide justification for further research and development such as optimized sensor placement, design verification, validation, and optimization.
21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
Improving Cost and Efficiency of the Scalable Solid Oxide Fuel Cells Power System
The objective of this project was to design and develop a 20kW range small-scale solid oxide fuel cells (SOFC) power system for applications such as data centers and commercial buildings. The original plan included a 5,000 hours demonstration and a Techno-Economic Analysis (TEA) which were dropped as part of project termination. The original project plan was to use a stack with a cross-flow cell design which had previously been tested for 500 hours at a community college in Malta, NY. However, it was decided to move to the advanced R-SOFC co-flow cell developed under Department of Energy Award DE-FE0031971. The advanced cell design has the advantage of a larger active area for the same manufacturing footprint which results in fewer required cells for the same stack power, hence a higher volumetric power density (kW/L) and lower cost per kW than the original cross-flow cell design. A full SOFC system Simulink model was developed and calibrated with testing data from a fuel cell stack and BOP (balance of plant) components. The simulation results from the calibrated model showed an acceptable match with the experimental data. A structural analysis conducted for various load scenarios indicated no high stress areas for all spatial directions. Major electrical system components were acquired, built and successfully tested. System sensors were verified and validated against controls. Safety checks, a diagnostic check, PID tuning, and control software commissioning tasks were also conducted. The power electronics prototype was delivered and trial testing completed. Balance of Plant component testing and simulation work was conducted to characterize Reformer-Heat Exchanger heat transfer and backpressure and reformer catalyst methane conversion and product selectivity. Simulations were conducted to design the Anode and Cathode fluid passages and size the air-air and fuel-fuel heat exchangers. A Burner operation map was created from test data and the Anode Gas Recirculation blower was tested to evaluate its durability. The SOFC system used a horizontal style design where components sit directly on a casting with a direct connection to the skid. This design has efficient packaging and a small footprint with approximate dimensions of 750 mm x 700 mm x 1700 mm. An SOFC system was built and successfully tested at the Malta, NY facility The system for over 500 hours under load of which over 300 hours was at full load of 20 kW.
30 DIRECT ENERGY CONVERSION↗
Field validation of dynamic mechanical torque measurements using fiber-optic strain sensors for geared wind turbines
Abstract Accurate knowledge of the mechanical loads of wind turbine gearboxes has become essential in modern, highly loaded gearbox designs, as maintaining or even improving gearbox reliability with increasing torque density demands is proving to be challenging. Unfortunately, the traditional method of measuring dynamic mechanical torque using strain gauges placed on the outer surface of a rotating shaft and transmitting the resulting signal is unsuitable for serial deployment due to technical and economic constraints. An alternative method based on fiber-optic strain sensors placed on the stationary outer surface of the gearbox ring gear has been proposed. Like shaft torsion, the radial deformation of the ring gear is proportionate to the rotor torque. Placing the sensors on a stationary component is a cost-effective alternative for serial implementation because the need for complex and expensive data transfer via wireless transmission or a slip ring is eliminated. In this paper, we present the results of an extensive field experiment conducted to evaluate the torque measurement accuracy of this novel sensing solution installed on the gearbox of a Gamesa G97 2-MW wind turbine at the National Renewable Energy Laboratory’s Flatirons Campus. Torque measurements derived from fiber-optic strain sensors placed on the ring gear of the planetary stage are compared to conventional torque measurements from strain gauges placed on the main shaft. Two different torque estimation data processing methods were evaluated, with the method based on operational deflection shapes providing the most accurate results with an average normalized root mean square error below 0.7% for a load revolution distribution analysis. The effect of operating conditions on the torque estimate was also investigated, and the third planet-passing operational deflection shape was found to be the least sensitive to nontorque load-related effects. The fiber-optic strain sensors’ successful operation during the complete test campaign has demonstrated a robust and accurate solution for fleet-wide enhanced gearbox remaining useful life estimation.
17 WIND ENERGY↗
MARVEL Instrumentation, Control, and Software Considerations
This paper details the various I&C considerations and design decisions made throughout the MARVEL (Micro-reactor Applications Research Validation and Evaluation) project, including sensor and actuator selection, safety-related functionality, digital control hardware and software, and testing methodologies. Key challenges such as managing radiation, temperature, and space constraints are discussed, along with the trade-offs between using standard equipment and custom solutions. The successful integration of off-the-shelf components, the emphasis on minimizing safety-related instrumentation, and the lessons learned from prototyping and testing are highlighted. The authors aim to provide insights that can benefit future micro-reactor designs and emphasize the importance of real-world testing in advancing reactor technology.
46 - INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AN↗
Molecularly Imprinted Polymer Sensor Empowered by Bound States in the Continuum for Selective Trace-Detection of TGF-beta
The integration of advanced materials and photonic nanostructures can lead to enhanced biodetection capabilities, crucial in clinical scenarios and point-of-care diagnostics, where simplified strategies are essential. Herein, a molecularly imprinted polymer (MIP) photonic nanostructure is demonstrated, which selectively binding to transforming growth factor-beta (TGF-β), in which the sensing transduction is enhanced by bound states in the continuum (BICs). The MIP operating as a synthetic antibody matrix and coupled with BIC resonance, enhances the optical response to TGF-β at imprinted sites, leading to an augmented detection capability, thoroughly evaluated through spectral shift and optical lever analogue readout. The validation underscores the MIP-BIC sensor capability to detect TGF-β in spiked saliva, achieving a limit of detection of 10 fM and a resolution of 0.5 pM at physiological concentrations, with a precision of two orders of magnitude above discrimination threshold in patients. The MIP tailored selectivity is highlighted by an imprinting factor of 52, showcasing the sensor resistance to interference from other analytes. The MIP-BIC sensor architecture streamlines the detection process eliminating the need for complex sandwich immunoassays and demonstrates the potential for high-precision quantification. This positions the system as a robust tool for biomarker detection, especially in real-world diagnostic scenarios.
77 NANOSCIENCE AND NANOTECHNOLOGY↗
Optimization and Experimental Validation of Annular Finned PCM-HX for a Domestic Hot Water Heater Application
The load profile for domestic water heating is time-dependent and can result in high energy demand during peak operating times. Shifting this peak load can have significant environmental and economic impacts. Phase change material (PCM)-based thermal energy storage (TES) is a potentially useful technology for peak load shifting in domestic hot water (DHW) applications thanks to its high latent heat and energy density. In this study, an annular finned-tube PCM-HX design concept was optimized for a load-shifting TES unit to meet the Department of Energy standard for a medium-usage DHW heater using a resistance-capacitance model (RCM) integrated with a Multi-Objective Genetic Algorithm. The optimized design comprised 70 identical annular finned-tube PCM-HX units connected in parallel and utilizing RT62HC as the PCM. A single PCM-HX unit was prototyped and tested in a vertically oriented setup with upward heat transfer fluid (HTF) flow. The hot water supply time was defined based on a cutoff temperature of 51.7°C. The as-designed mass flow rate (1.5 g/s) was tested to assess the performance of the prototyped PCM-HX unit for RCM validation. For the experimental investigation, RTD sensor bundles measured HTF temperature at the PCM-HX inlet and outlet, and a Coriolis flow meter accurately measured the HTF mass flow rate. The simulated discharging power underpredicted the experimental result by about 12%, and the simulated hot water supply time underpredicted the experimental result by approximately 13% for the as-designed mass flow rate (1.5 g/s). The average deviation of the hot water supply temperature between the experimental and RCM results during the complete PCM solidification process was 1.3 K for the as-designed mass flow rate. The overall good agreement between the experimental and RCM results provides confidence that computationally efficient models such as RCM can be utilized for design optimization of PCM-HXs.
42 ENGINEERING↗
NWB Sensors Infrared Cloud Imager Data Products from SGP
NWB Sensors is a company which has developed a commercially available Infrared Cloud Imager (ICI). For more information, consult the company's webpage, https://www.nwbsensors.com/infrared-cloud-imager. To validate the radiometric accuracy of the ICI, NWB Sensors deployed it to the ARM SGP User Facility in 2023. The primary motivation of this deployment was to perform an intercomparison between the ICI and the Atmospheric Emitted Radiance Interferometer (AERI). The AERI spectral radiance data product can be integrated across the response function of the ICI and directly compared to the zenith radiance observed by the ICI. In addition, the ICI uses proprietary models of the downwelling clear-sky radiance in its cloud processing algorithms. They are based on surface meteorology and precipitable water vapor (PWV). These models were validated by comparing their predicted radiances to those derived from radiative transfer models of the ARM radiosondes. Finally, PWV observations derived from the ICI's onboard GNSS-based PWV retrieval system were compared against those from the microwave radiometer. This dataset contains the ICI radiance and cloud data products.
Atmosphere↗
The NREL Sensor Laboratory Detection of Hydrogen Emissions
The development of a functional hydrogen detection system is a multifaceted process that integrates hardware, deployments strategies, and analytics which can be supported by the NREL Sensor Laboratory: 1. Support of the design, validation and optimization of sensing prototypes; 2. Guide optimized sensing element development, including control electronics; 3. Laboratory testing to validate/optimize metrological performance (measurement range, detection limit, etc.); 4. Provide test sites for field deployments representative of real-world scenarios with controlled hydrogen releases; 5. Develop sensor placement and operation guidance; 6. Provide guidance on electronics to accommodate facility integration; 7. Electrical safety designs to allow for operation within restricted zones; 8. Integration into facility monitoring and control systems; 9. Guide incorporation of cyber security elements to protect facilities from malicious attacks; 10. Modeling and application of advanced analytics to detect and quantify emissions; 11. Higher Order dispersion models to guide sensor placement for reliable detection; 12. Advanced analytics for improved metrological performances, and to inform inverse modeling; 13. Market support and commercialization (national and international markets); 14. Commercial deployments in H2@SCALE markets (e.g., HUBs and other large-scale hydrogen markets); and 15. Leverage off international collaborations/partnerships (e.g., NREL is on the advisory board for the European initiative "pre-Normative Research on Hydrogen Releases Assessment"-NHyRA).
08 HYDROGEN↗
Ten questions concerning low-cost indoor air quality sensors: Perspectives from research and practice
Low-cost indoor air quality (IAQ) sensors are increasingly being used in homes and commercial and public buildings, driven by growing concerns about the impact of air on health, cognitive performance, and occupant wellbeing. These sensors offer a potentially transformative opportunity to increase spatial and temporal coverage of IAQ monitoring at a fraction of the cost of conventional reference instruments. However, their widespread use raises questions around accuracy, calibration, placement, data handling and interpretation, and integration into existing standards and workflows. This paper presents ten critical questions concerning the use of low-cost IAQ sensors in buildings, drawing on the latest empirical research, field deployments, and emerging practice. It discusses potential frameworks for deployment and evaluation, examines current sensor capabilities for measuring common pollutants, identifies methodological gaps in validation and uncertainty quantification, and outlines the extent to which existing IAQ standards can accommodate sensor-based evidence. The paper also explores how monitoring needs and deployment models vary by building type, the potential of real-time IAQ data to support building operations, and the ethical and legal implications of widespread sensor use. While significant challenges remain in ensuring data quality and building stakeholder trust, new applications are emerging through open data initiatives and advances in analytics and visualization. As the technology, science, and standards co-evolve, low-cost IAQ sensors are poised to become integral to routine building operation, building science, and environmental health research.
Parkinson, Thomas↗
Model Development and Analysis of a High-Fidelity Neutron Transport Sensor: The Quadrupole Detector Concept for Measurement of the Neutron Flux Gradient
Accurate reconstruction of the neutron flux distribution within a reactor core is essential for safe and efficient reactor operation. Traditional power shape synthesis in Light Water Reactors relies on hundreds of in-core detectors. However, this approach becomes impractical for Advanced Reactors and Microreactors due to limited space and harsh environments. To address this challenge, we propose a data-driven methodology that combines high-fidelity modeling with real-time ex-core sensor measurements, enabling the reconstruction of core power distribution while minimizing the reliance on intrusive in-core instrumentation. This project began in FY24 and achieved two initial milestones: (1) the definition of a three-year development plan for a Digital Twin framework and (2) the development of high-fidelity neutronics models of the Purdue University Reactor One (PUR-1) using both MCNP6 and OpenMC. The PUR-1 reactor, a zero-power facility, was selected due to its suitability for neutronics-focused modeling and the availability of experimental data for validation. Both models were benchmarked using neutron flux measurements obtained from irradiated gold foils, which were strategically placed within the core during a dedicated campaign in July 2024. This report marks the continuation and completion of those foundational tasks. The OpenMC model has been refined (improved geometric accuracy, expanded cross-section libraries, and refined sampling) and validated using additional experimental data. An updated sensor design—based on quadrupole configuration—was designed to measure both ex-core flux and its spatial gradient. These measurements will serve as inputs to a neural network-based reconstruction algorithm. Finally, the methodology was demonstrated on a two-dimensional test case representative of the heterogeneous material composition of the PUR-1 reactor core. A neural network implementation of the Kirchhoff-Helmholtz integral equation was employed to solve the boundary value problem using peripheral sensor measurements. The preliminary results confirm the strong potential of the proposed approach for accurate and minimally invasive neutron flux reconstruction.
22 GENERAL STUDIES OF NUCLEAR REACTORS↗
A Hermetic Package Technique for Multi-Functional Fiber Sensors through Pressure Boundary of Energy Systems Based on Glass Sealants
This paper presents a hermitic fiber sensor packaging technique that enables fiber sensors to be embedded in energy systems for performing multi-parameter measurements in high-temperature and strong radiation environments. A high-temperature stable Intrinsic Fabry–Perot interferometer (IFPI) array, inscribed by a femtosecond laser direct writing scheme, is used to measure both temperature and pressure induced strain changes. To address the large disparity in thermo-expansion coefficients (TECs) between silica fibers and metal parts, glass sealants with TEC between silica optical fibers and metals were used to hermetically seal optical fiber sensors inside stainless steel metal tubes. The hermetically sealed package is validated for helium leakages between 1 MPa and 10 MPa using a helium leak detector. An IFPI sensor embedded in glass sealant was used to measure pressure. The paper demonstrates an effective technique to deploy fiber sensors to perform multi-parameter measurements in a wide range of energy systems that utilize high temperatures and strong radiation environments to achieve efficient energy production.
Optics↗
Applications of fuzzy logic and best-worst method for tritium sensor selection
Accurate assessment of tritium as a fuel source is critical in fusion reactions, necessitating effective sensor evaluation methods. This study investigates a multi-criteria decision-making framework for selecting tritium sensors, integrating fuzzy logic to enhance decision quality. Initial attempts at applying fuzzy logic were found to be too elementary and failed to capture the complexity of multi-criteria selection; this prompted a refined approach that incorporated expert insights and advanced ranking techniques for sensor evaluation. The research used a two-stage methodology. In the first stage, important criteria and sub-criteria for sensor performance were identified and defined. These criteria were then weighted and scored using a fuzzy best-worst method, drawing upon expert opinions to ensure relevance and validity. The second stage involved interpreting information about varying sensors to rank them based on their overall criteria scores, encouraging the selection of the most suitable options. The result of the study is a proposed method for effective sensor selection in fusion reactors, which in turn will significantly improve the reliability of tritium monitoring in fusion applications.
11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
Accurate Ultrasonic Thickness Measurement for Arbitrary Time-Variant Thermal Profile
Ultrasonic thickness measurement of mechanical structures is one of the most popular and commonly used nondestructive methods for various kinds of process control and corrosion monitoring. With ultrasonic propagation speed being temperature-dependent, the thickness measurement can be performed reliably only when the thermal profile is completely known. Most conventional techniques assume the temperature of the test structure is uniform and at room temperature across its thickness. Such assumptions may lead to large errors in the thickness measurement, especially when there are significant temperature variations across the thickness. State-of-the-art techniques use external temperature measurements or implement iterative methods to compensate for the unknown thermal profiles. However, such techniques produce unsatisfactory results when the heat distribution is complex or varies rapidly with time. In this work, we propose a two-sensors technique, using both compressive and shear excitations, with a non-iterative rapid data processing method for accurate thickness measurement under arbitrary time-variant thermal profile. The independent behavior of shear and compressive waves is used to formulate a real-time thickness estimation technique. The developed technique is experimentally validated on a steel plate with fixed acoustic sensors. Test results show that the error in thickness estimation can be reduced by up to 98% compared to conventional thickness gauging methods.
36 MATERIALS SCIENCE↗
Extracted Radar Columns and In Situ Sensors (RadCLss) Value-Added Product Report
In order to validate precipitation, in 2010 the U.S. Department of Energy (DOE) Atmospheric Radiation Measurement (ARM) user facility procured 3- and 5-cm wavelength radars for documenting the macrophysical, microphysical, and dynamical structure of precipitating systems. To maximize the scientific impact, ARM supported the development of an application chain to correct for various phenomena in order to retrieve the “point” values of moments of the radar spectrum and polarimetric measurements. In estimation from ARM radars, a workflow was created to directly compare radar “point” values with various in situ observations at the surface.
54 ENVIRONMENTAL SCIENCES↗