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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 361 records · Page 20
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Evaluating Thermostats' Deadbands Using HVAC Hardware-In-the-Loop Experiment for Advanced Control Strategies: Preprint

Smart thermostats have gained significant popularity due to their potential for optimizing energy consumption and enhanced user control while ensuring occupants' comfort. The deadband, also referred to as temperature differential, is defined as the temperature difference between the desired setpoint and upper threshold or lower threshold for the HVAC equipment to turn on. It is a key factor influencing energy efficiency and user satisfaction. This paper presents a comparative analysis of the deadbands of five different smart thermostats, tested with a heat pump, aiming to identify variations in their deadband settings and implications for energy management. The experimental study was conducted using a HVAC hardware-in-theloop (HIL) system that integrates smart thermostats with physical HVAC equipment in a simulated house environment. The study explores the trade-offs between energy efficiency and occupant comfort and highlights how different thermostats participating in demand response event cycle differently based on their deadband settings. The findings offer valuable insights into how selecting the right thermostat or configuring smart thermostat with appropriate deadband settings can be leveraged to enhance demand response capabilities, shift loads effectively and improve operational flexibility in HVAC systems.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2022

Assessing the Threat: Weaving Cybersecurity into the Building Development Process

Today’s connected lighting systems have the potential to reduce energy consumption and operational costs via the use of the data they collect and share with other building systems (e.g., HVAC, building automation, security). However, many market available products are new to being networked, and when networked components in lighting and other building systems are not sufficiently secured, they present opportunities for criminals to exploit. Further, security vulnerabilities in one system can be used as lateral steppingstones that allow access to other prized assets on the same network. These cybersecurity concerns could deter the adoption and use of connected systems, which then could jeopardize long-term national objectives for reduced energy usage. The workflows described here and presented in more detail in the referenced reports are examples of how these frameworks and tools can be put to practical use during system design and specification.

attack surface, Building development, threat analy↗
DOE OSTI2021

Dataset of low global warming potential refrigerant refrigeration system for fault detection and diagnostics

Abstract HVAC and refrigeration system fault detection and diagnostics (FDD) has attracted extensive studies for decades; however, FDD of supermarket refrigeration systems has not gained significant attention. Supermarkets consume around 50 kWh/ft 2 of electricity annually. The biggest consumer of energy in a supermarket is its refrigeration system, which accounts for 40%–60% of its total electricity usage and is equivalent to about 2%–3% of the total energy consumed by commercial buildings in the United States. Also, the supermarket refrigeration system is one of the biggest consumers of refrigerants. Reducing refrigerant usage or using environmentally friendly alternatives can result in significant climate benefits. A challenge is the lack of publicly available data sets to benchmark the system performance and record the faulted performance. This paper identifies common faults of supermarket refrigeration systems and conducts an experimental study to collect the faulted performance data and analyze these faults. This work provides a foundation for future research on the development of FDD methods and field automated FDD implementation.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2024

Fuel driven near isothermal compressor

A gas compressor system includes a compression liquid holding tank in fluid communication with a combustion tank. A combustible fluid is directed to the combustion tank. An ignition system is provided for igniting the combustible fluid. A compression liquid flows between the liquid holding tank, the combustion tank, and a compression tank. A compressible gas is provided in the compression tank. The ignition of the combustible fluid drives the compression liquid from the combustion tank to the compression tank, compressing the compressible liquid. An HVAC&R system and a method of compressing gas are also disclosed.

Momen, Ayyoub Mehdizadeh↗
DOE OSTI2023

A new control score concept for building performance assessment

In buildings, performance assessment often focuses on energy use with metrics such as energy use intensity (EUI) used to benchmark performance. However, energy performance of a building is fundamentally determined by the control system that engages the energy-using systems. There are two aspects of control that are of particular importance: (1) the ability to regulate process variables to their setpoints; and (2) whether the setpoints are at the right levels and/or following desired profiles. Most buildings do not reach their energy efficiency potential due to deficiencies in control performance and operators do not have access to metrics that can illuminate these deficiencies. Here this paper addresses this problem by providing novel techniques that combine these two aspects of control performance into a single standardized score on the scale of 0-10. The concept of a standardized control scores enables all systems in a building to be compared on the same scale and also for scores to be rolled up to different levels in the building and system hierarchy for system-wide analysis. The paper presents the theory for the method, describes a prototype tool for displaying scores, and presents results from application to a large building in Minneapolis.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2021

Lifting the Garage Door on Spawn, An Open-Source BEM-Controls Engine

Spawn is the latest whole-building energy simulation engine developed by the US Department of Energy, National Labs and industry. Whereas EnergyPlus was designed as a successor to DOE-2, Spawn is not a direct successor of–nor is it intended as an imminent replacement for– EnergyPlus. Instead, Spawn reuses parts of EnergyPlus while supporting new use cases in HVAC and controls. Spawn is intended to provide several capabilities that significantly advance beyond EnergyPlus. It is intended to support the evaluation of novel HVAC and district energy systems in a more physically realistic way. Critically, it can model control in a physically realistic way, using portable specifications that can be compiled for execution on control platforms. Spawn is also intended to support co-simulation in an intrinsic way to enable integration with third-party models. This paper describes the software architecture of Spawn from model authoring to compilation and simulation. It explains how Spawn reuses the envelope and daylighting modules of EnergyPlus and couples them to HVAC and control models from the Modelica Buildings Library using the Functional Mockup Interface (FMI) standard. It presents a number of examples that: i) validate Spawn’s coupled simulation approach by comparing its results to those of EnergyPlus, ii) illustrate the Spawn methodology for modeling and simulating HVAC systems, and iii) evaluate the performance of Spawn’s Quantized State System (QSS) time integration algorithms

Wetter, Michael↗
DOE OSTI2024

Design and Manufacturing of High Performance, Reduced Charge Heat Exchangers

Air-to-fluid heat exchangers (HXs) play a critical role as the main heat transfer component in Heating, Ventilation, Air-Conditioning, and Refrigeration (HVAC&R) systems. However, their airside thermal resistance significantly inhibits their overall performance. Furthermore, these HXs must be continually more compact to meet the latest refrigerant charge limits to reduce emissions. Recent literature suggests that traditional HX geometries (e.g., round or flat tubes with fins), have reached their limits, and more sophisticated shape- and topology-optimized designs are required to achieve the next jump in performance. This research sheds light on the next generation of air-to-refrigerant HXs and aims to address several practical issues to commercialization such as novelty challenges (improved performance for significant charge reduction; modeling expertise & time investment), manufacturing challenges (non-round tube manufacturing; tube-header integration; product qualification, e.g., burst pressure testing, extreme operational environment, etc.), and operational challenges (flow maldistribution, fouling & wetting, noise & vibration). For example, a >20% improvement on one (or more) HX-level performance metrics (e.g., envelope volume, airside pressure drop, face area, capacity, refrigerant charge, weight, cost, etc.) must be achieved before a HX design is considered for commercialization. We present a new, comprehensive and experimentally validated air-to-refrigerant HX optimization framework with simultaneous thermal-hydraulic performance and mechanical strength considerations for novel, non-round, shape- and topology-optimized tubes capable of optimizing single and two-phase HX designs for any refrigerant choice and performance requirement with significant engineering time savings compared to conventional design practices. The framework was exercised for a wide range of applications and refrigerants, resulting in HXs which achieved greater than 20% improved performance, 20% reductions in size, and 25% reductions in refrigerant charge. To enable non-round tube bundle use in next generation HVAC&R equipment, novel manufacturing techniques were investigated, including the development of conventional manufacturing methods for small diameter, non-round tubes and novel tube-header integration strategies. In total, ten HX prototypes were manufactured, nine using conventional methods directly attributed to this project and one using advanced additive manufacturing methods. The five-year manufacturing feasibility of the proposed HXs was found to have a good outlook. The non-round tube HX simulated performance was validated through comprehensive experimental testing, including nine in-house component-level tests, one independent component-level test at an industry partner laboratory, and in-house system-level tests of using a commercially-available, residential packaged A/C unit which was retrofitted with a non-round tube prototype HX. It was found that HX designs proposed by the new framework can successfully predict experimental thermal-hydraulic performance within ±10-20% the first time with no manual design changes, eliminating the need for time-consuming and expensive prototyping efforts. This work will accelerate design and time to market for next generation HXs while simultaneously facilitating industry transition to new refrigerants at lower charge.

42 ENGINEERING↗
DOE OSTI2022

Multi-scale and multi-physics analysis, design optimization, and experimental validation of heat exchangers utilizing high performance, non-round tubes

Air-to-refrigerant heat exchangers (HXs) are fundamental components in HVAC&R systems, and considerable research has been dedicated designing continually smaller, lighter, and more efficient HX designs. In recent years, researchers have leveraged advancements in Computational Fluid Dynamics (CFD), Finite Element Analysis (FEA), and optimization algorithms to consider primary tube shape and topology optimization to design highly compact, high performance HXs for a multitude of applications. In this research, we present a computationally efficient, comprehensive, multi-scale, and multi-physics analysis and optimization method for air-to-refrigerant HXs featuring automated CFD and FEA simulations and approximation-assisted optimization. This methodology was utilized to design HXs with shape-optimized, non-round tubes which outperform current state-of-the-art tube-fin HXs without compromising structural integrity. The optimal HXs were shown to deliver similar thermal performance to the baseline HXs while also achieving more than 20% reductions in airside pressure drop and core envelope volume and more than 30% reduction in internal volume. Comprehensive experimental validation of the optimization methodology was conducted through the testing of two prototypes in a standardized wind tunnel facility under multiple operating conditions. For prototype #1 under dry evaporator conditions, the predicted heat load agreed within ± 10% of measured values and the predicted airside pressure drop agreed within ± 30%, while for dehumidifying conditions, the predicted sensible and latent heat loads agreed within ± 10% and ± 20% of the measured values, respectively. For prototype #2, the predicted condenser heat load agreed within ± 3.0% of measured values, and the predicted airside pressure drop agreed within ± 27%. The acceptable agreement between simulation and experimental results for the present application highlights the flexibility of the novel optimization methodology to design next generation HXs with improved performance and reduced volume, weight, and environmental impact.

42 ENGINEERING↗
DOE OSTI2023

Sensitivity analysis of an automated fault detection algorithm for residential air-conditioning systems

The state of the art of fault detection and diagnosis (FDD) for residential air-conditioning systems is expensive and not yet amenable to widespread implementation. FDD for homes can significantly reduce utility costs, and increase the lifespan of the equipment. The cost barriers currently, however, make FDD for homes economically unviable for large scale implementation. In prior work, we offered a solution to reduce FDD costs by proposing an automated fault detection algorithm to serve as a screening step before more expensive FDD tests can be conducted. The algorithm uses only the home thermostat and local weather information to identify thermodynamic parameters and detect high-impact air-conditioning faults, including those that occur during equipment installation. We had tested the algorithm on a single EnergyPlus™ model of a home in Orlando, Florida. The thermodynamic parameter identification process is highly nonconvex involving several local optimal solutions. In this paper we propose a novel method to select the best model for fault detection from among the list of local optimal solutions to make the algorithm more robust to homes of different construction, without which the fault detection process would be infeasible. Another unique contribution of the paper is implementing the solution on real-world data. We also bring the algorithm closer to market by testing it on real-world data. We implement the algorithm on data obtained from experiments conducted by the Florida Solar Energy Center (FSEC) on a laboratory home equipped with a heat pump where faults were intentionally added for a period of seven months. The algorithm successfully detected an undercharge fault with 70.6% accuracy, concurrent duct leakage and undercharge faults with 85.2% accuracy, and duct leakage faults with 69.1% accuracy. A sensitivity analysis is also performed on EnergyPlus models of nine types of homes that vary in construction to demonstrate the robustness of the algorithm. Finally, the algorithm achieves an average accuracy of 71% for no-fault condition, 77% for 40% undercharge fault, and 76% for duct-leak fault.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2023

STRESS AND FATIGUE ANALYSIS OF AIR-TO-REFRIGERANT HEAT EXCHANGERS WITH NON-ROUND TUBE SHAPES

Air-to-refrigerant heat exchangers are fundamental components in Heating, Ventilation, Air Conditioning, and Refrigeration (HVAC&R) systems. Recent research has shown that heat exchangers utilizing small hydraulic diameter, non-round, shape-optimized tubes to be promising next design update. Such tubes can improve performance, reduce material and lower refrigerant charge. However, such tube designs may be more susceptible to fatigue issues. Therefore, stress and fatigue analyses of such heat exchangers are critical to ensure structural integrity, reliability, and manufacturability. In the present work, a mechanical model is developed to obtain the stress distributions in heat exchangers with round, ellipse, and airfoil-shaped tubes. The results indicate that under 3.45 MPa internal pressure, the maximum stresses don't surpass 190 MPa.

Zhang, Mingkan↗
DOE OSTI2023

Review of Variable Geometry Air-to-Refrigerant Heat Exchangers

Air-to-refrigerant heat exchangers (HXs) are fundamental components to HVAC&R systems and as a result there is an ever-increasing need for performance and packaging improvements. Typically, HX’s are designed in uniform arrangements with the goal of providing the necessary heat transfer for minimal material costs. Recent research on fin tube heat exchangers (FTHX) with variation in one or more key parameters has shown significant potential for increasing heat transfer, reducing pressure losses, and making HXs more resilient to environmental externalities like airflow maldistribution and frost accumulation. In particular, researchers have increased heat transfer by 7.6% and j/f by 16% via non-uniform tube and winglet shapes. Additionally, multiple cases have shown that variable geometry heat exchangers (VGHX) are able to match the performance of conventional HXs with reductions in material mass and envelope volume of up to 33% and 40%, respectively. This paper presents a literature review of VGHXs specifically with regards to non-uniform FTHX’s.

42 ENGINEERING↗
DOE OSTI2026

ResStock Measure Documentation: Dual Fuel Heat Pump

This report is part of a series describing different ResStock measures. "Measures" refers to energy efficiency retrofits that can be applied to buildings during modeling. This documentation covers the "Dual Fuel Heat Pump" measure upgrade methodology and briefly discusses key results.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2021

Design Optimization of A-Type Heat Exchangers based on High Performance, Non-Round Tubes

Air-to-refrigerant heat exchangers (HXs) have been the topic of considerable research as they are the fundamental heat transfer components of HVAC&R systems. For residential and commercial applications, indoor heat exchangers are often in A-type configurations to reduce air-conditioner system footprint while still delivering the required cooling or heating. Classical HX design practices typically assume a uniform frontal air velocity profile to facilitate the use of conventional tube-fin airside heat transfer and pressure drop correlations for performance prediction. However, it is well-reported throughout the literature that A-type HXs experience significant airflow maldistribution which can severely degrade HX performance. Additionally, recent advancements in simulation software such as Computational Fluid Dynamics (CFD), Finite Element Analysis (FEA) and optimization algorithms have led researchers to consider primary heat transfer surface optimization to achieve highly compact HXs which do not require fins. In this paper, an A-type HX which utilizes shape-optimized non-round tubes is optimized for minimum duct size and airside pressure drop. This is achieved through coupling of an experimentally validated finite volume HX model with automated 2D CFD simulations of airflow through the HX for airside thermal-hydraulic performance evaluation. Preliminary results show that the optimal designs deliver similar capacity while achieving 20% reductions in airside pressure drop and duct cross-section area. Additionally, the optimal design apex angles in this study were similar to those from previous A-Type HX optimization studies for conventional tube-fin HX geometries, suggesting that the apex angle for optimal A-Type configuration performance may be independent of tube geometry.

42 ENGINEERING↗
DOE OSTI2022

Material Compatibility of 3D Printed Polymer Composites with Low GWP Refrigerants

The recent development of 3D printing brings numerous opportunities to develop polymer heat exchangers with desired configurations and allows access to the new complex engineering design for better performance. To be used in the HVAC&R system, the compatibility of these materials to refrigerants needs to be thoroughly investigated and understood. This study tested the material compatibility of the printed polymer composites according to the ASHRAE Guideline 38 using metal pressure vessels. These printed parts were tested with R-134A, R-1234YF, R-1234ZE, R-1233ZD(E), and 32-3 MAF POE (10 wt.%) was used as the lubricants. The change in volume, mass, hardness, and mechanical properties was studied in detail. Different compatibility of the composites with refrigerants was observed when the composition of the composite changed. After exposure to refrigerants, the morphological and thermal properties were studied with the scanning electron microscope, thermogravimetric analysis, and differential scanning calorimetry to further reveal the influence of these refrigerants.

Li, Kai↗
DOE OSTI2024

Practical challenges of model predictive control (MPC) for grid interactive small and medium commercial buildings

To the urgent call for mitigating climate change, substantial initiatives have been undertaken to deploy grid-interactive heating, ventilation, and air-conditioning (HVAC) controls, such as model predictive control (MPC) for buildings. These efforts typically aim to curtail peak energy demand, shift load and enhance overall energy efficiency. With the recent development of low-cost MPC technologies that don’t require extensive instrumentation or manual modeling, small and medium commercial buildings (SMCBs), which rarely utilize advanced HVAC control systems, have become candidates for grid-interactive efficient buildings (GEBs). However, despite the potential benefits and maturity of the technology itself, several practical challenges remain in real-world implementation. In this paper, we share the practical challenges that we have encountered in implementing and testing three types of MPC solutions (ON/OFF unit, dualfuel, and VRF systems) on multiple SMCB sites. We describe the MPC deployment process and discuss the lessons learned. The site selection, eligibility, and retrofit availability (e.g., utility price structure, thermostat communications, etc.) are the main discussion points at the beginning of the project. Also, the modeling automation and the best practices for interacting with endusers and handling erroneous situations are presented for successful operations.

woo Ham, Sang↗
DOE OSTI2026

Oversizing and Part-Load Problems

Oversizing, the common engineering practice of specifying devices with capacity exceeding the actual load requirement, is a widespread practice across virtually all building technologies end-use categories, including HVAC, electrical systems, lighting, appliances, and plug loads. This practice, driven by factors like design uncertainty, institutional pressures, and risk aversion, results in wasted capital investment, control difficulties, and excessive energy consumption due to inefficient part-load operation. Part-load operation, where devices run below maximum capacity, is the dominant operating mode in most energy systems and presents a complex design challenge. Solutions to match output to load fall into three broad categories: constraining the output, adjusting the device’s internal behavior, and linking output to energy storage or other waste-heat reuse applications. The energy implications of part-load are critical, as efficiency often drops sharply as load decreases across a wide diversity of devices. To quantify the extent of this problem, we derive a dimensionless Part-Load Metric (PLM) based on device efficiency and its frequency distribution of operating hours at various output levels. The PLM quantifies the deviation of a device's actual efficiency from its maximum design efficiency. This metric also serves as a measure of "capital inefficiency," enabling engineers to compare the impact of different part-load solutions and providing a unified framework for evaluating performance across various devices and systems.

Meier, Alan↗
DOE OSTI2021

A Flexible and Generic Functional Mock-up Unit Based Threat Injection Framework for Grid-interactive Efficient Buildings: A Case Study in Modelica

Grid-interactive efficient buildings (GEBs) have been considered as an important asset to support the power grid reliability by utilizing the demand flexibility offered by GEBs. GEBs are enabled by advances in sensors and controls, and the communication between building equipment, whole buildings, and the grid. The integration of different building technologies and network-based communication system makes GEBs vulnerable to passive threats such as equipment failure and active threats such as cyber-attacks. Modeling and simulation is an effective way to evaluate the impact of threats on the system performance. This paper proposes a generic and flexible threat injection framework for commonly-used building energy simulators such as EnergyPlus and Modelica to support threat modeling and evaluation. This framework leverages functional mock-up unit (FMU) to develop a general modeling interface for threat injection and simulation. A numerical case study using Modelica as a building energy simulator is conducted to demonstrate the capability of the framework for supporting single/multiple-order threat modeling and simulation of a GEB. Four threats and their combinations are injected on a Modelica-based threat-free building energy and control system, including operating supply fan at its full speed, remotely cycling the chiller on and off, blocking the chiller from receiving the chilled water supply temperature setpoints, and hijacking the global zone air temperature setpoint. Simulation results show that the cyber-attack that leads to short-term signal blocking has small effects on the system operation due to the "self-healing" feature of the heating, ventilation, and air-conditioning (HVAC) interactive control system. The threat that takes control of resetting the global zone air temperature setpoints has the most adverse impact on the system energy use, peak power demand, thermal comfort and the provision of demand flexibility. The combination of four threats have aggregative effects on the system but the effects are less than the additive effects of the individual threat.

Fu, Yanyang↗
DOE OSTI2021

Operating a commercial building HVAC load as a virtual battery through airflow control

Virtual battery (VB) is an innovative method to model flexibility of building loads and effectively coordinate them with other resources at a system level. Unlike a real battery with a dedicated power conversion system for charging control, methods are required for operating building loads to deviate from the baseline to respond to grid signals. This paper presents a VB control for a commercial heating, ventilation, and air conditioning (HVAC) system to follow the desired power consumption in real-time by adjusting zonal airflow rates. The proposed method consists of two parts. At the system level, a mixed feedforward and feedback control is used to estimate the desired total airflow rate. At the zone level, two priority-based algorithms are then proposed to distribute the total airflow rate to individual zones. In particular, a zonal airflow limit estimation method is proposed using machine-learning techniques, in contrast to physics-based thermal models in existing studies, to more accurately capture zonal thermal dynamics and improve temperature control performance. An office building on the Pacific Northwest National Laboratory campus is implemented in EnergyPlus, and used to illustrate and validate the proposed control.

Wang, Jiyu↗