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This is a collection of papers drawn from the 2019 ASME InterPACK Conference. The content spans the areas of heterogeneous integration, servers, flexible and wearable electronics, photonics, power electronics, energy storage, and autonomous and electric vehicles.
The wind energy market is currently dominated by horizontal axis wind turbines (HAWTs); however, vertical axis wind turbines (VAWTs) are emerging as a design alternative, especially for deep-water offshore siting due to their low center of gravity, ease of access to drivetrain components, and overall simplicity. Due to the absence of a pitch mechanism in large-scale Darrieus VAWTs, stall control has often been used to manage power and loads. Introducing a pitching mechanism in H-type VAWTs has been studied, but this diminishes the mechanical simplicity advantage, and the use of a pitching mechanism in a large-scale Darrieus-type VAWT is not practical. This work examines an innovative, alternative method to control the rotor dynamics of a large-scale 5 MW VAWT to maximize power while constraining loads without introducing any new or complex mechanical elements. This control strategy is termed intracycle revolution per minute (RPM) control, where the rotational speed of the turbine is allowed to vary in an optimal fashion with the azimuthal location of blades as opposed to typical constant RPM operation. An optimization framework is formulated for an open-loop optimal control problem and solved to maximize power subject to constraints on aerodynamic design loads. Results are presented to demonstrate the benefits and the performance limits of intracycle RPM control for large-scale 5 MW Darrieus VAWTs, namely, (1) power production (quantified in terms of AEP) that can be increased subject to baseline load limits and (2) opportunities to significantly increase AEP or decrease loads via intracycle RPM control that are examined for both two-bladed and three-bladed VAWTs.
The feasibility of inertial energy storage in a spacecraft power system is evaluated on the basis of a conceptual integrated design that encompasses a composite rotor, magnetic suspension, and a permanent magnet (PM) motor/generator for a 3-kW orbital average payload at a bus distribution voltage of 250 volts dc. The conceptual design, which evolved at the Goddard Space Flight Center (GSFC), is referred to as a Mechanical Capacitor. The baseline power system configuration selected is a series system employing peak-power-tracking for a Low Earth-Orbiting application. Power processing, required in the motor/generator, provides a potential alternative configurations that can only be achieved in systems with electrochemical energy storage by the addition of power processing components. One such alternative configuration provides for peak-power-tracking of the solar array and still maintains a regulated bus, without the expense of additional power processing components. Precise speed control of the two counterrotating wheels is required to reduce interaction with the attitude control system (ACS) or alternatively, used to perform attitude control functions. Critical technologies identified are those pertaining to the energy storage element and are prioritized as composite wheel development, magnetic suspension, motor/generator, containment, and momentum control. Comparison with a 3-kW, 250-Vdc power system using either NiCd or NiH2 for energy storage results in a system in which inertial energy storage offers potential advantages in lifetime, operating temperature, voltage regulation, energy density, charge control, and overall system weight reduction.
Recent progress in developing and implementing Pt-alloy cathode catalysts and thin (10-15 micron) low resistance membranes has enabled high performance state of art (SOA) membrane electrode assembly (MEA) with low Pt loading. However, these high performing MEAs do not meet durability requirements, especially at peak power, because of complex degradation mechanisms that are sensitive to the materials, MEA design, and fuel cell operating strategy. Specifically, power degradation of the cathode occurs via Pt and Co dissolution as well as deterioration of O 2 transport properties. Additionally, thin membranes are subject to failure due to manufacturing defects in the adjacent gas diffusion media and electrodes and the formation of membrane-attacking radical species caused by high gas crossover. In this project led by General Motors LLC (GM), the objective was to enhance the durability of SOA MEA through optimization of operating conditions, instead of new materials development. Along with our project partners, we have mapped the impact of operating conditions on the durability of SOA MEA. Output of the project include a low Pt loading SOA MEA that exceeds Department of Energy (DOE) 2020 target of >1 W/cm 2 at rated power and pathway to achieve >5000 h of durability. Durability studies in the project provide a detailed understanding of failure modes and operating condition sensitivity on cathode and membrane failure, critical for defining operating conditions and hybridization strategies that can guide system controls to maximize low-Pt MEA life. The project also generated and validated degradation models that will provide future research direction, critical for guiding future cycles of automotive MEA development.
A pointing/roll mechanism for the Ultraviolet Coronagraph Spectrometer (UVCS) is presented along with a description of the mechanism control algorithm. The mechanism, operating in space, will position the 2.1 meter long, 0.7 meter diameter UVCS instrument in pitch and yaw, within a 54 arc-minute half angle cone, and will also allow it to rotate + or - 179.75 deg. After considerable design effort, an optimum mechanical solution was achieved, which meets all scientific requirements as well as weight, volume, and power budgets. Evolution of the mechanism is presented along with the design status.
Wave energy, if all been harvested along the U.S. coastline, can power around 65% of the energy consumption in U.S.. Comparing to other renewable energy sources like solar or wind, ocean wave can provide up to 90% of steady uptime. With the high energy density (2-3 kW/m 2 ), it can produce more energy with the same amount of installation area comparing to the energy density of wind turbine (0.6 kW/m 2 ) and solar panel(0.2 kW/m 2 ). The predictability of wave provides advantages like planning installation, power dispatching, and maintenance activities. Although with all these advantages, wave energy converter system is still in the research stage due to its high system cost per electricity production. One of the challenges that need to be solved is the irregularity from the wave motion that leads to high instantaneous peak power into the wave energy converter, which usually reaches up to 10 - 20 times of the average power. The high peak power will not only bring high mechanical/electrical stress but also result in an overrating design of the components in the system. Another obstacle that prevents the wave energy system from moving forward is the high testing cost from the validations in wave-energy-test sites or tank-test sites. A high-fidelity multi-disciplinary system model, including hydrodynamics, mechanical dynamics, electromagnetics, and power electronics, is needed to predict the behavior of the system and reduce the cost of design validation.
This paper presents an overview of health management issues and challenges that are specific to rotorcraft. Rotorcraft form a unique subset of air vehicles in that their propulsion system is used not only for propulsion, but also serves as the primary source of lift and maneuvering of the vehicle. No other air vehicle relies on the propulsion system to provide these functions through a transmission system with single critical load paths without duplication or redundancy. As such, health management of the power train is a critical and unique part of any rotorcraft health management system. This paper focuses specifically on the issues and challenges related to the dynamic mechanical components in the main power train. This includes the transmission and main rotor mechanisms. This paper will review standard practices used for rotorcraft health management, lessons learned from fielded trials, and future challenges.
Understanding the response of the Offshore Wind Turbine (OWT) subjected to realistic applied loads requires modeling the whole structure including its soil-foundation system. This requires unique and innovative testing facilities. OWT systems experience cyclic and dynamic loading due to wind, wave, current, rotor vibrations (i.e., 1P load) and vibrations caused by the blade shadowing effects (2P/3P loads). These loads are complicated in nature and have varying amplitudes, frequencies, and directions. Investigating the response of the entire OWT system including the soil-foundation system under these complex loading conditions, requires: (1) full understanding of the loading characteristics including: the power take-off mechanical load (1P and 3P), and areo- and hydrodynamic loads that the OWT system is subjected to; (2) testing facility with unique multidirectional loading capabilities that allows for simultaneous application of realistic wind, wave and machine loads, axial gravity loads, and induced overturning moments; and (3) unique and cost-effective testing techniques that allow for accurate analysis of the overall response of the OWT system under realistic conditions such as: Real-Time Hybrid Simulation (RTHS).
A concept for generating high-efficiency, low-cost, solar-cell power is outlined with reference to solar cell parameters, optical concentrators, and thermal control procedures. A design for a 12.5-kw power module for space operation is discussed noting the optical system, spectrum splitter, light conversion system, cell cooling, power conditioner, and tracking mechanism. It is found that for an unconcentrated array, efficiency approaches 60% when ten or more bandgaps are used. For a 12-band system, a computer program distributed bandgaps for maximum efficiency and equal cell currents. Rigid materials and thin films have been proposed for optical components and prisms, gratings, and dichroic mirrors have been recommended for spectrum splitting. Various radiator concepts are noted including that of Weatherston and Smith (1960) and Hedgepeth and Knapp (1978). The concept may be suitable for the Solar Power Satellite.
Power electronics packages typically comprise a dielectric substrate bonded to a metal layer and attached to heat sinks using a low-thermal-conductivity solder. These multiple layers increase the effective thermal resistance of the package and are responsible for package failures under cyclic thermal loads. Bonding the aluminum nitride dielectric layer (AlN) directly to a low coefficient of thermal expansion (CTE) aluminum silicon carbide (AlSiC) cold plate using copper-aluminum (Cu-Al) transient liquid phase (TLP) bonding has been shown to improve the mechanical reliability of the power electronic packages while making the package more compact by bringing the cooling solutions closer to the devices. This study aims to characterize the Cu-Al bonds formed during the TLP bonding of AlSiC with three different power electronics substrates: pure aluminum nitride (AlN), aluminum (DBA), and copper (DBC). The material compositions and microstructures of the bonds were analyzed using scanning electron microscopy (SEM), x-ray spectroscopy (EDS), confocal scanning acoustic microscopy (C-SAM), and x-ray diffraction (XRD). ..alpha..-Al solid compound was identified as the dominant phase in AlN-AlSiC and Al-AlSiC, with a notable presence of SiC particles. In contrast, three intermetallic phases - ..theta..-CuAl2, ..eta..-CuAl, and ..gamma..'- Cu9Al4 - were observed in the Cu-AlSiC bond. A computational solid-state diffusion model was developed to predict the intermetallic compounds (IMCs) formed during Cu-Al TLP bonding in each system, which supported the observation that an initial Cu volume fraction of 20 % in the material layers produced a final bond composition of >95 % Al with minimal IMC growth. However, increased Cu concentrations produced higher concentration gradients, leading to increased growth of IMCs, Kirkendall voids, and interstitial cracks.
Transcription-coupled repair is essential for the removal of DNA lesions from the transcribed genome. The pathway is initiated by CSB protein binding to stalled RNA polymerase II. Mutations impairing CSB function cause severe genetic disease. Yet, the ATP-dependent mechanism by which CSB powers RNA polymerase to bypass certain lesions while triggering excision of others is incompletely understood. Here we build structural models of RNA polymerase II bound to the yeast CSB ortholog Rad26 in nucleotide-free and bound states. This enables simulations and graph-theoretical analyses to define partitioning of this complex into dynamic communities and delineate how its structural elements function together to remodel DNA. We identify an allosteric pathway coupling motions of the Rad26 ATPase modules to changes in RNA polymerase and DNA to unveil a structural mechanism for CSB-assisted progression past less bulky lesions. Our models allow functional interpretation of the effects of Cockayne syndrome disease mutations.
The engineering feasibility of developing a basic mechanical system necessary for extracting large amounts of power (on the order of 10 to 20 MW) from the wind is considered using the concept of vertical airfoils moving along a closed horizontal track system. Attention is focused on those components necessary for the conversion of wind energy to mechanical energy, although the general characteristics and critical aspects of other components are also considered. The four phases of this program are: (1) Establishment of component specifications and interface requirements for major system components; (2) formulation of alternative sets of conceptual designs for major system components; (3) engineering analysis of various components and systems; and (4) re-examination of basic concept and identification of any desirable follow-up work.
Introduction: The Advanced Supersonic Para-chute Inflation Research Experiment-2 (ASPIRE2) program is a sounding rocket flight test to be conducted at Wallops Island, VA in early 2025. This program is a risk mitigation exercise for the Mars Sample Retrieval Lander (MSRL) program and builds upon the success of the 2017 & 2018 ASPIRE program, [1,2]. While the ASPIRE program certified the strengthened 21.5 m diameter disk-gap-band (DGB) deployed at Mach 1.7, ASPIRE2 will certify a 24 m diameter DGB deployed at Mach 2.1. The need to certify this increased parachute performance is driven the increased lander mass for MSRL; over 50% increase in comparison to M2020. Modeling: Like its predecessor, ASPIRE2 is developing a multi-body flight dynamics simulation to predict parachute dynamics and aide in designing the flight test that will target Mars-relevant flight conditions, as shown in Figure 1. This work de-scribes the parachute modeling, flight mechanics simulations (from payload separation to splash-down), and design trades used to prepare for the 2025 ASPIRE2 flight. Discussed herein are comparisons between ASPIRE and ASPIRE2, noting key differences in the parachute modeling and vehicle configuration. A study on the attitude control system performance impacts with respect to payload section design will also be presented. This work will quantify the pre-flight parachute performance in the presence of uncertainties, such as those associated with the separation from the sounding rocket, atmosphere, the parachute system, and vehicle mass. The pre-flight predictions will include Monte Carlo analyses, powered by the flight mechanics simulations to show the ASPIRE2 vehicle performance in meeting program requirements on parachute deployment conditions (Mach & dynamic pressure), parachute loads, vehicle attitude at key milestones, and the vehicle splashdown conditions.
Understanding the nature of recombination mechanisms is essential for higher power conversion efficiency in photovoltaic (PV) devices. Here we use a combination of time-resolved terahertz spectroscopy and numerical modeling to determine the bulk Shockley-Read-Hall lifetime and interface and back surface recombination velocities in CdTe thin film stacks. Furthermore, the measurement was facilitated by fabricating wire-grid device structures using conventional laser scribing. Evaluation of a glass/FTO/SnO2/CdS/CdTe stack treated with CdCl2 allowed separation of the CdTe absorber bulk lifetime, 1.6 ns, from the back surface recombination velocity, ~6x10 4 cm/s, and indicated that CdTe/CdS interface recombination velocity had no significant impact on carrier dynamics.
Disk accretion powers many astronomical objects, including pre-main sequence stars, interacting binary systems, and active galactic nuclei. Unfortunately, models developed to explain the behavior of disks and their surroundings - boundary layers, jets, and winds - lack much predictive power, because the physical mechanism driving disk evolution - the viscosity - is not understood. Observations of many types of accreting systems are needed to constrain the basic physics of disks and provide input for improved models. Symbiotic stars are an attractive laboratory for studying physical phenomena associated with disk accretion. These long period binaries (P(sub orb) approx. 2-3 yr) contain an evolved red giant star, a hot companion, and an ionized nebula. The secondary star usually is a white dwarf accreting material from the wind of its red giant companion. A good example of this type of symbiotic is BF Cygni: our analysis shows that disk accretion powers the nuclear burning shell of the hot white dwarf and also manages to eject material perpendicular to the orbital plane (Mikolajewska, Kenyon, and Mikolajewski 1989). The hot components in other symbiotic binaries appear powered by tidal overflow from a very evolved red giant companion. We recently completed a study of CI Cygni and demonstrated that the accreting secondary is a solar-type main sequence star, rather than a white dwarf (Kenyon et aL 1991). This project continued our study of symbiotic binary systems. Our general plan was to combine archival ultraviolet and optical spectrophotometry with high quality optical radial velocity observations to determine the variation of line and continuum sources as functions of orbital phase. We were very successful in generating orbital solutions and phasing UV+optical spectra for five systems: AG Dra, V443 Her, RW Hya, AG Peg, and AX Per. Summaries of our main results for these systems appear below. A second goal of our project was to consider general models for the outbursts of symbiotic stars, with an emphasis on understanding the differences between disk-driven and nuclear-powered eruptions.
Fine control over the mechanical properties of thin sheets underpins transcytosis, cell shape, and morphogenesis. Applying these principles to artificial, liquid-based systems has led to reconfigurable materials for soft robotics, actuation, and chemical synthesis. However, progress is limited by a lack of synthetic two-dimensional membranes that exhibit tunable mechanical properties over a comparable range to that seen in nature. In this study, we show that the bending modulus, B , of thin assemblies of nanoparticle surfactants (NPSs) at the oil–water interface can be varied continuously from sub- k B T to 10 6 k B T , by varying the ligands and particles that comprise the NPS. We find extensive departure from continuum behavior, including enormous mechanical anisotropy and a power law relation between B and the buckling spectrum width. Our findings provide a platform for shape-changing liquid devices and motivate new theories for the description of thin-film wrinkling.
This presentation discusses the fourth report in NREL’s Storage Futures Study (SFS) publications. The SFS is a multiyear research project that explores the role and impact of energy storage in the evolution and operation of the U.S. power sector. The SFS is designed to examine the potential impact of energy storage technology advancement on the deployment of utility-scale storage and the adoption of distributed storage, and the implications for future power system infrastructure investment and operations. This report describes the expanded capabilities of the Distributed Generation Market Demand (dGen) model to analyze the economics of distributed (behind-the-meter) PV paired with battery storage systems and presents projections of adoption for the contiguous United States out to 2050 under a range of scenarios. These scenarios use technology cost and performance assumptions consistent with the National Renewable Energy Laboratory’s 2020 Standard Scenarios paired with updated battery cost projections and existing policies. Additional scenarios evaluate sensitivities to the value of backup power and DER compensation mechanisms, collectively characterizing the future potential for behind-the-meter storage and identifying key drivers of adoption. Adoption projections of DER and battery storage at high spatial and temporal resolution, as presented in this report, can enable informed planning of technical infrastructure that can help planners capture the benefits and mitigate challenges to support the ongoing trend toward distributed electricity generation.
A design study was made on a rotary transformer for transferring electrical power across a rotating spacecraft interface. The analysis was performed for a 100 KW, 20 KHz unit having a ""pancake'' geometry. The rotary transformer had a radial (vertical) gap and consisted of 4-25 KW modules. It was assumed that the power conditioning comprised of a Schwarz resonant circuit with a 20 KHz switching frequency. The rotary transformer, mechanical and structural design, heat rejection system and drive mechanism which provide a complete power transfer device were examined. The rotary transformer losses, efficiency, weight and size were compared with an axial (axial symmetric) gap transformer having the same performance requirements and input characteristics which was designed as part of a previous program. The ""pancake'' geometry results in a heavier rotary transformer primarily because of inefficient use of the core material. It is shown that the radial gap rotary transformer is a feasible approach for the transfer of electrical power across a rotating interface and can be implemented using presently available technology.