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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

National Community Solar Partnership Multifamily Affordable Housing Portfolio Screening Approach

Community solar offers multiple benefits to providers and residents of multifamily affordable housing (MFAH), including access to affordable renewable energy for low- and moderate-income households, tax credits and other financial benefits for property owners, and increased community resilience when paired with energy storage. Even so, MFAH providers interested in realizing these benefits may need support to identify where to start or how to expand and accelerate solar deployment across their property portfolios once they have completed their first few installations. This fact sheet describes a portfolio screening approach for MFAH providers to evaluate their multi-state building portfolios for community solar project viability. The approach was developed by the National Renewable Energy Laboratory as part of its support for the National Community Solar Partnership (NCSP) MFAH Collaborative. By utilizing NREL's companion Policy Screening Workbook in conjunction with the web-based tools PVWatts® Calculator and REopt™ (Renewable Energy Integration and Optimization), MFAH providers can take a data-informed approach to identifying and prioritizing buildings in their portfolios that are most amenable to community solar development.

community solar↗
DOE OSTI2020

CoSim: A Simulator for Co-Scheduling of Batch and On-Demand Jobs in HPC Datacenters

The increasing scale and complexity of scientific applications are rapidly transforming the ecosystem of tools, methods, and workflows adopted by the high-performance computing (HPC) community. Big data analytics and deep learning are gaining traction as essential components in this ecosystem in a variety of scenarios, such as, steering of experimental instruments , acceleration of high-fidelity simulations through surrogate computations, and guided ensemble searches. In this context, the batch job model traditionally adopted by the supercomputing in-frastructures needs to be complemented with support to schedule opportunistic on-demand analytics jobs, leading to the problem of efficient preemption of batch jobs with minimum loss of progress. In this paper, we design and implement a simulator, CoSim, that enables on-the-fly analysis of the trade-offs arising between delaying the start of opportunistic on-demand jobs, which leads to longer analytics latency, and loss of progress due to preemption of batch jobs, which is necessary to make room for on-demand jobs. To this end, we propose an algorithm based on dynamic programming with predictable performance and scalability that enables supercomputing infrastructure schedulers to analyze the aforementioned trade-off and take decisions in near real-time. Compared with other state-of-art approaches using traces of the Theta pre-Exascale machine, our approach is capable of finding the optimal solution, while achieving high performance and scalability.

batch job preemption↗
DOE OSTI2024

Parameter identification methods for low-order gray box building energy models: A critical review

The body of knowledge on gray box building energy modeling (GBBEM) has been developed over the past few decades and has undergone some important changes recently. Starting with simple methods and simple buildings, the science of GBBEM has grown to encompass complex and more computationally intensive techniques and complex commercial buildings. Numerous works including a recent review have considered model structure and inputs in a nearly systematic way, but no extant work systematically reviews the approaches for GBBEM parameter search initialization and final identification, despite this being arguably the most difficult and impactful part of the modeling process. To this end, we critically review 55 extant works describing advantages, limitations, and domain of applicability of several classes of parameter initialization and optimization techniques specifically for GBBEM. We categorize the classes of methods and analyze the evidence of their applicability for different applications within the field of GBBEM. We find an emerging consensus that initialization of parameter searches for anything other than the simplest building elements is often challenging and sometimes requires a stochastic approach to begin the parameter identification process. After this initial process, faster methods have been used in some cases but often the nature of the problem requires stochastic methods for this portion of the process as well. For less complex systems, more deterministic and efficient methods have been shown to be effective. Finally, we draw conclusions as to the domain of applicability of different classes of initialization and optimization techniques for GBBEEM and offer suggestions for research directions that are likely to prove fruitful.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2023

Structural evolution during solution-based synthesis of Li 7 P 3 S 11 solid electrolyte by synchrotron X-ray total scattering

Solution-based synthesis has emerged as a promising approach for scalable and efficient synthesis of solid electrolytes (SEs). However, the ionic conductivity of solution-synthesized SEs is much lower than that of SEs synthesized by solid state approaches. The structural evolution during the synthesis of SEs is crucial to explaining the decreased ionic conductivities but has not been well understood. Here, in this work, we use synchrotron X-ray total scattering combined with pair distribution function (PDF) analysis to understand the structural evolution during annealing of the solution-processed precursor for the synthesis of Li 7 P 3 S 11 SEs. Combining Bragg diffraction and diffuse scattering, X-ray total scattering enables detection of structural information including phase transition and crystallinity. The results show that the formation of Li 7 P 3 S 11 glass-ceramic starts at 230 °C. Increasing the annealing temperature helps to improve the crystallinity, but the degree of crystallization is still lower than 70.3% even after annealing at 290 °C when thermal decomposition of Li 7 P 3 S 11 to Li 4 P 2 S 6 has occurred. PDF analysis also revealed the existence of acetonitrile used in the solution-based synthesis in the SEs after annealing at high temperatures. The results rationalize the synthesis–property relationship, explain why annealing at 290 °C provides the highest ionic conductivity at the studied temperatures due to an optimal balance for achieving a high crystallinity while suppressing severe decomposition of Li 7 P 3 S 11 , and provide novel insights to develop approaches for synthesizing superior Li 7 P 3 S 11 SEs on a large scale.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2021

CAN-D: A Modular Four-Step Pipeline for Comprehensively Decoding Controller Area Network Data

Controller area networks (CANs) are a broadcast protocol for real-time communication of critical vehicle subsystems. Original equipment manufacturers of passenger vehicles hold secret their mappings of CAN data to vehicle signals, and these definitions vary according to make, model, and year. Without these mappings, the wealth of real-time vehicle information hidden in the CAN packets is uninterpretable, severely impeding vehicle-related research, including CAN cybersecurity and privacy studies, aftermarket tuning, efficiency and performance monitoring, and fault diagnosis to name a few. Guided by the four-part CAN signal definition, we present CAN-D (CAN-Decoder), a modular, four-step pipeline for identifying each signal's boundaries (start bit and length), endianness (byte ordering), signedness (bit-to-integer encoding), and by leveraging diagnostic standards, augmenting a subset of the extracted signals with meaningful, physical interpretation. En route to CAN-D, we provide a comprehensive review of the CAN signal reverse engineering research. All previous methods ignore endianness and signedness, rendering them incapable of decoding many standard CAN signal definitions. Incorporating endianness grows the search space from 128 to 4.72E21 signal tokenizations and introduces a web of changing dependencies. In response, we formulate, formally analyze, and provide an efficient solution to an optimization problem, allowing identification of the optimal set of signal boundaries and byte orderings. In addition, we provide two novel, state-of-the-art signal boundary classifiers—both of which are superior to previous approaches in precision and recall in three different test scenarios—and the first signedness classification algorithm, which exhibits a $>$ 97% F-score. Altogether, CAN-D is the only solution with the potential to extract any CAN signal that is also the state of the art. In evaluation on 10 vehicles of different makes, CAN-D's average $\ell ^1$ error is five times better (81% less) than all previous methods and exhibits lower average error, even when considering only signals that meet prior methods’ assumptions. Finally, CAN-D is implemented in lightweight hardware, allowing for an on-board diagnostic (OBD-II) plugin for real-time in-vehicle CAN decoding.

42 ENGINEERING↗
DOE OSTI2024

Electron Cooling in NICA Acceleration Complex

The Nuclotron-based Ion Collider fAcility (NICA) is under assembling at JINR. NICA will provide colliding beams for study of hot strongly interacting baryonic matter and spin physics. The NICA injection complex includes a tandem of 2 superconducting synchrotrons: Booster (up to 600 MeV/u) and Nuclotron (up 3.9 GeV/u fully stripped heavy ions). Since the start of injection complex commissioning in 2020 its four Runs were carried out. To the present time the beams of He, Fe, C and Xe were accelerated. Booster electron cooling was first used for cooling of continuous Fe¹⁴⁺ beam at the energy of 3.2 MeV/u in Run II. In the last Run we demonstrated longitudinal cooling of Xe²⁸⁺ in the presence of RF voltage at the Booster injection energy. This regime is required for accumulation in Booster the intensity required for Collider operation. The cooling enabled a 2 times intensity increase of slow extracted beam from Nuclotron. Optimization of Booster electron cooling for beam accumulation will be carried out in the next Run. Another (high voltage) electron cooling system will be used in the NICA Collider rings for ion accumulation in a barrier bucket and consecutive bunch formation.

43 PARTICLE ACCELERATORS↗
DOE OSTI2021

An Indirect Search for Weakly Interacting Massive Particles in the Sun Using Upward-going Muons in NOvA

I present the first Dark Matter search results using the full data set collected with the upward-going muon trigger in NOvA. Weakly Interactive Massive Particles (WIMPs) are a theoretical non-baryonic form of Dark Matter. The nature of Dark Matter is one of the most exciting open questions in modern physics. Though its existence can be inferred by astrophysical evidence, its properties are not yet understood. If we assume that Dark Matter particles can produce Standard Model particles through their interactions, an indirect search can help shed light on this mystery.The NOvA collaboration has built a 14 kton, fine-grained, low-Z, total absorption tracking calorimeter at an off-axis angle to the NuMI neutrino beam. Even though the detector is optimized to observe electron neutrino appearance from a muon neutrino beam, it has a unique potential for more exotic searches given its excellent granularity and energy resolution and relatively low-energy neutrino thresholds. In fact, with an efficient upward-going muon trigger and sufficient background suppression offline, NOvA is capable of a competitive indirect Dark Matter search for low-mass WIMPs.The idea of the upward-going muon trigger is first to select high-quality muon tracks, then use the timing information of all of the hits of each track to estimate directionality. In this way, the background flux is suppressed by more than a factor of 10^5 at trigger level to a rate of approximately 1 Hz. To further optimize this search, we use only upward-going muons that point to the Sun, so our search occurs at night when the Sun is on the other side of the Earth. This strategy also allows us to use the time when the Sun is above the horizon as a control region to estimate the background. Ultimately, implementation of a cut based and maximum likelihood analysis provides a powerful tool for rejecting background and selecting a sample of neutrino-induced upward-going muons. The overall background rejection power achieved by the analysis is substantial and impressive. Starting with approximately 150,000 events per second, we reduced it to 40 events per year. Since no statistically significant excess was found, a 90\% C.L. upper limit on the expected muon flux of upward-going muons has been set using the upper limit on the number of events given the number of observed events in the signal region. Lastly, by assuming the theory behind the upward-going muon flux, a limit on the WIMP-nucleon spin-dependent cross-section in the Sun was estimated. Although the limits on the spin-dependent cross-section do not appear to be competitive with previous indirect Dark Matter searches, the upward-going muon flux limits are promising. The upward-going muon flux limits could extend these results to a broader class of models that are not specific to the dark matter theory but produce upward-going muons, leading to competitive results.

Principato, Cristiana↗
DOE OSTI2024

Test and Validate Distributed Coaxial Cable Sensors for in situ Condition Monitoring of Coal-Fired Boiler Tubes

This project aims to test, validate, and advance the technology readiness level (from TRL5 to TRL7) of a novel low-cost distributed stainless-steel/ceramic coaxial cable sensing (SSC-CCS) technology for in situ monitoring of the boiler tube temperature in existing coal-fired power plants. The novel SSC-CCS sensing technology and associated condition-based monitoring (CBM) software to be demonstrated in this project will lead to an improved understanding of the boiler tube failure mechanisms and a prognostic system to improve the overall performance, reliability, and flexibility of the nation’s coal-fired power plant fleet. A boiler tube monitoring system with distributed coaxial cable temperature sensors and a sensor acquisition system was constructed. The high-temperature coaxial cable sensor with a length of 1.3m was made by using a quartz tube (1mm inner diameter (ID) and 6mm outer diameter (OD)) to concentrically separate a 304 stainless-steel (SS) rod (1mm OD) and SS tube (7.94mm OD and 6.16mm ID). The sensor acquisition system includes a vector network analyzer (VNA), a radio frequency (RF) power amplifier, multiple switches and a USB hub. The distributed stainless-steel quartz coaxial cable sensor (SSQ-CCS) had a linear response to temperature with a resolution uncertainty of σ = 0.77℃. To withstand the harsh conditions of 3,300 steam pressures and 800℃ high temperatures, the sensor was shielded by a protective tube made of the same material as the boiler tube. The protection tube had an OD of 1.5 inches and a thickness of 0.25 inches. In the laboratory tests, the sensor showed good sensitivity and fast response. The drift was bounded between +0.33% and -0.67% during a test at 600℃ for 350 hours, indicating good stability of the sensor. A field test was conducted where four sensors were welded on four superheat tubes (SH-Ts) at a coal-fired power station over 400 days. Conventional thermocouples were welded to the superheater tubes alongside the coaxial cable sensors for the purpose of comparison. Two sensors were capable of distributed sensing, with three multiplexed sensing sections. The other two sensors were single section. During the 400-day test period, the power plant experienced startups and shutdowns. At the steady state operations, the temperature of the boiler tube is about 600℃ (1112°F). The sensors recorded the entire coal-firing processes (start-up, steady state, and shut-down) and the glitch event. A GSM modem and a Watchdog were added to the system to ensure reliable data recording. The GSM modem sent daily messages to plant managers and Clemson team to inform the status of the sensor system. If the system was not normally working, the Watchdog would reboot the system automatically. The new coaxial cable based distributed sensing technology has been proven to be successful in both laboratory and field tests. A comprehensive four-stage multi-physics computational framework has been developed to assist the design, optimization, installation, and operation of SSQ-CCS. With the consideration of various operation conditions, we predict the distributions of flue gas temperatures within coal-fired boilers, the temperature correlation between the boiler tube and SSQ-CCS, and the safety of SSQ-CCS. A conditional-based monitoring system is implemented as well. The computational framework developed in this work can guide the future operation of coal-fired plants and other power plants for the safety prediction of boiler operations.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2024

Sensitivity of thermodynamic profiles retrieved from ground-based microwave and infrared observations to additional input data from active remote sensing instruments and numerical weather prediction models

Accurate and continuous estimates of the thermodynamic structure of the lower atmosphere are highly beneficial to meteorological process understanding and its applications, such as weather forecasting. In this study, the Tropospheric Remotely Observed Profiling via Optimal Estimation (TROPoe) physical retrieval is used to retrieve temperature and humidity profiles from various combinations of input data collected by passive and active remote sensing instruments, in situ surface platforms, and numerical weather prediction models. Among the employed instruments are microwave radiometers (MWRs), infrared spectrometers (IRSs), radio acoustic sounding systems (RASSs), ceilometers, and surface sensors. TROPoe uses brightness temperatures and/or radiances from MWRs and IRSs, as well as other observational inputs (virtual temperature from the RASS, cloud-base height from the ceilometer, pressure, temperature, and humidity from the surface sensors) in a physical iterative retrieval approach. This starts from a climatologically reasonable profile of temperature and water vapor, with the radiative transfer model iteratively adjusting the assumed temperature and humidity profiles until the derived brightness temperatures and radiances match those observed by the MWR and/or IRS instruments within a specified uncertainty, as well as within the uncertainties of the other observations, if used as input. In this study, due to the uniqueness of the dataset that includes all the above-mentioned sensors, TROPoe is tested with different observational input combinations, some of which also include information higher than 4 km above ground level (a.g.l.) from the operational Rapid Refresh numerical weather prediction model. These temperature and humidity retrievals are assessed against independent collocated radiosonde profiles under non-cloudy conditions to assess the sensitivity of the TROPoe retrievals to different input combinations.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2021

Optimizing accuracy and efficacy in data-driven materials discovery for the solar production of hydrogen

The production of hydrogen fuels, via water splitting, is of practical relevance for meeting global energy needs and mitigating the environmental consequences of fossil-fuel-based transportation. Water photoelectrolysis has been proposed as a viable approach for generating hydrogen, provided that stable and inexpensive photocatalysts with conversion efficiencies over 10% can be discovered, synthesized at scale, and successfully deployed. While a number of first-principles studies have focused on the data-driven discovery of photocatalysts, in the absence of systematic experimental validation, the success rate of these predictions may be limited. We address this problem by developing a screening procedure with co-validation between experiment and theory to expedite the synthesis, characterization, and testing of the computationally predicted, most desirable materials. Here, starting with 70 150 compounds in the Materials Project database, the proposed protocol yielded 71 candidate photocatalysts, 11 of which were synthesized as single-phase materials. Experiments confirmed hydrogen generation and favorable band alignment for 6 of the 11 compounds, with the most promising ones belonging to the families of alkali and alkaline-earth indates and orthoplumbates. This study shows the accuracy of a nonempirical, Hubbard-corrected density-functional theory method to predict band gaps and band offsets at a fraction of the computational cost of hybrid functionals, and outlines an effective strategy to identify photocatalysts for solar hydrogen generation.

08 HYDROGEN↗
DOE OSTI2021

National Security & International Studies (Q1 FY2021 Newsletter)

Happy New Year to everyone. Activity in the office continues to be at a high pace with the addition of the Strategic Analyses and Assessments (SAA) Office from ALDX, and the Mission Integration (MI) Office (formerly known as Nuclear and Military [NMA] Office) from DDW. We are working closely to optimize the impact of our combined offices. In this issue of our newsletter, we will highlight programs from the SAA Office portfolio, delve into our interactions with the Project on Nuclear Issues (PONI) program from CSIS, introduce you to new staff in NSIS and review a new joint postdoc program with the UC Institute on Global Conflict and Cooperation and the Center for Global Security Research at LLNL. I also encourage you to take a look at the new NSIS website for more information on the office. Finally, the NSIS office will soon be kicking off a webinar series on starting with topics of interest to the Director’s Strategic Resilience Initiative and will grow beyond that. Stay tuned for more information. --John Scott, Acting Office Director, NSIS

99 GENERAL AND MISCELLANEOUS↗
DOE OSTI2024

Space Charge Forces analytical model for emittance compensation

Space charge forces represent main induced effects in an RF-injector that degrade the beam quality. In this scenario the laser distribution sent on the photocathode acquires an important role in the emittance compensation process, as the slice analysis shows. Starting from the preliminary studies performed on [1], a novel semi-analytical model of space charge forces is proposed in detail for bunch with arbitrary charge distribution to derive expressions of self-induced forces. The performance of the fields at low energy regime (as the field has not expired RF forces) is under present analysis, we can investigate use of this model in low charge regime. Further, the model has been bench-marked with the behavior of the distributions present in the literature and studied for new ones. It has also been applied for the study of the optimization of a C-band hybrid photoinjector now being commissioned, thus explaining the factor two reduction of the emittance observed at the exit of the gun by changing the initial distribution at the cathode.

Carillo, M.↗
DOE OSTI2025

Beam optics ramping in underconstrained lattice design: Application to Electron-Ion Collider hadron storage ring cooling section

This paper presents the lattice design and optics ramping strategy for the cooling section of the hadron storage ring at the electron-ion collider. The main challenge is that available tuning knobs exceed beam-optics constraints. Independently optimized injection and top-energy optics often yield disconnected solutions, making interpolation impossible. To address this, we propose two new methods. The first is an intermediate-penalty scheme that ensures ramping path continuity by penalizing constraint violations at intermediate states. The second is a continuation-based approach that adapts high-energy optics to low energy, guided by an adaptive weighting scheme to balance injection and ramping constraints. The solutions meet all beam dynamics and hardware limits. The two methods offer a general strategy for ramping in systems where the solution space is under-constrained and the starting and target configurations are far apart.

43 PARTICLE ACCELERATORS↗
DOE OSTI2020

Status and results from the CUORE experiment

The Cryogenic Underground Observatory for Rare Events (CUORE) is a tonne-scale cryogenic experiment located at the Laboratori Nazionali del Gran Sasso that exploits bolometric technique to search for neutrinoless double beta decay [0$vββ$] of 130 Te. The detector consists of a segmented array of 988 natural TeO 2 cubic crystals arranged in a cylindrical compact structure of 19 towers. The detector construction was completed in August 2016 and data taking started in Spring 2017. Here, we present a brief description of the bolometric technique for rare events search and the CUORE detector, then we concentrate on the data analysis results. In this respect, we focus on the procedure for data processing and on the first 0$vββ$ results we obtained from a total TeO 2 exposure of 86.3 kg · yr. Next, we illustrate the main background sources and the CUORE background model, from which we obtain the most precise measurement of 130 Te 2$vββ$ half-life to date. Finally, we discuss the improvements achieved with 2018 and 2019 detector optimization campaigns and the current perspectives of our experiment.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗
DOE OSTI2021

Mitigation of Acute Ammonia Emissions With Biochar During Swine Manure Agitation Before Pump-Out: Proof-of-the-Concept

Ammonia (NH 3 ) emissions from animal agriculture can cause eutrophication of water ecosystems and are precursors to secondary particulate matter (PM 2 .5 ). NH 3 emissions from stored swine manure represent nutrient loss affecting the fertilizing value of manure. The short-term emission bursts occur when farmers agitate manure before emptying storage and fertilizing fields. There is no proven technology to mitigate gaseous emissions during agitation, while the hazards of acute releases (e.g., H 2 S) are well-known. Biochar mitigates NH 3 emissions from manure over the long-term. The objective of this research was to evaluate the mitigation of acute NH 3 emissions during/after agitation. Two biochars, highly alkaline and porous (HAP from corn stover) and red oak (RO), were tested. The 6 and 12 mm-thick layers of biochar powder were surficial applied followed by 3 min agitation. NH 3 concentrations were measured before/during/after agitation. Mitigation was assessed by comparing: (i) the maximum (peak) flux, (ii) total emission (from agitation start till NH 3 concentration returned to the before-agitation), and (iii) the total emissions during agitation. The 12 mm HAP significantly ( p < 0.05) reduced (i–iii) by 63, 70, and 85%, respectively. The 6 mm HAP significantly reduced (i–iii) by 76, 75, and 78%, respectively. The 12 mm RO significantly reduced (i–iii) by 9, 53, and 57%, respectively. The 6 mm RO significantly reduced (i–iii) by 61, 86, and 63%, respectively. The NH 3 emission kinetics model confirmed that a 6 mm dose was just as effective as the larger dose. More research is needed to optimize and scale-up mitigating emissions and retention of nutrients in manure with biochar.

Chen, Baitong↗
DOE OSTI2022

Manufacturing Science

The Manufacturing Science area of leadership spans the application of fundamental science research and development activities to understand the critical steps in manufacturing processes for the purposes of control and optimization. Although manufacturing is an applied area of research, fundamental science underpins our knowledge of both traditional and transformational manufacturing processes. For example, casting, welding, and many modern additive manufacturing processes that see wide use are broadly classified as solidification processes, with material transitioning from liquid to solid phases upon cooling from higher temperature. However, our understanding of the detailed physics involved in such processes is incomplete, and solidification remains a grand challenge for materials science. To enable adoption of transformative fabrication processes or to accelerate development of traditional ones, it is necessary to develop a detailed mechanistic understanding spanning multiple scales, starting with atomic building blocks (defects, interfaces, composition) and extending all the way up to macroscale performance in moderate and/or extreme environments.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Toward fully automated UED operation using two-stage machine learning model

To demonstrate the feasibility of automating UED operation and diagnosing the machine performance in real time, a two-stage machine learning (ML) model based on self-consistent start-to-end simulations has been implemented. This model will not only provide the machine parameters with adequate precision, toward the full automation of the UED instrument, but also make real-time electron beam information available as single-shot nondestructive diagnostics. Furthermore, based on a deep understanding of the root connection between the electron beam properties and the features of Bragg-diffraction patterns, we have applied the hidden symmetry as model constraints, successfully improving the accuracy of energy spread prediction by a factor of five and making the beam divergence prediction two times faster. The capability enabled by the global optimization via ML provides us with better opportunities for discoveries using near-parallel, bright, and ultrafast electron beams for single-shot imaging. It also enables directly visualizing the dynamics of defects and nanostructured materials, which is impossible using present electron-beam technologies.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Regal Beloit Final Technical Report

The original project proposal submitted from NovaTorque Inc (NovaTorque) in 2016 was to improve the existing motor with 95% efficiency by reducing the losses by 21% to achieve 96%. A few months after the proposal was submitted, NovaTorque lost funding and went out of business. The assets of NovaTorque were then acquired by Regal Beloit Corporation (“Regal Beloit” or “Regal”). When the NovaTorque proposal was selected, the project was transferred to Regal Beloit. Once we had production samples from the new Regal production line, they were tested at the Regal Beloit test lab in Wausau, WI. The original NovaTorque motor had an efficiency of 95%, but when the technology was transferred to Regal Beloit, there were multiple manufacturing improvements made, even though the basic electromagnetic design did not change. The test results in Wausau showed that the motors made at the Regal Beloit plant had an efficiency of 96%. Since the goal of the project was to reduce the losses by 21%, a new efficiency target of 96.8% became the project objective. In the first budget period, motors were tested to get the baseline performance. We then used FEA modeling with ANSYS Maxwell to model the existing motor to get correlation between the FEA simulations and the actual test results. Once the model was validated, we evaluated some changes that could be made to the stator to reduce the losses and improve efficiency without changing the rotor or stator housing, keeping the modifications easy to implement. The changes were primarily in the area of making the stator axially shorter and adding Soft Magnetic Composite (SMC) tooth tips. In the second budget period, we proceeded to design and build the new stator that was identified above and identified additional improvements in the process that included a stator machining modification and the use of rectangular wire. When we actually built the motor, the choice of rectangular wire turned out to be a problem. The wire was made by squishing round wire to get the rectangular shape, which caused work hardening, making the wire too stiff to make the desired coils. We shifted to annealed square wire which was better, but we still could not maintain the proper coil envelope. The result was that we had reduced cross section area for stator laminations. We also had to have a radial offset resulting in a radial misalignment between the stator and rotor because of the oversized coils. After the motor was completed, it was shipped to Texas A&M University for testing. With the loss of flux from these issues, the measured motor efficiency was only 96.3%. The primary focus of this motor was to make sure our FEA simulation model predicted the measured losses and overall efficiency, this we moved on to the FEA simulation. The FEA simulations of the motor “as built” with misalignments had good correlation with the test results, so the next step was to use that model to optimize the design of the motor for a final build. This time we considered changes to the stator and rotor and also minor changes to the housing diameter. In the third budget period, we did the detailed design and construction of the final prototypes. The final prototypes had a slight increase in the stator diameter to fit in a standard Regal Beloit housing. We shortened the stator and use more layers of wire in the coils. We also increased the cone angle of the rotor and stator from the original 110 degrees to 130 degrees to get some additional efficiency and optimized the stator cross section. The predicted efficiency from the FEA simulations was 96.9%. When completed, the motors were tested. We were a little short of reaching our target efficiency goal of 96.8%. We were only able to get to 96.7% efficiency. While it may be possible with additional iterations in designs and future builds to gain that additional 0.1%, we believe that we are close to the best we can achieve from a practical viewpoint, and additional iterations would be more work than the potential gains would be worth. No other motor in this class can even reach the 96% that we started with.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗