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Secondary Pore Network Design Optimization Analytical Diffusion Model for Lithium Ion Battery
Fast ion transport along the electrode thickness is required for Lithium ion battery (LIB) to sustain continuous high-rate discharge or charge currents, which is a desired feature for the fast charging of electric vehicle batteries. Advance in LIB electrode manufacturing allows to control, to a certain extent, the electrode microstructure architecture in order to improve the macroscopic performances of these devices. For instance, several groups have experimentally tested architectures tailored specifically to increase the through plane ionic diffusion in regards for fast charge application by adding channels or groove-like large pores oriented along the electrode thickness. These voids do not replace the existing pores of the electrode microstructure but consist in a second, coarser, pore network, called the secondary pore network (SPN). The model quantifies the impact of SPN on ionic diffusion with a composite electrode through a simple analytical approach, considering various pore channel geometries and comparing to standard electrodes with identical gravimetric and identical volumetric specific theoretical capacity. The goal is to find optimal SPN design parameters according to three optimization objectives aiming to balance the improved overall through-plane, thanks to the coarse aligned channels, and the degraded in-plane diffusion, due to the porous matrix densification required to maintain gravimetric and volumetric specific theoretical capacity. The analytical model must be considered as a pre-screening tool to quickly investigate large design space, that can be refined later with more complex electrochemical CPU-expensive numerical models.
Design optimization methods for high-performance research reactor core design
Typical objectives of high-performance research reactors include neutron scattering, materials irradiation, and isotope production. The creation of a core that optimizes these multiple objectives often presents a multidimensional (i.e., in design space), multiobjective optimization problem. The developed systematic approach discussed herein draws on response surface methodology to validate and leverage a surrogate model to serve in place of high-fidelity computational analyses. Optimization and design analysis methods leverage this surrogate model to provide a flexible tool for generating optimized designs and understanding the impact of design decisions on desired metrics. In applications to High Flux Isotope Reactor (HFIR) low-enriched uranium (LEU) core designs, neutronic, isotopic evolution, and thermal hydraulic analyses are used to generate key performance and safety metrics for assessing the feasibility and fitness of given designs. Three optimized designs that determine different desired metrics and constraints (e.g., key metric weighting and fabrication constraints) are presented, providing potential design options that satisfy the requirements for HFIR’s conversion from high enriched uranium to LEU fuel.
A Novel Framework for Performance Evaluation and Design Optimization of PCM Embedded Heat Exchangers for the Built Environment
This research sheds light on the performance evaluation and design optimization of PCM-HXs for the built environment, addressing several barriers to practical issues to PCM-HX commercialization such as modeling aspects (i.e., modeling expertise and computational / time investment, etc.), manufacturing aspects (i.e., at-scale manufacturing, cost assessments, etc.) and experimental performance assessment (i.e., reliable experimental data, assessment of multiple PCM-working fluid combinations, etc.). We present a novel, comprehensive, and experimentally-validated design optimization framework for PCM-HXs capable of simulating any PCM-HX geometry with reasonable accuracy and significant computational time savings when compared to traditional CFD-based design practices. The framework was validated for a wide range of PCM-HX configurations, including a design optimization for a domestic hot water heater application where TES partially replaces electrical heating input. The resulting PCM-HXs were found to deliver 34-68% of the total daily hot water supply with only 5-10% package volume increase from the water heater, thus within U.S. DOE targets for TES systems. To identify the most promising HXs for PCM applications, first-order geometry and cost analyses were conducted based on off-the-shelf HX products. As part of this work, 9 PCM-HX prototypes were manufactured using additive and conventional manufacturing methods. Detailed economy-of-scale assessments were conducted for the most promising PCM-HXs and were found to have a good outlook for the next 5-10 years. The PCM-HX design optimization framework was validated through comprehensive in-house experimental testing using newly-developed PCM-to-fluid test facilities. In total,10 total in-house component-level experiments were conducted using these prototypes, including 9 with water and 1 with refrigerant (R410A) as the working fluid. It was found that the framework can successfully predict experimental thermal-hydraulic performance within ±10-20% the first time without manual design changes, eliminating the need for time-consuming and expensive prototyping efforts as part of the design process. As part of this work, a publicly-available PCM web tool was released which includes a PCM property database (531 PCMs) and PCM-HX modeling tool to assist the design community on common PCM-HX use-cases, e.g., single/multiple flow path(s) fluid-to-PCM and air-to-fluid-to-PCM configurations (https://ceeeweb.umd.edu/pcmapp/). This work will accelerate the design and time to market for next generation PCM-HXs.
Development of Building Design Optimization Methodology: Residential Building Applications
Building design optimization is a highly complex problem, requiring long computational running processes because of the many options that exist when a building is being designed. This paper introduces an integrated approach through which to perform this optimization within an acceptable time frame. The approach includes the methods of variable selection, model simplification, and a sequential optimization process. Using singular value decomposition, a large number of design variables is reduced to a smaller subset that can be solved more quickly through the optimization algorithm. To expedite the variable selection process, a modeling approach that quickly simulates annual energy consumption was developed to replace full annual energy simulations. The developed methodology was applied to two residential buildings in the US, and the results are discussed herein. To assess the accuracy of the integrated optimization methodology, the optimized life cycle costs are compaa variables demonstrating the strongest contributions in the optimization study were identified. The proposed methodology significantly shortened the time requirements for the optimization processes of the two case studies by 74% and 84%; the optimized life cycle costs were within 0.05% and 0.06%, respectively, of the optimum point.
Sequential ensemble-based optimal design for parameter estimation
The ensemble Kalman filter (EnKF) has been widely used in parameter estimation for hydrological models. The focus of most previous studies was to develop more efficient analysis (estimation) algorithms. On the other hand, it is intuitively understandable that a well-designed sampling (data-collection) strategy should provide more informative measurements and subsequently improve the parameter estimation. In this work, a Sequential Ensemble-based Optimal Design (SEOD) method, coupled with EnKF, information theory and sequential optimal design, is proposed to improve the performance of parameter estimation. Based on the first-order and second-order statistics, different information metrics including the Shannon entropy difference (SD), degrees of freedom for signal (DFS) and relative entropy (RE) are used to design the optimal sampling strategy, respectively. The effectiveness of the proposed method is illustrated by synthetic one-dimensional and two-dimensional unsaturated flow case studies. It is shown that the designed sampling strategies can provide more accurate parameter estimation and state prediction compared with conventional sampling strategies. Optimal sampling designs based on various information metrics perform similarly in our cases. Furthermore, the effect of ensemble size on the optimal design is also investigated. Overall, larger ensemble size improves the parameter estimation and convergence of optimal sampling strategy. Although the proposed method is applied to unsaturated flow problems in this study, it can be equally applied in any other hydrological problems.
Low Space Harmonic Content Windings (LSHWs) Applied to Improve the Pareto Front in Design Optimization of Electric Machines
In design optimization of high performance electric machines where the power density is increasingly a key metric, it is often desirable to maximize the average torque output within a given volume. However, if a smooth output is also required, the torque ripple may become a hurdle as it tends to increase with the average torque for conventional windings. A direct benefit of low space harmonic content windings (LSHWs), featuring the suppression or elimination of targeted non-working orders in the winding magnetomotive force (MMF), is the torque ripple reduction. This paper provides a detailed analysis of torque ripple pairs and the space-time harmonic order mapping, with concise results that applies to both distributed windings and fractionalslot concentrated windings (FSCWs) of any slot/pole combination. Metamodel-based optimizations are performed to compare two LSHWs with a conventional winding. Improved Pareto fronts are validated, which confirms higher torque producing capabilities at various torque ripple thresholds for LSHWs.
Gradient-Informed Design Optimization of Select Nuclear Systems
In this work, we present a gradient-informed design optimization of nuclear reactor core components based on neutronics objectives with both continuous and discrete materials. The main argument in favor of using gradient-informed design optimization is that it scales well with increasing dimensionality of the design space. First, a challenge problem with 121 free parameters is solved with a gradient-informed method and then with a genetic algorithm. Then, a challenge problem to optimize the flux profile of a simplified assembly with eight axial zones is solved. Both challenge problems are solved using directly calculated derivatives from Tools for Sensitivity and Uncertainty Analysis Methodology Implementation (TSUNAMI) in the SCALE package. Furthermore, we demonstrate how a discrete optimization problem—selection of materials for 121 voxels—can be lifted into a continuous problem with mixed materials. In the continuous space, adjoint-based gradients are well-defined, and gradient descent is applicable. Then, a forcing function is introduced that with the selection of an appropriately sized hyperparameter can be used to guide the optimized continuous solution back into a discrete solution. This paper presents an account of the challenges that were faced when applying a gradient-informed optimization algorithm using a Monte Carlo calculation to estimate the gradient information and compares a gradient descent optimization method to a genetic algorithm optimization of the same geometry. Overall, this work demonstrates the potential use of adjoint-based gradient calculations in design optimization of nuclear systems.
Common-mode inductor saturation analysis and design optimization based on spectrum concept
Understanding the CM inductor core saturation mechanism and reducing core flux density is critical for CM inductor design optimization. Instead of a time domain method, this paper introduces frequency domain spectrum concept for CM inductor core saturation analysis and design optimization, which will provide designers a better understanding of CM inductor design. First, both core permeability and converter modulation index's opposite influence on DM flux density and CM flux density are identified. Then, CM flux density is further investigated based on the spectrum concept. Three components in the CM inductor which may cause large CM flux density and core saturation are summarized: (1) switching frequency related components, (2) impedance resonance frequency related components, and (3) modulation frequency related components. Each component is investigated for CM flux density reduction and filter design optimization. A connecting AC and DC side midpoint with notch filter structure is proposed to reduce modulation frequency related components. Experiment results are presented to verify the proposed concept and method.
Optimal Design of Megahertz $LLC$ Converter for 48-V Bus Converter Application
Intermediate bus architecture employing 48-V bus converters is widely used in power supply applications. With the rapid increase of demanded power by these loads, higher efficiency and power density are driving better performance power management solutions. In this article, a Gallium Nitride (GaN) based design of a two-stage solution is proposed. The first stage is a multi-phase Buck for regulation. The second stage is an LLC converter with a fixed switching frequency for isolation. The detailed design and optimization of the LLC converter are studied. To achieve high power density and high efficiency, the transformer design becomes critical at megahertz frequency. The matrix transformer concept is applied and a merged winding structure is used for flux cancellation, which effectively reduces the ac winding losses. A novel primary termination and via structure is proposed, resulting in a great loss reduction. In addition, to study the current sharing of parallel winding layers, a 1-D analytic model is proposed, and a symmetrical winding layer scheme is used to balance the current distribution. Finally, the prototype for the two-stage bus converter is developed, with a peak efficiency of 96% and a power density of 615 W/in 3 .
Optimal design of acoustic metamaterial cloaks under uncertainty
In this work, we consider the problem of optimal design of an acoustic cloak under uncertainty and develop scalable approximation and optimization methods to solve this problem. The design variable is taken as an infinite-dimensional spatially-varying field that represents the material property, while an additive infinite-dimensional random field represents the variability of the material property or the manufacturing error. Discretization of this optimal design problem results in high-dimensional design variables and uncertain parameters. To solve this problem, we develop a computational approach based on a Taylor approximation and an approximate Newton method for optimization, which is based on a Hessian derived at the mean of the random field. We show our approach is scalable with respect to the dimension of both the design variables and uncertain parameters, in the sense that the necessary number of acoustic wave propagations is essentially independent of these dimensions, for numerical experiments with up to one million design variables and half a million uncertain parameters. Additionally, we demonstrate that, using our computational approach, an optimal design of the acoustic cloak that is robust to material uncertainty is achieved in a tractable manner. The optimal design under uncertainty problem is posed and solved for the classical circular obstacle surrounded by a ring-shaped cloaking region, subjected to both a single-direction single-frequency incident wave and multiple-direction multiple-frequency incident waves. Finally, we apply the method to a deterministic large-scale optimal cloaking problem with complex geometry, to demonstrate that the approximate Newton method’s Hessian computation is viable for large, complex problems.
Heat Exchanger Design Optimization for Mitigation of Diesel Engine Exhaust Fouling
Abstract The design optimization of a diesel exhaust-coupled heat and mass exchanger that drives a 2.71 kW cooling capacity absorption heat pump is presented in this study. Fouling layer thermal resistance and pressure drops from single-tube experiments are used to develop a thermodynamic, heat transfer, and pressure drop model for the exhaust-coupled desorber. A parametric study is performed to select a desorber design that meets system performance while minimizing footprint. Experimental heat duties and pressure drops are within 10% and 3%, respectively, of the model predictions. Thus, large data sets from single-tube experiments with representative geometries are successful in accounting for fouling effects at the component level. Desorber design optimization based on this approach ensures continued heat pump performance after fouling. This study, along with the single-tube experiments, presents a systematic approach to design exhaust-coupled heat exchangers while considering the effects of fouling. These results are applicable for a wide range of waste-heat recovery applications, and this method can be extended to different geometries and operating conditions.
DCFC + Hydrogen Station Design Optimization [Slides]
Both direct current fast charging (DCFC) and Hydrogen stations are working to create successful long-term business models; however, analyses for DCFC and hydrogen fueling infrastructure are almost always performed separately. This work provides a detailed exploration of the benefit of integrating DCFC and hydrogen stations to lower the total system cost from load balancing and equipment cost sharing. To achieve this we have adapted the REopt optimization framework to simultaneously optimize the design and operation of integrated DCFC and H2 fueling station. Results indicate that 1) combining hydrogen fueling and DCFC stations can significantly reduce lifetime costs compared to separated stations. 2) Co-location with additional site load reduces DCFC costs, however, integration of DCFC with hydrogen provides an even greater cost reduction. 3) Adding PV to combined stations further reduces the lifetime station cost. 4) Capital investments in station combination today can help reduce the cost of operating DCFC tomorrow and 5) product diversification acts as a hedge against variability and enables a more dynamic response to market changes.
Designing optimal experiments: an application to proton Compton scattering
Interpreting measurements requires a physical theory, but the theory’s accuracy may vary across the experimental domain. To optimize experimental design, and so to ensure that the substantial resources necessary for modern experiments are focused on acquiring the most valuable data, both the theory uncertainty and the expected pattern of experimental errors must be considered. We develop a Bayesian approach to this problem, and apply it to the example of proton Compton scattering. Chiral Effective Field Theory (χEFT) predicts the functional form of the scattering amplitude for this reaction, so that the electromagnetic polarizabilities of the nucleon can be inferred from data. With increasing photon energy, both experimental rates and sensitivities to polarizabilities increase, but the accuracy of χEFT decreases. Our physics-based model of χEFT truncation errors is combined with present knowledge of the polarizabilities and reasonable assumptions about experimental capabilities at HI γ S and MAMI to assess the information gain from measuring specific observables at specific kinematics, i.e. to determine the relative amount by which new data are apt to shrink uncertainties. The strongest gains would likely come from new data on the spin observables Σ 2x and Σ 2x' at ω≃140 to 200 MeV and 40° to 120°. These would tightly constrain γ E1E1 –γ E1M2 . New data on the differential cross section between 100 and 200 MeV and over a wide angle range will substantially improve constraints on α E1 –β M1 , γ π and γ M1M1 –γ M1E2 . Good signals also exist around 160 MeV for Σ 3 and Σ 2z' . As a result, such data will be pivotal in the continuing quest to pin down the scalar polarizabilities and refine understanding of the spin polarizabilities.
Co-design optimization of combined heat and power-based microgrids
With the emergent need for clean and reliable energy resources, hybrid energy systems, such as the microgrid, are widely adopted in the United States. A microgrid can consist of various distributed energy resources, for instance, combined heat and power (CHP) systems. Here, the CHP module is a distributed cogeneration technology that produces electricity and recaptures heat generated as a by-product. It is an energy-efficient technology converting heat that would otherwise be wasted to valuable thermal energy. For an optimal system configuration, this study develops a novel co-design optimization framework for CHP-based cogeneration microgrids. The framework provides the stakeholder with a method to optimize investments and attain resilient operations. The proposed co-design framework has a mixed integer programming (MIP) model that outputs decisions for both plant designs and operating controls. The microgrid considered in this study contains six components: the CHP, boiler, heat recovery unit, thermal storage system, power storage system, and photovoltaic plant. After solving the MIP model, the optimal design parameters of each component can be found to minimize the total installation cost of all components in the microgrid. Furthermore, the online costs from energy production, operation, maintenance, machine startup, and disruption-induced unsatisfied loads are minimized by solving the optimal control decisions for operations. Case studies based on designing a CHP-based microgrid with empirical data are conducted. Moreover, we consider both nominal and disruptive operational scenarios to validate the performance of the proposed co-design framework in terms of a cost-effective, resilient system.
Towards an Agent-Based Blackboard System for Reactor Design Optimization
The field of reactor design is rich with opportunities for applications of computational optimization algorithms; these applications can range from preliminary core design to reactor shuffling patterns. Many of these schemes rely on sets of previously generated solutions (sometimes referred to as “generations”) to inform future decisions. While it is important to build upon prior knowledge, this process requires a full generation of solutions to be formed before future solutions can be examined. Rather than relying on a generational scheme to perform an optimization, we propose using an agent-based approach in conjunction with a blackboard framework for performing reactor design optimizations. Utilizing an agent-based approach allows agents to perform tasks independently, while retaining the ability to build off of previous solutions. We develop an agent-based blackboard system (ABBS) for determining the Pareto front (PF) in sodium fast reactor design optimization problems and compared this with the Non-Dominated Sorting Genetic Algorithm II (NSGA-II). Our goal is to evaluate the viability of the ABBS in producing a PF that is comparable with the NSGA-II algorithm. The design space consists of the fuel height, fuel smear, and plutonium fraction in the core, and we seek to minimize the reactivity swing and plutonium mass, while maximizing the burnup. The diversity, coverage, and spread of the PFs generated by the two methods are examined, and the ABBS is able to converge to the same PF as the NSGA-II algorithm. These results show that the ABBS is able to find optimal designs that are similar to those found by the NSGA-II algorithm. We conclude our study by applying the ABBS to the design of a sodium-cooled fast reactor to dispose of weapons-grade plutonium. The ABBS finds a core design that can burn upwards of 17.5 kg of weapons-grade plutonium per year and degrade an additional 195 kg of weapons-grade plutonium per year into non-weapons-grade material.
Bayesian D‐Optimal Designs for Gaussian Process Surrogate Models
Computer experiments often employ space-filling strategies to create surrogate models with strong predictive performance. The impact of model parameter estimation for Gaussian process surrogates, however, is often overlooked. Obtaining a better initial estimate of the covariance lengthscale parameter, θ, can greatly improve the resulting Gaussian process fit through more effective sequential acquisitions during active learning. In this work, we propose a novel initial design maximizing the Bayesian D-optimality criterion of the Gaussian process lengthscale parameter. Previously published results have shown the emphasis on lengthscale estimation to be promising, but relied on an empirically driven design creation process. Our Bayesian D-optimal designs are rooted in information theory and lead to more informative sequential acquisitions by improving lengthscale estimation. In many cases, these gains eventually result in better surrogates than those seeded with space-filling initial designs. Furthermore, Bayesian D-optimal designs can be tailored to either isotropic or anisotropic covariance structures, and the Bayesian framework enables the inclusion of prior knowledge in the design process, offering greater flexibility and adaptability. Through several simulation studies, we demonstrate the advantages of Bayesian D-optimal designs in terms of both lengthscale estimation accuracy and predictive performance during active learning.
Target Design Optimization of KIPT Neutron Source Facility
Argonne National Laboratory (ANL) of the United States developed and designed a neutron source facility for Kharkov Institute of Physics and Technology (KIPT) of Ukraine. The facility was constructed at Kharkov, Ukraine and its commissioning process has been started. The facility has an electron accelerator driving a subcritical assembly. The electron beam power is 100 kW using 100 MeV electrons. The subcritical assembly has WWR-M2 fuel assemblies with U-235 enrichment of 19.7 wt%. The facility will be utilized to perform basic and applied nuclear research, to produce medical isotopes, and to train young nuclear specialists. Solid target design with stacked disks is selected and each target disk is cooled by water from both side. Tungsten or natural uranium is the target material. This paper presents the target design optimization to maximize the neutron yield and the neutron flux level of the facility while satisfying the thermal-hydraulic design criteria. Monte Carlo computer code MCNPX is utilized for the neutron yield analyses with ENDF/B-VII.0 nuclear data libraries, as a function of target thickness using a simplified target model without cladding or coolant channels. It’s found that the neutron yield saturates at target thickness 60 ~ 70 mm for both tungsten and uranium materials. For the final target design with cladding and coolant channels, the total uranium thickness is 56.5 mm, and the total tungsten thickness is only 33.0 mm. The tungsten material has a large absorption cross section for thermal neutrons. If the tungsten thickness is increased, the neutron yield gain is offset by the neutron absorption reaction. The paper presents the design optimization analyses for both target materials.