Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “prototyping and performance testing”

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

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 595 records · Page 33

Seamless Transition of Critical Infrastructures using Droop Controlled Grid-forming Inverters

Seamless recovery of power to critical infrastructures, after grid failure, is a crucial need arising in scenarios that are increasingly becoming more frequent. Here, this article proposes a seamless transition strategy using a single and unified mode-dependent droop controlled grid-forming inverters. The control strategy achieves the following objectives: 1) regulates the output active and reactive power by the droop-controlled inverters to a desired value while operating in on-grid mode; 2) seamless transition and recovery of power injections into the load after grid failure by inverters that operates in grid-forming mode all the time; 3) requires only a single bit of information on the grid/network status for the mode transition. A framework for assessing the stability of the system and to guide the choice of parameters for controllers is developed using control-oriented modeling. A controller hardware-in-the-loop-based real-time simulation study on a test system based on the realistic electrical network of a commercial-scale medical center is conducted for initial prototyping of the control strategy. A hardware experiment is conducted with two 3 - $\phi$, 480 -V, 125 -kVA grid-forming inverters, a 3 - $\phi$, 480 -V, 270 -kVA grid simulator, a physical grid switch, and a physical load bank. The experimental data establishes the effectiveness of the always grid-forming operation and control of inverters in meeting power delivery objectives when on-grid and off-grid under various kinds of loads and scenarios while minimizing transients during transitions. Furthermore, performance comparison with existing strategies showcases the advantage of the proposed strategy.

24 POWER TRANSMISSION AND DISTRIBUTION↗

Multiple Stream Low-Cost Recycling Method

The global composite industry generates large quantities of waste and which mostly end as landfill due to lack of meaningful end-use applications for the multiple waste streams. In a recent report by the Electric Power Research Institute (EPRI), waste generated by the wind industry could reach 370,000 tons a year of composite wind energy blades being decommissioned and scrapped. Wind energy is just one major industry utilizing composite materials. The waste generated by industry includes End-of-Life (EoL) materials and manufacturing process scrap. GreenTex Solutions has developed a unique and innovative technology to recycle the composite waste streams in a range of forms made from production waste and EoL materials. This includes manufacturing waste materials such as dry chopped fiber tow, loose fibers, shredded fibers from reinforcement fabrics, cured/semi-cured prepregs, and it also includes fully-cured composite structure waste (such as edge trims from cured parts) from manufacturing aircraft, automobiles, wind blades, boats, and composite cylinders (tanks). Current recycling methods involve recovering the structural fiber by removing the matrix resin through methods such as pyrolysis. The resulting fibers are used in injection molding or wet laid nonwoven mats and other usable forms. The GreenTex technology bypasses these intermediate steps to create the lowest possible recycling processing costs and the lowest embodied energy/CO2 emissions. The end-product from the GreenTex technology is a finished industrial composite part/application versus intermediate fibers or fabrics. The GreenTex manufacturing process enables cross-industry reuse of recycled feedstock by taking waste from multiple industries (wind energy, aerospace, marine, etc.) and recycles the waste into a product used in other industries. The initial target market application is structural flooring for intermodal shipping containers and truck bodies. One of the team’s key partners is Wabash National which produced 29,000 truck bodies in 2019. The current flooring system is comprised of solid oak “butcher board” laminated panels. Additionally, Mediterranean Shipping Containers (MSC) transports over 1.8 million twenty-foot equivalent units per year in intermodal shipping containers. The current container floor is laminated hardwood that is harvested from the rain forests of Central and South America. The project is to develop a flooring system made from recycled composites that can be qualified for both companies (Wabash and MSC). Initial prototypes validated that the recycled composites panels are lighter and thinner with much higher mechanical strength. These results suggest a typical truck trailer would have 20% lower tare weight. The GreenTex technology is not limited to flooring and is widely applicable to other transportation elements such as walls, roof elements, cab areas and related structural components. Under this project different composite waste streams were evaluated and then combined to develop a formulation that would meet the targeted performance criteria for a flooring system. Wet compression molding was used to fabricate plaques at different tonnage using various composite waste streams. The plaques were tested for flexure and impact.

36 MATERIALS SCIENCE↗

CEBAF Accelerator Tunnel Robot Project

Advancements in the field of robotics allow for the use of remotely controlled robots to perform tasks that have typically required human intervention. Jefferson Lab has explored the possibilities of robots placed in the accelerator tunnel to perform remote inspections that would otherwise require powering down equipment and completing lengthy radiological surveys that impact beam operations. A robotic solution ? driven by a human operator ? could not only reduce accelerator down time but also support the Lab's radiation exposure policy (known as "ALARA" - As Low As Reasonably Acceptable) by handling routine tunnel and beamline investigations in place of a human being. However, operating a remote device in a radioactive, high electronic-noise area is not a trivial task and drop-in solutions are rarely as simple as they seem. We will present the past prototypes that were tested as well follow-on technology developed from the project. We will also briefly survey current applications of robots at accelerator facilities with an eye toward future applications.

McGuckin, Theodore↗

SD-WAN Evaluation Criteria for a Defense Information Systems Network Expeditionary Customer Edge

The Defense Information Systems Agency (DISA) has identified a service provision gap midway between the capacity and capability of a Defense Information Systems Network (DISN) transport Edge Points of Presence (POP) and U.S. Department of Defense (DoD) Enterprise Classified Travel Kit (DECTK). Some deployed force 100-user Tactical Operations Centers are in field locations far removed from the DISN transport core, in challenging environmental conditions with limitations on space, weight, power, and cooling for network equipment. As part of a multi-phase project, Pacific Northwest National Laboratory (PNNL) will gather and analyze requirements, design, develop, prototype, and test a miniaturized and ruggedized DISN Customer Edge POP scaled to support approximately 100 users in a field Tactical Operations Center. An Expeditionary Customer Edge (ECE) will be more suitable for field deployment than a DISN transport Edge POP, using ruggedized hardware and network function virtualization (NFV) to operate in challenging field environmental conditions, plus reduce weight, power, and cooling requirements. A key enabling technology for ECE is Software Defined Wide Area Networking (SD-WAN). This document provides: • A brief overview of SD-WAN use cases and how they apply to ECE • How SD-WAN technology compares to existing networks like DISN that use Optical Transport Networking (OTN) and Multiprotocol Label Switching (MPLS) • SD-WAN functional requirements relevant to ECE • A description of an ECE Virtual Prototype, including simulated wide area network paths and a DISN-representative implementation of MPLS, in Cisco Modeling Labs • Detailed network flow walkthroughs • Evaluation criteria based on ECE-relevant SD-WAN functional requirements Finally, an appendix provides an informal evaluation of Speedify—a commercial retail Virtual Private Network service—against the ECE SD-WAN evaluation criteria.

42 ENGINEERING↗

Performance study of a novel dew point evaporative cooler in the climate of central Europe using building simulation tools

This paper presents the performance research of a hybrid air conditioning system (System II) equipped with novel dew point evaporative cooler (DPIEC) for a retail building located in temperate climatic conditions. The new cooler has a dedicated, adaptable structure that maximizes its performance in the climate conditions of central Europe. The unit can operate as a typical regenerative air cooler when outdoor air is drier than indoor air, it can operate as a counter-flow heat recovery unit when indoor conditions are more dry than outdoor and it can operate as a combination of both arrangements. The year-round, hourly-stepped building energy simulations were carried-out using a prognostic tool of energy consumption. The novel dew point evaporative cooler application potential was established using the black-box model based on regression equations was established based on experimental tests on a prototype of novel DPIEC. The hybrid system operation was compared to the typical air handling unit equipped with a standard energy wheel for heat recovery (System I). Presented research shows that DPIEC can cover about 95% of total cooling loads while the energy wheel covers only 9% of total cooling load. System II allows us to save 65% of seasonal electricity consumption comparing to System I. It comes from the fact that during most of the cooling season DPIEC is in operation and it covers most of the cooling loads without the need to switch the chilled water system.

Air conditioning↗

Transition Core Analysis for HEU to LEU Fuel Conversion at the University of Missouri Research Reactor

A new type of low-enriched uranium (LEU) fuel based on an alloy of uranium and molybdenum is expected to allow the conversion of U.S. domestic high-performance research and test reactors requiring high density fuel from highly enriched uranium (HEU) to LEU. The University of Missouri Research Reactor (MURR (R)) has undergone design and performance calculations for conversion to this LEU fuel. Presented in this paper is the analysis of a crucial step in the conversion process: the sequence of MURR transition cores from all fresh to equilibrium burnup LEU operations. During the initial conversion from HEU to LEU fuel, MURR will operate atypically due to the lack of burned LEU elements. Given the constraints of MURR operation and experiments, a proposed transition scheme minimizes the time MURR operates atypically compared to the prototypic cycles currently run with HEU fuel and moves quickly to the same sort of equilibrium cycles for the LEU fuel.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

Data-Driven Digital Twin for Reliability Assessment of DC/DC Buck Converter

In commercial applications, the operation of DC/DC converters significantly impacts overall system performance and long-term reliability. This study introduces a data-driven digital twin (DT) approach for estimating critical degradation parameters of DC/DC BUCK converter under steady-state condition. Initially, a circuit-level MATLAB/Simulink digital model (DM C ) is refined against a hardware prototype’s switching model dataset using offline particle swarm optimization. The optimized digital model’s steady-state response is then verified with its average model response while varying the duty and load. Subsequently, degradation profiles are imposed on the inductor, capacitor, MOSFET in the DMC. A large dataset is generated from this model, allowing training, validation, and testing of machine learning (ML) models for component health regression tasks. The proposed method employs random forest ML models, achieving impressive regression results with a squared R value as high as 0.99978 and a root mean square error of 4.2× 10 –6 . The method is further validated on a medium power level DC/DC BUCK prototype with varying load conditions, and includes the analysis of MOSFET’s on-resistance under degradation conditions. This data-driven DT method shows promise for identifying parasitic degradation and ohmic loss parameters, enhancing converter reliability assessments in a non-invasive, generalized, and computationally efficient manner.

14 SOLAR ENERGY↗

Polymer Additive Manufacturing for Marine Renewable Energy Applications: Best Practices, Research Trends, and Current Challenges

Additive manufacturing (AM) is a rapidly growing technology space, not only for prototyping, but is also becoming more feasible at larger scales and increasing component quantities. There are a large variety of AM processes and materials available to users and effectively applying those processes and materials to a specific use case can be challenging. One specific area where AM could be particularly beneficial is marine renewable energy (MRE). Not only is MRE a relatively nascent industry with a near-term need for rapid deployments and prototype testing, but developers could also see long-term benefits from the broad variety of environmentally resistant materials available and the ability to manufacture complex geometries that AM technologies offer. Over the past 4 years, AM materials have played an increasing role in the Advanced Materials project; a multi-year, multi-laboratory research project funded by the U.S. Department of Energy's Water Power Technologies Office, with the main goal of reducing barriers to the adoption of complex materials in the MRE industry. The primary focus of this project is to develop test methods and generate datasets to understand the long-term performance of advanced materials in marine environmental and address specific material challenges as they arise. This report provides an extensive overview of the research that has been performed specific to AM polymers as part of the Advanced Materials project. The intention of this document is to provide recommendations of best practices with regards to material selection, mechanical test method development, and design practices, lessons learned along the way, current research trends, and ongoing challenges with regards to AM polymers in marine environments. In particular, this report focuses on several key aspects: Material and process selection, Environmental conditioning and subsequent degradation quantification through mechanical characterization, Composite reinforcements on AM polymer substrates, Adhesion of instrumentation for mechanical characterization and loads measurements, Protective coatings for preventing biofouling and water ingress, Other MRE case studies where AM has proved particularly useful. Ultimately, we hope that the test methods that have been developed, data generated, and lessons learned from this research will be valuable to the MRE community (researchers and developers alike), as well as other industries, and can be used as a reference point as the respective MRE and AM industries continue to grow and mature.

16 TIDAL AND WAVE POWER↗

Design, construction, and testing of no-insulation small subscale solenoids for compact tokamaks

Fusion energy systems studies (FESS) for next-step devices based on the most promising magnetic configurations indicate that high magnetic fields and high current density for magnet coil systems may reduce device size and lower the cost. High current density and radiation resistant fusion magnets are particularly beneficial for low cost, low aspect ratio compact reactor designs such as Fusion Nuclear Science Facility (FNSF), Fusion Pilot Plant (FPP) of low-aspect ratio spherical tokamak (ST) or compact stellarators. Unlike typical high field magnets for nuclear magnetic resonance (NMR), magnetic resonance imaging (MRI), or high energy physics research applications, neutron irradiation damage to organic insulations in the coil winding pack is a critical issue for next generation fusion reactors where orders of magnitude higher neutron fluence than those in present experimental reactors such as ITER are expected. Moreover, a high coil winding pack current density is needed for high field magnets in low cost, compact radial build next step fusion reactors. The slow current charging time, however, is an issue in fully non-insulated coils. In this work, we present the design, construction and testing of subscale Nb3Sn solenoids, up to half the diameter of the central solenoid (CS) for National Spherical Torus Experiment (NSTX), with and without inter-layer insulation for enhancing radiation resistance while improving the winding pack current density and coil performance. The major radius for the NSTX/NSTX-Upgrade (reference for compact ST) is 0.854/0.934 meter, and 4.8 meters for FNSF. The magnetic field for NSTX/NSTX-U at the plasma center is 0.6/1 Tesla and 9 Tesla for FNSF. The inner diameter of the central solenoid coil is 0.2/0.4 meter for NSTX/NSTX-U and 1.2 meters for FNSF. The current charging and discharging behavior of the prototype solenoids was investigated to quantify performance advantages of a simplified coil fabrication without error-prone vacuum pressure impregnation (VPI) for the removal of epoxy organic insulation. Scalability of the no insulation concept for fusion can be addressed via engineered coating for novel insulation on contact resistance or intra-layer no insulations. Radiation resistance and coil winding efficiency were significantly improved in the no insulation coils for next step compact fusion reactors.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

Filterbank Multicarrier Communications for High Mobility Underwater Acoustic Links

This paper presents a new method of designing prototype filters that are robust against time and frequency dispersive (i.e., doubly dispersive) underwater acoustic (UWA) channels. The proposed design uses a modified form of Slepian sequences as a basis set to arrive at a design that is maximally compact along both time and frequency/Doppler dimensions. This keeps the inter-symbol interference confined to a small number of adjacent data symbols, both across time and frequency dimensions. It also minimizes the ramp-up (at the beginning) and ramp-down (at the end) of each synthesized data packet. Here, we test our design by making use of the BELLHOP/VirTex channel simulator and compare its performance with that of the widely used orthogonal frequency division multiplexing (OFDM) method. Our emphasis is on scenarios where the channel impulse response extends to a few hundreds of milli-seconds and the relative speed of communicating vehicles can be as large as 10 m/s. We find that while OFDM fails in majority of these scenarios, the proposed design continues to work well in all the scenarios that we simulate.

97 - MATHEMATICS AND COMPUTING↗

Experimental Studies and Energy Modeling for Evaluating Performance of Various Deep Wall Retrofits

The Pacific Northwest National Laboratory, Oak Ridge National Laboratory, and the University of Minnesota conducted a three-year, multipart study on residential retrofit wall assemblies. The project, which was funded by the U.S. Department of Energy’s Building Technology Office, aimed to compare a range of residential wall retrofit systems that prioritized affordability, durability, and energy savings potential. The research team identified, constructed, tested, simulated, and analyzed the feasibility and economics of 16 wall retrofit assemblies (14 test configurations and two baseline configurations) that can be applied to the exterior side of existing walls (either with or without the existing cladding). The 16 wall assemblies were installed in an in-situ laboratory environment, to evaluate the ease of construction and study the thermal and hygrothermal performance of the walls. This paper presents the methodology used to evaluate the thermal performance of the walls and discusses the energy modeling results of the study. The results from the experiments were used to calibrate a THERM model of each wall assembly, which was then applied to a whole building using the EnergyPlus 8.6 simulation engine. A residential prototype building was used to extrapolate whole-building energy savings in each U.S. climate zone. To capture the conditions of the largest number of homes in the United States, the most frequent building characteristics (e.g., attic insulation level, window specifications, foundation insulation, etc.) were extracted from ResStock data and applied to the prototype model. Results from the energy modeling showed that the climate zones with the highest potential for retrofit savings are those which are heating-dominated (i.e., Cold and Very Cold climate designations). In these climate zones, heating and cooling energy savings due to the wall retrofits alone ranged from 21.5% to 38.2%.

Nagda, Harshil↗

First-ever deployment of a SiPM-on-tile calorimeter in a collider: a parasitic test with 200 GeV p p collisions at RHIC.

We describe the testing of a prototype SiPM-on-tile iron-scintillator calorimeter at the Relativistic Heavy Ion Collider (RHIC) during its 200 GeV p p run in 2024. The prototype, measuring 20 × 20 cm 2 and 24 radiation lengths in depth, was positioned in the STAR experimental hall, approximately 8 m from the interaction point and 65 cm from the beam line, covering a pseudorapidity range of about 3.1 < η < 3.4. By using the dark current of a reference SiPM as a radiation monitor, we estimate that the prototype was exposed to a fluence of about 10 10 1-MeV n eq /cm 2 . Channel-by-channel calibration was performed in a data-driven way with the signature from minimum-ionizing particles during beam-on conditions. AGeant4 detector simulation, with inputs from thePythia8 event generator, describes measurements of energy spectra and hit multiplicities reasonably well. These results mark the first deployment, commissioning, calibration, and long-term operation of a SiPM-on-tile calorimeter in a collider environment. This experimental campaign will guide detector designs and operational strategies for the ePIC detector at the future EIC, as well as other applications.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

Bench Testing Data and Report for an Early Prototype Pitch Resonator WEC

This dataset encompasses data and documentation from bench tests conducted on an early prototype of a "pitch resonator" wave energy converter (WEC). The testing aimed to validate numerical models and reduce risks associated with the pitch resonator concept, which is designed to convert the pitching and rolling motions of a buoy into electrical power. The project's goal is to provide supplementary power, in the range of 10-100 watts, to the National Science Foundation's Ocean Observatories Initiative Pioneer Array. Two distinct testing phases are documented: one using a single degree of freedom (1DOF) test rig, and another employing a six degree of freedom (6DOF) Stewart platform, known as the Large Amplitude Motion Platform (LAMP). These tests assessed various factors, such as system performance in different motion scenarios, the torque exerted by wave forces, and the impact of mounting configurations. The dataset includes raw test data in MATLAB (.mat) format, detailed metadata, and a report describing the experimental procedures and preliminary findings.

16 TIDAL AND WAVE POWER↗

COVID-19: Spatiotemporal social data analytics and machine learning for pandemic exploration and forecasting

This task focused on developing a preliminary approach to use machine learning (ML) to explore the relationship between county-level societal variables and COVID-19 parameters, including COVID-19 cases rates and counts and COVID-19 death rates and counts. The objective was to develop and test a prototype approach for linking COVID-19 and county-level data. The task focused on enhancing and applying existing LANL ML techniques to COVID-19. Our novel ML methods have been a subject of a recently approved U.S. patent. The codes based on these methods are already open-source released. Our ML tools (NMFk/NTFk) are applied to extract hidden features (signals, waves) in the analyzed datasets and automatically identify their optimal number. The features are extracted by identifying counties that have similarities between the county-level societal variables and the COVID-19 parameters. These demonstration analyses will facilitate the ongoing pandemic simulations and predictions performed by Los Alamos other institutions, as well as lay the groundwork for future work.

60 APPLIED LIFE SCIENCES↗

Advanced Sensors for In-Situ Amine Degradation Monitoring in Post-Combustion Carbon Capture

In order to improve the long-term performance of post-combustion carbon capture technologies, improvements to the detection of solvent degradation or reduction in CO2 capture efficiency are necessary. A pair of sensors were deployed to the National Carbon Capture Center’s (NCCC) to monitor CO2 capture and solvent degradation. The CO2 sensors were located to measure before capture and after capture concentrations of CO2 to measure the capture efficiency of the solvent system. Amine degradation sensors were located at four locations along the main solvent lines corresponding to CO2 loading and temperature: hot rich, cold rich, hot lean, and cold lean. Experimental results from laboratory tests using the sensors are shown, along with prototype designs that were deployed to the field site.

Brister, Matthew↗

Development and testing of a fission-like neutron field for dosimetry and instrument calibrations based on deuterium-tritium generator

For nearly five decades 252 Cf sources have been used for testing and calibration over a wide range of neutron detection devices used for nuclear safety and radiation protection. However, the vastly increased cost of 252 Cf sources, its short half-life, and concerns about future shortage have prompted nuclear facilities and radiological calibration laboratories that rely on high-intensity neutron sources to seek alternatives. There appear to be no other radionuclide neutron sources that would match “like-to-like” 252 Cf performance characteristics. Alternatives of producing a fission-like neutron spectrum based on commercially available deuterium-tritium (D-T) generators, and without any fissionable materials or beryllium, have been explored. This paper describes efforts of designing the spectrum shaping assembly, its construction and installation. The produced neutron field was evaluated both from the perspective of the neutron fluence spectrum and the resulting dosimetric outcome. Finally, it was tested for practical application by examining response of various health physics instruments and personal monitoring devices in comparison to the response of those devices when exposed to 252 Cf. In conclusion, the response of survey-type instruments tested within the prototype, surrogate fission, reference field are acceptably close to their response in the targeted 252 Cf field.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

Development of a High-Efficiency Hybrid Dry Cooler System for sCO 2 Power Cycles in CSP Applications

This project addressed a major gap in supercritical CO 2 (sCO 2 ) power cycle research by focusing on the pre-cooler, a component that had received little attention despite its significant impact on cycle efficiency and plant economics. The team developed a compact dry cooler using brazed/diffusion-bonded microchannel passages paired with formed air-side fins, advancing the technology from TRL-2 toward commercial readiness. Compared to conventional fin-tube coolers, the design cuts installation footprint by roughly half for 10+ MWth systems while achieving better heat transfer and lower approach temperatures, translating into a projected LCOE reduction from 6.04 ¢/kWh to between 5.85 and 5.94 ¢/kWh. While fabrication of an aluminum MW-scale prototype revealed brazing and sealing challenges at larger scales, lessons learned informed a subsequent 1 MWth unit that was successfully built and delivered for integration into Sandia's Gen3 Particle Pilot Plant, advancing the technology to TRL-7 with a path toward TRL-8 pending successful testing.

30 DIRECT ENERGY CONVERSION↗

10 Boron-film-based gas detectors at ESS

The development of detectors for the European Spallation Source is an important parallel element to the effort put into the design and construction of the neutron source and instruments. The 10Boron-film-based detector developments that started over a decade ago as basic detector concepts have now reached technical maturity after intense prototyping work and numerous testing campaigns. Several of the ESS beamlines that will soon enter the commissioning phase started welcoming the detector systems built with the 10 B-film converter technology. The real-size demonstrators evolved in the last 2–3 years into a diverse suite of gas proportional counters for use in diffraction, reflectometry and small-angle scattering studies in spite of the operational complexity posed by the requirements for large-area coverage, low material budget and robustness for operation in the high-flux and high-radiation environment of ESS. The detectors are now being shipped to ESS or undergoing the last performance and calibration tests before being handed over to the instrument teams for installation in the host beamlines. A common feature of these detector systems is the very large number of readout channels that they are instrumented with in order to fulfill the demanding requirements for sensitivity, spatial resolution and count-rate capability. Across all of the detector types that will operate at ESS, the integration, testing and commissioning of the read-out technologies and software tools for data reduction, calibration and analysis are the focus of the detector and integration teams. These will yield a wealth of knowledge about their operation as well as initial results on the in-situ performance, a very important asset to ensure rapid commissioning of the detectors when neutrons from the ESS source become available. In this paper we will give an overview of the 10 B-film-based detector technologies included in the ESS detector suite that are currently facing the transition from the production phase to installation and integration with the other beamline components, which comes with its own specific challenges of both organizational and technical nature.

47 OTHER INSTRUMENTATION↗