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

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At least 73 records · Page 4
All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Xylan-cellulose core structure of oat water-extractable β-glucan macromolecule: Insight into interactions and organization of the cell wall complex

Water-extractable β-glucan with high molar mass (HM) determines health benefits of oat food. Oat β-glucan was extracted by a standardized in vitro digestion method and co-existing water-extractable polysaccharide (WEP) fraction and its HM-arabinoxylan (HM-AX) subfraction were isolated to identify their highly acid-resistant subunit and investigate molecular interactions between constituent polymers. The WEP and HM-AX samples consisted of arabinoxylans (AXs) (74 and 76 %, respectively), however, cellulose constituted the secondary component (6.6 and 12.8 %, respectively). Multi-detection HPSEC along with specific enzymatic hydrolysis of AXs revealed the presence of the HM-xylan domain (16 and 34 %, respectively) built of numerous single- and multi-component populations with random coil and rod-like conformations, which were embedded in a xylan matrix with spherical conformation and controlled the macromolecular shape. Unlike single-component populations, the multi-component ones were resistant to hydrolytic action of AX-hydrolyzing enzymes and represented the subunits that anchor matrix polysaccharides onto cellulose surface. These results indicate that water-extractable β-glucan macromolecule comprises as integral element a cellulose core with two linking populations, HM-xylan and low molar mass glucomannan, which are surrounded by a feruloylated AX-arabinan-arabinogalactan composite and next laminated by β-glucan matrix. Here, the stiff cellulose-xylan backbone is the basis of HM β-glucan organization, controlled by its cellulose-like segments.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2022

Root angle is controlled by EGT1 in cereal crops employing an antigravitropic mechanism

Root angle in crops represents a key trait for efficient capture of soil resources. Root angle is determined by competing gravitropic versus antigravitropic offset (AGO) mechanisms. Here we report a root angle regulatory gene termed ENHANCED GRAVITROPISM1 ( EGT1 ) that encodes a putative AGO component, whose loss-of-function enhances root gravitropism. Mutations in barley and wheat EGT1 genes confer a striking root phenotype, where every root class adopts a steeper growth angle. EGT1 encodes an F-box and Tubby domain-containing protein that is highly conserved across plant species. Haplotype analysis found that natural allelic variation at the barley EGT1 locus impacts root angle. Gravitropic assays indicated that Hvegt1 roots bend more rapidly than wild-type. Transcript profiling revealed Hvegt1 roots deregulate reactive oxygen species (ROS) homeostasis and cell wall-loosening enzymes and cofactors. ROS imaging shows that Hvegt1 root basal meristem and elongation zone tissues have reduced levels. Atomic force microscopy measurements detected elongating Hvegt1 root cortical cell walls are significantly less stiff than wild-type. In situ analysis identified HvEGT1 is expressed in elongating cortical and stele tissues, which are distinct from known root gravitropic perception and response tissues in the columella and epidermis, respectively. We propose that EGT1 controls root angle by regulating cell wall stiffness in elongating root cortical tissue, counteracting the gravitropic machinery’s known ability to bend the root via its outermost tissues. We conclude that root angle is controlled by EGT1 in cereal crops employing an antigravitropic mechanism.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2025

Modeling hydraulic fracture opening and closure with proppant transport and settlement

Hydraulic fracturing is a widely used reservoir stimulation technique for improving fluid circulation in rock formations with extremely low permeability, particularly in enhanced geothermal systems (EGS). To better understand the complex processes involved and improve hydraulic stimulation performance, we have developed ELK (ELectrical fracKing), a MOOSE-based 3D finite element application designed to model the behavior of proppant-fluid mixtures in propagating fractures. ELK integrates both the fluid and proppant components, incorporating particle-driven processes such as gravity settling, particle-particle interactions, and strong density and viscosity contracts, in addition to conventional fluid-driven fracture propagation. In this contribution, we extend ELK to model propped fracture closure, which occurs after the injection phase due to a dramatic drop in the effective stress on the fracture plane. During the shut-in, flowback, and production periods, the fracture width decreases, with the closure behavior depending on proppant concentration.. At low concentrations, closure follows a nonlinear joint law linked to the stiffness of asperities in the fracture walls. While at high concentrations, it is controlled by the properties of packed proppant bed. The extended ELK application is validated against several benchmark examples, including the propagation of an inclined frictional crack, fracture opening and sliding in response to fluid injection, and flowback analysis. We believe that ELK’s enhanced capabilities can serve as a valuable tool for the design and optimization of EGS deployment.

15 - GEOTHERMAL ENERGY↗
DOE OSTI2025

Unified Universal Control and Coordination of Inverter-Based Resources, and Validation for a PV + Battery Hybrid Plant

As renewable energy deployment grows, hybrid power plants (HPPs) combining photovoltaic (PV) and battery systems must evolve to offer both energy and grid stability services. These systems typically include a mix of grid-following (GFL) and grid-forming (GFM) inverters, presenting unique coordination and control challenges. This Department of Energy–funded project developed and validated a Unified Universal Control and Coordination (UUCC) framework for such PV + battery hybrid plants, enabling seamless and stable operation, including ultrafast black start, autonomous synchronization, and robust frequency and voltage regulation, under different grid conditions. The project significantly advanced the understanding of inverter-based resource (IBR) control by developing and validating three complementary system-level approaches for hybrid GFL/GFM operation: 1. A combined Virtual Resistance (VR)-based GFL and Virtual Oscillator Control (VOC)-based GFM method, where each inverter type is governed by a specialized control strategy. Together, these achieve stable, fast-response coordination, eliminating inrush current and enabling smooth black start and grid synchronization across a wide range of grid strengths. 2. A Deadbeat-based UUCC strategy, which uses discrete-time, switching-cycle-level control for both GFL and GFM inverters. This approach replaces traditional PI/PLL control with a control parameter-free, high-bandwidth framework that supports stable LVRT and instantaneous synchronization under all conditions. 3. A benchmark comparison with Siemens’ commercial GFM microgrid controller, which provided a fast baseline platform. The commercial approach decoupled v & f control was implemented on a commercial microgrid controller.The baseline commercial benchmark helped highlight superior transient response and black start performance offered by the deadbeat and VOC approaches. These technical contributions offer substantial improvements over conventional inverter control schemes, which often rely on slow phase-locked loop (PLL)-based synchronization, require careful control parameters tuning, and prone to unstable in weak grids with GFL inverters and in stiff grid with GFM inverters therefore challenging for hybrid GFL+GFM under all grid conditions. The deadbeat-based UUCC framework enables simpler, faster, and more robust operation of hybrid IBR systems using wide-bandgap (WBG) devices such as SiC power semiconductors. The rapid expansion of hybrid distributed energy resources (DERs), including residential and commercial PV-BESS installations such as Tesla Powerwall, PV with vehicle-to-grid (V2G) capability, and other integrated configurations, presents complex operational challenges for medium-voltage radial distribution feeders. These networks are subject to frequent disturbances such as faults, switching operations, rapid reclosing sequences, and feeder reconfigurations, all of which introduce dynamic stress on IBRs. In addition, planned feeder segmentation and deliberate islanding for resilience will require DERs that can autonomously perform blackstart, establish voltage and frequency references, and resynchronize with the main grid. The advanced deadbeat-based UUCC control and blackstart functionalities developed in this project directly address these requirements, enabling decentralized and autonomous operation of inverter-dominated DERs in distribution systems under a wide range of fault and reconfiguration scenarios. From a public benefit perspective, these innovations enable more reliable and cost-effective integration of renewable energy into distribution networks. The ability to autonomously black start and stabilize grids under varying grid conditions support accelerates recovery from outages and support decentralized resilient energy systems. By reducing system complexity and improving performance, this project lays critical groundwork for future inverter-dominated power grids that are clean, reliable, and accessible to all.

14 SOLAR ENERGY↗
DOE OSTI2022

Control Design of Series-connected PV-powered Grid-forming Converters via Singular Perturbation

We report modular architectures that consist of several series-connected dc-ac converters have been a focal point of recent innovations in transformerless medium-voltage applications. In this paper, we consider an architecture consisting of dc-ac modules containing a quadruple active bridge dc-dc converter, which generates three floating dc links that feed grid-side dc-ac inverters. Practical implementation of such a converter module in PV systems requires a variety of controllers that collectively achieve maximum power point tracking, dc-link regulation, and ac-side power control. Design of such multi-loop systems is generally quite challenging due to the potential for destabilizing interactions among loops. Here we propose a design approach where singular perturbation theory is used to decompose the timescales at which each control loop operates and provides a systematic framework for parametric selection. Our approach also ensures system stability of multiple modules with identical controls connected in series across a grid. The paper concludes with experimental results of three 1000 W series-connected converter modules across a stiff grid.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2024

Performance Testing of an Integrated Magnetic Power Take-Off

A wave energy converter (WEC) and the power take-off (PTO) generator system can be represented by using a mass-spring-dampener model. By incorporating a negative stiffness spring within the PTO, the overall stiffness of the PTO can be lowered allowing the impedance of the PTO to be more closely matched with the WEC. By designing for impedance matching the WEC can greatly enhance its power generation capability. This project has involved the design, fabrication and testing of a new type of linear-stroke length and rotary stroke length adjustable negative stiffness magnetic springs for use within a wave energy converter (WEC). The magnetic springs were studied by using 3-D finite element analysis with the objective of creating high energy density and a long linear stroke length. After the construction and testing of both a proof-of-principle adjustable linear and rotary magnetic spring prototype the rotary (torsional) magnetic spring was selected for scaling up analysis. The selected scaled-up proof-of-principle magnetic spring had a peak torque of 850 Nm with a ±45 degree stroke length. By translating the inner rotor relative to the outer rotor, the stiffness could be adjusted to be either negative or positive stiffness. During this project a magnetic lead screw was also studied, and it was shown that by combining the magnetic lead screw with a linearly translating magnetic spring a very long rotary stroke length could be attained. However, as the magnetic lead screw increased complexity and reduced overall energy density relative to a rotary (torsional) spring, this design approach was not further pursed. Dynamometer testing of the variable stiffness magnetic springs was first completed by Portland State University and following this the magnetic spring performance was independently verified by Sandia National Laboratory (Sandia). A WEC analysis when using a variable stiffness magnetic spring was completed by using the WecOptTool. WecOptTool is an open-source WEC optimization software developed by Sandia that supports efficient power take-off (PTO) and control optimization. Wave condition data from the Oregon PacWave test-site was used in this study. The analysis showed that a WEC with a tunable stiffness value could consistently achieve about 80% of its maximum theoretical power production. The use of a tunable stiffness WEC, rather than zero-stiffness or a constant stiffness WEC was also shown to lead to a smaller maximum PTO force requirement. The variable stiffness magnetic spring was integrated into an experimental WEC developed by Sandia, called a Wave-Bot. Sandia successfully completed water-tank testing of the Wave-Bot at the Navy’s Carderock, Maryland, wave-basin test site. The wave-basin testing helped to experimentally demonstrate the operating capabilities and increased power generation capability of a WEC containing an integrated variable stiffness magnetic spring. A WEC capacity factor analysis was also completed. The capacity factor was defined as the ratio of annual average WEC generator power to the maximum (RMS) generated power. This capacity factor provided a means of identifying the ratio of potential revenue to cost. It was calculated that if a tunable variable stiffness magnetic spring has RMS constraints it could operate with a capacity factor above 30%. This is comparable to a wind turbine’s capacity factor.

16 TIDAL AND WAVE POWER↗
DOE OSTI2025

From TPL assessment to design optimization: Wave energy converter control co-design applied to the RM3

The Reference Model (RM) project developed six marine energy converter concepts using a sequential design methodology, which, while widely adopted in the industry, often overlooks interactions between system components, resulting in suboptimal designs. One such example is the Reference Model 3 (RM3), a two-body point absorber wave energy converter (WEC). An assessment using the Technology Performance Level (TPL) revealed that RM3’s low power-to-cost ratio, partly due to expensive steel construction, limits its techno-economic performance. Here, this study aims to redesign RM3 by reducing its scale and employing control co-design to integrate WEC and Power Take-Off (PTO) dynamics, constraints, and cost considerations within an optimization framework. We demonstrate the limitations of RM3’s current PTO design and explore the benefits of scaling down to enhance techno-economic viability by lowering material costs. Using WecOptTool, we conduct a parameter sweep over gear ratios and spring stiffnesses for various Commercial Off-The-Shelf generators in irregular wave conditions. Our findings emphasize the importance of aligning PTO components with WEC dynamics, showing that control co-design and strategic scaling can improve RM3’s power-to-cost ratio. This study presents a transferable example of applied control co-design for other WECs, supporting early-stage developers in their design decisions.

Off the shelf components↗
DOE OSTI2023

Biologically inspired reinforcement using polydopamine of polymer bound composites

Interfacial strength plays a critical role in the mechanical properties of a composite system. In this work, a proven mock high explosive (HE), 5-iodo-2’-deoxyuridine (IDOX) was coated by the adhesive promoting polymer polydopamine (PDA), then formulated with an Estane binder system to form an improved HE mock composite. An extensive comparison study of mechanical properties was performed to determine the effects, if any, of PDA on the composite system. To aid in interpretation of the mechanical test data, neutron reflectometry experiments were performed to determine the thickness and structure of the as deposited PDA films. The mechanical performance of PDA-treated IDOX was then compared to untreated specimens by compression testing in the Brazilian disk geometry. The results strongly suggested that the structure of PDA consists of two layers: one low in density caused by polymer agglomerates attaching to the substrate during polymerization, and the second high in density caused by controlled linear deposition of polydopamine. Finally, the mechanical testing showed that PDA greatly increased the stiffness and yield strength of IDOX based mocks without causing any disruption to the underlying crystal system.

42 ENGINEERING↗
DOE OSTI2021

Non-degenerate parametric mixing and Q-enhancement in ALN Lamb wave resonator

In this Letter, we explore a non-degenerate phase independent parametric quality factor (Q)-enhancement technique for aluminum nitride (AlN) Lamb wave resonators. Unlike other active Q-enhancement techniques which require precise phase control of the electronic feedback loop, this technique is implemented by parametrically pumping AlN material stiffness to realize a negative resistance seen at the signal path. The negative resistance is dependent on the nonlinear material modulation and multi-resonance coupling in the device. A nonlinear circuit model is developed to simulate the parametric coupling of each resonance and extract the nonlinearity of AlN from experimental data. With proper pump frequency and pump power, the device quality factor is boosted in both simulation and experiment. The demonstrated Q-enhancement method is simple to implement and can be applied to other types of resonators that have nonlinear behavior and support multi-resonance operation.

42 ENGINEERING↗
DOE OSTI2020

Evolution of Elastic and Mechanical Properties During Fault Shear: The Roles of Clay Content, Fabric Development, and Porosity

Phyllosilicates weaken faults due to the formation of shear fabrics. Although the impacts of clay abundance and fabric on frictional strength, sliding stability, and porosity of faults are well studied, their influence on elastic properties is less known, though they are key factors for fault stiffness. We document the role that fabric and consolidation play in elastic properties and show that smectite content is the most important factor determining whether fabric or porosity controls the elastic response of faults. We conducted a suite of shear experiments on synthetic smectite-quartz fault gouges (10–100 wt% smectite) and sediment incoming to the Sumatra subduction zone. We monitored Vp, Vs, friction, porosity, shear and bulk moduli. We find that mechanical and elastic properties for gouges with abundant smectite are almost entirely controlled by fabric formation (decreasing mechanical and elastic properties with shear). Though fabrics control the elastic response of smectite-poor gouges over intermediate shear strains, porosity is the primary control throughout the majority of shearing. Elastic properties vary systematically with smectite content: High smectite gouges have values of Vp ~ 1,300–1,800 m/s, Vs ~ 900–1,100 m/s, K ~ 1–4 GPa, and G ~ 1–2 GPa, and low smectite gouges have values of Vp ~ 2,300–2,500 m/s, Vs ~ 1,200–1,300 m/s, K ~ 5–8 GPa, and G ~ 2.5–3 GPa. We find that, even in smectite-poor gouges, shear fabric also affects stiffness and elastic moduli, implying that while smectite abundance plays a clear role in controlling gouge properties, other fine-grained and platy clay minerals may produce similar behavior through their control on the development of fabrics and thin shear surfaces.

58 GEOSCIENCES↗
DOE OSTI2025

Tunable shear thickening, aging, and rejuvenation in suspensions of shape-memory-endowed liquid crystalline particles

The morphological features of particles, notably shape anisotropy, critically influence the rheological properties of dense suspensions, spanning both natural and engineered systems. This work explores the potential of using shape memory particles to dynamically regulate suspension fluid flow through controllable shape transformations. First, we synthesize shape-memory particles with programmable anisotropy from liquid crystal elastomers, such that the stiffness and shapes of the particles can be tuned by manipulating temperature. Our findings reveal that suspensions from such particles exhibit significant tunability in shear thickening behavior, transitioning from discontinuous shear thickening to a Newtonian-like response within a narrow temperature range of 60 ° C. This capability to modulate rheological responses in situ presents an approach for addressing processing challenges in many applications where control over flow behavior is paramount. Furthermore, we also show that suspensions composed of these anisotropic particles can undergo physical aging, and evolve into a glassy state. This state can be escaped upon activation of the shape memory effect. This reversibility underscores the potential for using such materials to engineer systems that can enter or come out of kinetic arrest by leveraging internal mechanical responses to external stimuli. The insights gained here not only broaden our understanding of the interplay between particle geometry and suspension dynamics but also pave the way for leveraging ensembles of stimuli-responsive objects to precisely control collective behaviors in many-body systems.

Science & Technology - Other Topics↗
DOE OSTI2024

Identification of Dynamic Force Coefficients for an Additively Manufactured Hermetic Squeeze Film Bearing Support Damper Utilizing a Pass-Through Channel

Abstract The following paper presents breakthrough experimental results for a new hermetic squeeze film damper (HSFD) concept that is integrally designed within an externally pressurized tilting-pad radial gas bearing support. The flexibly damped gas bearing module was designed for a 7.2″ (183 mm) diameter shaft and fabricated using direct metal laser melting (DMLM); also known as additive manufacturing. The bearing and HSFD were sized based on ongoing studies for oil-free supercritical carbon dioxide (sCO2) power turbines in the 8.5 MW–10 MW power range. The development of the new damper concept was motivated by past dynamic testing on HSFD, which generated frequency-dependent stiffness and damping force coefficients. In efforts to eliminate the frequency dependency, a new HSFD architecture was conceived that adds accumulator volumes and a pass-through channel to previously conceived HSFD flow network designs. The other motivation for the work is the need to develop a cost-effective and reliable oil-free bearing technology that is scalable to large power turbomachinery applications. There were several objectives for the following work. The first objective was to successfully design and fabricate a single piece bearing-damper using additive manufacturing, while dimensionally controlling critical design features. The paper discusses the manufacturing steps and shows cut-ups that reveal adequate clearance control capability with internal damper clearances. The second objective was to perform experimental testing with the new HSFD design in efforts to extract stiffness and damping coefficients for excitation frequencies within 20–160 Hz and peak vibration amplitudes between 0.25 mils (6.35 microns) to 1 mil (25.4 microns). The test results for a single HSFD bearing module indicated that the design modifications to the HSFD architecture were successful in eliminating nearly all the frequency dependencies for the stiffness force coefficient. The dynamic tests yielded a stiffness coefficient that varied between 112 klb/in. (19.6 MN/m) and 96 klb/in. (16.8 MN/m). The damping force coefficient however, exhibited relatively more variation with frequency with values residing between 175 lb-s/in. (31 kN-s/m) to 214 lb-s/in. (37 kN-s/m). Finally, the paper advances a three-dimensional fluid-structure interaction (FSI) model using transient finite element analysis (FEA) coupled to a computational fluid dynamics (CFD) model. The FSI analysis performed between 20 Hz and 80 Hz was used to predict the stiffness and damping of the HSFD using a quarter-section model of the damper. The FSI analysis was able to support test results by showing only a 6–7.4% change in the magnitude of force coefficients. Stiffness predictions agree reasonably well with experiments whereas damping is underpredicted.

Engineering↗
DOE OSTI2026

Can classical DEM simultaneously capture compressibility and flowability of milled biomass?

Accurate prediction of the rheological behavior of biomass is essential for the design and operation of hoppers, feeders, and storage systems in biorefineries. This study examines whether the classical, coarse-grained discrete element method (DEM) formulation can simultaneously reproduce the compressibility and flowability of milled herbaceous biomass, using Miscanthus × giganteus as a representative material. The model represents particles as rigid spheres interacting through Hertz-Mindlin elastic-frictional contacts augmented with an area-dependent cohesion term. Laboratory cyclic compression and wedge-shaped hopper discharge experiments were used as calibration benchmarks. Although the model can independently reproduce each behavior by appropriately tuning particle Young's modulus E and cohesion energy density k, an extensive parametric investigation comprising more than 600 simulations reveals that the optimal parameter regions for compression and hopper flow are distinct and non-overlapping in (E, k) space. Surrogate surface analysis further shows that the corresponding objective-function valleys exhibit similar trends but are approximately parallel and spatially offset, precluding a unified calibration within the explored domain. Sensitivity analysis indicates that compressibility is governed predominantly by stiffness and cohesion, whereas the slope of the mass flow rate-opening relation in hopper discharge is primarily controlled by tangential friction. Extensions incorporating particle size distribution and clumped-sphere representations do not eliminate the incompatibility. These results systematically reveal, for the first time, the structural limitation of simplified DEM formulations in representing biomass rheological behavior, underscoring the necessity for models incorporating additional physical mechanisms, such as particle deformability or enhanced interlocking, to achieve unified predictive capability for biomass handling behavior.

09 BIOMASS FUELS↗
DOE OSTI2020

Nonlinear controller for nonlinear wave energy converters

The present invention is directed to a nonlinear controller for nonlinear wave energy converters (WECs). As an example of the invention, a nonlinear dynamic model is developed for a geometrically right-circular cylinder WEC design for the heave-only motion, or a single degree-of-freedom (DOF). The linear stiffness term is replaced by a nonlinear cubic hardening spring term to demonstrate the performance of a nonlinear WEC as compared to an optimized linear WEC. By exploiting the nonlinear physics in the nonlinear controller, equivalent power and energy capture, as well as simplified operational performance is observed for the nonlinear cubic hardening spring controller when compared to an optimized linear controller.

Wilson, David G.↗
DOE OSTI2023

Formation and Shape Changing of Conductive Helical Ribbons via Deposition of Highly Stressed Films on Mechanically Responsive Substrates

Abstract This work demonstrates that the electrodeposition of highly stressed films on compliant ribbons is a robust process to obtain helical structures with excellent mechanical stability and potentially high thermal and electrical conductance. Electrodeposition on end‐tethered ribbons alters their axial and bending stiffness while imparting mechanical stress to drive the formation of a helix with a microscale diameter and pitch in a controlled and scalable manner. The process generates helices with diameters and pitches between 80 and 200 µm and lengths as large as several millimeters. The approach is amenable to parallel processing a large number of 3D structures on any substrate, including large‐area semiconductor wafers. This phenomenon is explained in terms of the change of stress gradients as material is added. Applications of the fabricated helices include antennas, metamaterials, and slow‐wave structures in frequency ranges not previously attainable.

Chemistry↗
DOE OSTI2022

Influence of wind turbine design parameters on linearized physics-based models in OpenFAST

Abstract. While most physics involved in wind energy are nonlinear, linearization of the underlying nonlinear wind system equations is often important for understanding the system response and exploiting well-established methods and tools for analyzing linear systems. Linearized models are important for eigenanalysis (to derive structural natural frequencies, damping ratios, and mode shapes), controls design (based on linear state-space models), etc. In controls co-design, wherein methods often rely on linearized time-domain models of the physics, the physical structure (often called the plant) and controller are designed and optimized concurrently, so it is important to understand how changes to the physical design affect the linearized system. This work summarizes efforts done to understand the impact of design parameter variations in the physical system (e.g., mass, stiffness, geometry, and aerodynamic and hydrodynamic coefficients) on the linearized system using OpenFAST.

17 WIND ENERGY↗
DOE OSTI2025

Multi-Functional Smart Structures for Smart Vehicles

This report summarizes the development of a new class of recyclable multi-functional composite materials for production of lightweight smart structures and surfaces. Functional high stiffness conductive composites were processed using molding methods that integrated continuous fiber and additively manufactured features. Methods for integration of sensing functionality and controls were also developed to reduce system cost while providing a new capability for structural health monitoring. This new class of composites is applicable to a broad range of vehicle interior, exterior and battery enclosure systems. By way of demonstration, a vehicle instrument panel cross car beam was developed that provided a 38% mass savings compared to steel while maintaining a cost penalty competitive to alternate lightweight material solutions. These technologies were validated for implementation by a uniquely qualified project team comprising a US automotive OEM, Tier 1 and Tier 2 supplier, with key contributions from Oak Ridge National Lab, Purdue University and Michigan State University.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2023

Soft Coiled Pneumatic Actuator with Integrated Length-Sensing Function for Feedback Control

SPIRA Coil actuators are formed from thin sheets of PET plastic laminated into a coil shape that unfurls like a “party horn” when inflated, while many soft actuators require large pressures to create only modest strains, SPIRA Coils can easily be designed and fabricated to extend over dramatic distances with relatively low working pressures. Internal metalized PET strips separate in the extended portion of the actuator, creating an electrical circuit with a resistance that corresponds to the actuator length. This paper presents and experimentally validates easy-to-use design models for the actuators’ self-retracting spring stiffness, its pneumatic extension force, and its internal length-sensing electrical resistance. Testing of the self-sensing capabilities demonstrates that the embedded sensor can be used to determine the actuator length with virtually no hysteresis. Feedback control with the resistance-based sensing resulted in length-control errors within 5% of the extended actuator length (i.e., 3 cm of 60 cm).

Greenwood, Jacob R. (ORCID:0000000310897854)↗