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DOE OSTI2022

A New Shape Optimization Approach for Lightweighting Electric Machines Inspired by Additive Manufacturing

Minimizing the mass in electric machines while maintaining superior performance is a new requirement for the advancement of drivetrains used in wind energy and electric mobility. Topology optimization (TO) for lightweighting electric machines using traditional approaches typically explores a restricted design space allowed by standard parametrizable geometry and manufacturing, while advanced methods, such as cell-based density approaches, suffer from a lack of robust manufacturability constraints during the optimization process. To overcome these drawbacks, we explore a grid-independent, boundary optimization where the outer shape of the magnet is parameterized using Bezier curves. We conduct a design of experiments (DOE) to study the effect of different magnet shapes on machine performance by varying the control points on the Bezier curves. A machine-learning-based surrogate model is constructed using the data from the DOE to quantify the relationship between the control points, air-gap torque, and mass. The control points are then optimized to maximize the torque density. The approach is used for minimizing electrical steel mass in the International Energy Agency (IEA) 15-MW radial flux direct-drive wind turbine generator. The new approach to shape optimization resulted in smooth and concise shapes that can be easily additively manufactured with up to a 20-ton reduction in electrical steel mass.

additive manufacturing↗

DOE OSTI2022

A New Shape Optimization Approach for Lightweighting Electric Machines Inspired by Additive Manufacturing: Preprint

Minimizing the mass in electric machines while maintaining superior performance is a new requirement for the advancement of drivetrains used in wind energy and electric mobility. Topology optimization (TO) for lightweighting electric machines using traditional approaches typically explores a restricted design space allowed by standard parametrizable geometry and manufacturing, while advanced methods, such as cell-based density approaches, suffer from a lack of robust manufacturability constraints during the optimization process. To overcome these drawbacks, we explore a grid-independent, boundary TO where the outer shape of the magnet is parameterized using Bezier curves. We conduct a design of experiments (DOE) to study the effect of different magnet shapes on machine performance by varying the control points on the Bezier curves. A machine-learning-based surrogate model is constructed using the data from the DOE to quantify the relationship between the control points, air-gap torque, and mass. The control points are then optimized to maximize the torque density. The approach is used for minimizing electrical steel mass in the International Energy Agency (IEA) 15-MW radial flux direct-drive wind turbine generator. The free-form boundary TO resulted in smooth and concise shapes that can be easily additively manufactured with up to a 20-ton reduction in electrical steel mass.

additive manufacturing↗

DOE OSTI2022

A Boundary Topology Optimization Approach for Lightweighting Electric Machines Inspired by Additive Manufacturing

Minimizing the mass in electric machines while maintaining superior performance has become a new requirement for the advancement of drivetrains used in wind energy and electric mobility. Topology optimization for light-weighting electric machines using traditional approaches typically explore a restricted design space allowed by standard parametrizable geometry and manufacturing, while advanced methods like cell-based density approaches suffer from a lack of robust manufacturability constraints during the optimization process. To overcome these drawbacks, we explore a grid-independent, boundary TO where the outer shape of the magnet is parameterized using Bezier curves. We conduct a design of experiments (DOE) to study the effect of different magnet shapes on machine performance by varying the control points on the Bezier curves. A machine-learning based surrogate model is constructed using the data from the DOE to quantify the relationship between the control points, air-gap torque and mass. The control points are then optimized to maximize the torque density. The approach is used for minimizing electrical steel mass in the IEA-15MW radial flux direct-drive wind turbine generator. The free-from boundary TO resulted in smooth and concise shapes that can be easily additively manufactured with upto 20-ton reduction in electrical steel mass.

additive manufacturing↗

NASA NTRS1994

Computerized Design and Generation of Low-noise Helical Gears with Modified Surface Topology

An approach for design and generation of low-noise helical gears with localized bearing contact is proposed. The approach is applied to double circular arc helical gears and modified involute helical gears. The reduction of noise and vibration is achieved by application of a predesigned parabolic function of transmission errors that is able to absorb a discontinuous linear function of transmission errors caused by misalignment. The localization of the bearing contact is achieved by the mismatch of pinion-gear tooth surfaces. Computerized simulation of meshing and contact of the designed gears demonstrated that the proposed approach will produce a pair of gears that has a parabolic transmission error function even when misalignment is present. Numerical examples for illustration of the developed approach are given.

Litvin, F. L.↗

DOE OSTI2022

An operator-based approach to topological photonics

Abstract Recently, the study of topological structures in photonics has garnered significant interest, as these systems can realize robust, nonreciprocal chiral edge states and cavity-like confined states that have applications in both linear and nonlinear devices. However, current band theoretic approaches to understanding topology in photonic systems yield fundamental limitations on the classes of structures that can be studied. Here, we develop a theoretical framework for assessing a photonic structure’s topology directly from its effective Hamiltonian and position operators, as expressed in real space, and without the need to calculate the system’s Bloch eigenstates or band structure. Using this framework, we show that nontrivial topology, and associated boundary-localized chiral resonances, can manifest in photonic crystals with broken time-reversal symmetry that lack a complete band gap, a result that may have implications for new topological laser designs. Finally, we use our operator-based framework to develop a novel class of invariants for topology stemming from a system’s crystalline symmetries, which allows for the prediction of robust localized states for creating waveguides and cavities.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2024

A novel design optimization framework to sustain remanufacturability

The ever-increasing global carbon emissions have urged the need for environmentally conscious/sustainable product design, for which the design for remanufacturing (DfRem) is one potential approach. DfRem targets at designing products that have multiple life cycles, thus significantly reducing raw material usage, energy consumption, and carbon emissions. In this paper, we develop a three-stage framework that consists of (1) systematic design space exploration and a multi-objective optimization formulation to minimize the likelihood of failure causes (such as fatigue and wear) and environmental footprint, (2) topology optimization to further reduce material usage without significantly affecting the load-carrying capability of the product, and (3) post-topology optimization design verification to ensure the proposed design satisfies all design constraints. The environmental impact can be assessed at varying comprehensiveness levels (e.g., design and manufacturing phase, use phase) and in terms of carbon or GHG emission, energy use, and waste generation. Because the novel design framework predominantly adjusted the geometry, we focused on mass-based change and energy savings due to sustained remanufacturability. The multi-objective optimization formulation in the first step results in a Pareto optimal set of possible design solutions that the designer can use for the second step. Finally, we demonstrate the utility of this framework through a case study of an engine cylinder head subjected to thermo-mechanical loads, where we find that about 5% of the product mass can be conserved with only about a 3% increase in surface area that has a fatigue life less than 10,000 cycles.

42 ENGINEERING↗

DOE OSTI2024

Design and Manufacturing of High Performance, Reduced Charge Heat Exchangers

Air-to-fluid heat exchangers (HXs) play a critical role as the main heat transfer component in Heating, Ventilation, Air-Conditioning, and Refrigeration (HVAC&R) systems. However, their airside thermal resistance significantly inhibits their overall performance. Furthermore, these HXs must be continually more compact to meet the latest refrigerant charge limits to reduce emissions. Recent literature suggests that traditional HX geometries (e.g., round or flat tubes with fins), have reached their limits, and more sophisticated shape- and topology-optimized designs are required to achieve the next jump in performance. This research sheds light on the next generation of air-to-refrigerant HXs and aims to address several practical issues to commercialization such as novelty challenges (improved performance for significant charge reduction; modeling expertise & time investment), manufacturing challenges (non-round tube manufacturing; tube-header integration; product qualification, e.g., burst pressure testing, extreme operational environment, etc.), and operational challenges (flow maldistribution, fouling & wetting, noise & vibration). For example, a >20% improvement on one (or more) HX-level performance metrics (e.g., envelope volume, airside pressure drop, face area, capacity, refrigerant charge, weight, cost, etc.) must be achieved before a HX design is considered for commercialization. We present a new, comprehensive and experimentally validated air-to-refrigerant HX optimization framework with simultaneous thermal-hydraulic performance and mechanical strength considerations for novel, non-round, shape- and topology-optimized tubes capable of optimizing single and two-phase HX designs for any refrigerant choice and performance requirement with significant engineering time savings compared to conventional design practices. The framework was exercised for a wide range of applications and refrigerants, resulting in HXs which achieved greater than 20% improved performance, 20% reductions in size, and 25% reductions in refrigerant charge. To enable non-round tube bundle use in next generation HVAC&R equipment, novel manufacturing techniques were investigated, including the development of conventional manufacturing methods for small diameter, non-round tubes and novel tube-header integration strategies. In total, ten HX prototypes were manufactured, nine using conventional methods directly attributed to this project and one using advanced additive manufacturing methods. The five-year manufacturing feasibility of the proposed HXs was found to have a good outlook. The non-round tube HX simulated performance was validated through comprehensive experimental testing, including nine in-house component-level tests, one independent component-level test at an industry partner laboratory, and in-house system-level tests of using a commercially-available, residential packaged A/C unit which was retrofitted with a non-round tube prototype HX. It was found that HX designs proposed by the new framework can successfully predict experimental thermal-hydraulic performance within ±10-20% the first time with no manual design changes, eliminating the need for time-consuming and expensive prototyping efforts. This work will accelerate design and time to market for next generation HXs while simultaneously facilitating industry transition to new refrigerants at lower charge.

42 ENGINEERING↗

DOE OSTI2020

Multi-Level Optimal Power Flow Solver in Large Distribution Networks

Solving optimal power flow (OPF) problems for large distribution networks incurs high computational complexity. We consider a large multi-phase distribution network of tree topology with a deep penetration of active devices. We divide the network into collaborating areas featuring subtree topology and subareas featuring subsubtree topology. We design a multilevel implementation of the primal-dual gradient algorithm to solve the voltage regulation OPF problems while preserving nodal voltage information and topological information within areas and subareas. Numerical results on a 4,521-node system verify that the proposed algorithm can significantly improve the computational speed without compromising any optimality.

41 EE - Solar Energy Technologies Office (EE-4S)↗

DOE OSTI2021

Band Engineering of Dirac Semimetals Using Charge Density Waves

New developments in the field of topological matter are often driven by materials discovery, including novel topological insulators, Dirac semimetals and Weyl semimetals. In the last few years, large efforts have been performed to classify all known inorganic materials with respect to their topology. Unfortunately, a large number of topological materials suffer from non-ideal band structures. For example, topological bands are frequently convoluted with trivial ones, and band structure features of interest can appear far below the Fermi level. This leaves just a handful of materials that are intensively studied. Finding strategies to design new topological materials is a solution. Here we introduce a new mechanism that is based on charge density waves and non-symmorphic symmetry to design an idealized Dirac semimetal. We then show experimentally that the antiferromagnetic compound GdSb 0.46 Te 1.48 is a nearly ideal Dirac semimetal based on the proposed mechanism, meaning that most interfering bands at the Fermi level are suppressed. Finally, its highly unusual transport behavior points to a thus far unknown regime, in which Dirac carriers with Fermi energy very close to the node seem to gradually localize in the presence of lattice and magnetic disorder.

36 MATERIALS SCIENCE↗

DOE OSTI2020

Multi-Level Optimal Power Flow Solver in Large Distribution Networks: Preprint

Solving optimal power flow (OPF) problem for large distribution networks incurs high computational complexity. We consider a large multi-phase distribution networks of tree topology with deep penetration of active devices. We divide the network into collaborating areas featuring subtree topology and subareas featuring subsubtree topology. We design a multi-level implementation of the primal-dual gradient algorithm for solving the voltage regulation OPF problems while preserving nodal voltage information and topological information within areas and subareas. Numerical results on a 4,521-node system verifies that the proposed algorithm can significantly improve computational speed without compromising any optimality.

41 EE - Solar Energy Technologies Office (EE-4S)↗

NASA NTRS1992

Supercomputer networking for space science applications

The initial design of a supercomputer network topology including the design of the communications nodes along with the communications interface hardware and software is covered. Several space science applications that are proposed experiments by GSFC and JPL for a supercomputer network using the NASA ACTS satellite are also reported.

Edelson, B. I.↗

DOE OSTI2023

Spectral localizer for line-gapped non-Hermitian systems

Short-ranged and line-gapped non-Hermitian Hamiltonians have strong topological invariants given by an index of an associated Fredholm operator. It is shown how these invariants can be accessed via the signature of a suitable spectral localizer. Here, this numerical technique is implemented in an example with relevance to the design of topological photonic systems, such as topological lasers.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2024

Roadmap for Optical Metasurfaces

Metasurfaces have recently risen to prominence in optical research, providing unique functionalities that can be used for imaging, beam forming, holography, polarimetry, and many more, while keeping device dimensions small. Despite the fact that a vast range of basic metasurface designs has already been thoroughly studied in the literature, the number of metasurface-related papers is still growing at a rapid pace, as metasurface research is now spreading to adjacent fields, including computational imaging, augmented and virtual reality, automotive, display, biosensing, nonlinear, quantum and topological optics, optical computing, and more. At the same time, the ability of metasurfaces to perform optical functions in much more compact optical systems has triggered strong and constantly growing interest from various industries that greatly benefit from the availability of miniaturized, highly functional, and efficient optical components that can be integrated in optoelectronic systems at low cost. This creates a truly unique opportunity for the field of metasurfaces to make both a scientific and an industrial impact. Furthermore, the goal of this Roadmap is to mark this “golden age” of metasurface research and define future directions to encourage scientists and engineers to drive research and development in the field of metasurfaces toward both scientific excellence and broad industrial adoption.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2022

Cyber Resilient Design and Controls for Energy Systems

As the grid of today is evolving into a highly distributed and autonomous cyber-physical system with higher penetration of Distributed Energy Resources (DERs) and autonomous controls that are dependent on the cyber infrastructure, there are novel and increasing challenges to cyber-resilient operation of the grid. While the traditional mechanisms take a "bolt on" approach to cybersecurity and resiliency, this talk presents two novel technologies developed at NREL that "bake in" security and resilience into the design and control of the grid. An Adaptive Resilience Metrics framework is a novel mechanism for system owners and operators to understand the impact of cyber and physical system design and topology on the resilient operation, while also helping determine optimal policies in response to adverse cyber events. Along with that a zero-knowledge proof-based technique helps incorporate security into the controls layer by focusing on computational integrity rather than data integrity. By leveraging design and control properties unique to Operational Technology systems these technologies will not only help enhance cyber-resilience for the grid of today, but a highly distributed and autonomous grid of tomorrow.

cyber resilience↗

DOE OSTI2023

Antiferromagnetism-driven two-dimensional topological nodal-point superconductivity

Magnet/superconductor hybrids (MSHs) hold the promise to host emergent topological superconducting phases. Both one-dimensional (1D) and two-dimensional (2D) magnetic systems in proximity to -wave superconductors have shown evidence of gapped topological superconductivity with zero-energy end states and chiral edge modes. Recently, it was proposed that the bulk transition-metal dichalcogenide 4Hb-TaS 2 is a gapless topological nodal-point superconductor (TNPSC). However, there has been no experimental realization of a TNPSC in a MSH system yet. Here we present the discovery of TNPSC in antiferromagnetic (AFM) monolayers on top of an s-wave superconductor. Our calculations show that the topological phase is driven by the AFM order, resulting in the emergence of a gapless time-reversal invariant topological superconducting state. Using low-temperature scanning tunneling microscopy we observe a low-energy edge mode, which separates the topological phase from the trivial one, at the boundaries of antiferromagnetic islands. As predicted by the calculations, we find that the relative spectral weight of the edge mode depends on the edge’s atomic configuration. Our results establish the combination of antiferromagnetism and superconductivity as a novel route to design 2D topological quantum phases.

30 DIRECT ENERGY CONVERSION↗

DOE OSTI2020

The reservoir network: A new network topology for district heating and cooling

Thermal district networks are effective solutions to substitute fossil fuels with renewable energy sources for heating and cooling. Moreover, thermal networking of buildings allows energy efficiency to be further increased. The waste heat from cooling can be reused for heating in thermal district systems. Because of bidirectional energy flows between prosumers, thermal networks require new hydraulic concepts. In this work, we present a novel network topology for simultaneous heating and cooling: the reservoir network. The reservoir network is robust in operation due to hydraulic decoupling of transfer stations, integrates heat sources and heat sinks at various temperature levels and is flexible in terms of network expansion. Furthermore, we used Modelica simulations to compare the new single-pipe reservoir network to a basecase double-pipe network, taking yearly demand profiles of different building types for heating and cooling. The electric energy consumed by the heat pumps and circulations pumps differs between the reservoir and base case networks by less than 1%. However, if the reservoir network is operated with constant instead of variable mass flow rate, the total electrical consumption can increase by 48% compared to the base case. As with any other network topology, the design and control of such networks is crucial to achieving energy efficient operation. Investment costs for piping and trenching depend on the district layout and dimensioning of the network. If a ring layout is applied in a district, the reservoir network with its single-pipe configuration is more economical than other topologies. For a linear layout, the piping costs are slightly higher for the reservoir network than for the base case because of larger pipe diameters.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

NASA NTRSDate not supplied

A Wall-Modeled LES Perspective for the High Lift Common Research Model Using LAVA

A new immersed boundary Wall-Modelled Large Eddy Simulation (WMLES) formulation is developed to study high-lift aerodynamics on the NASA High-Lift Common Research Model (HL-CRM). A sequence of Cartesian Octree grids with sizes ranging from 100 Million through 2.02 Billion grid points is utilized to systematically assess grid-sensitivity and convergence for the in-tunnel (QinetiQ) configuration of the model, and remarkable agreement between the immersed boundary and the curvilinear body-aligned WMLES formulations is reported on grids with comparable resolutions. In the free-air configuration of the model, consistent predictions between the Curvilinear Overset and the Cartesian Octree formulations are reported for angles of attack up to C(L,max) at a=19.57. However, some differences in the onset of stall are seen between the two methods for a>20°: while the curvilinear WMLES experiences wing-root separation with increasing angle of attack (Topology A), the Cartesian Octree formulation shows a different flow topology characterized by boundary layer weakness on the main element, emanating from the pylon-wing attachment (Topology B). In order to obtain further insight into the two-distinct topologies, carefully designed numerical experiments to isolate effects of the model standoff and the tunnel wall-boundary layers are conducted using the immersed boundary WMLES formulation. The increased incidence angle-of-attack on the inboard portion of the wing due to the standoff is shown to be sufficient for triggering a switch from Topology B to Topology A in Cartesian WMLES. The role of the floor boundary layer is further examined in detail by identification of additional corner-flow vorticity generated by the viscous juncture flow interactions between the floor boundary layer and the standoff leading to formation of a strong coherent and persistent vortex on the belly-side of the fuselage. The intensity of this vortex is shown to increase with the thickness of the floor boundary layer. A further increase in the incidence angle of attack near the leading-edge strake caused by the presence of this belly-side vortex is quantified for two-distinct floor boundary layers. Both of the floor boundary layers considered result in the onset of large scale wing-root separation at a=21.47in non-confined (free-air) configurations.

TTT↗

DOE OSTI2025

De Novo Design of High‐Affinity Miniprotein Binders Targeting Francisella Tularensis Virulence Factor

Abstract Francisella tularensis poses considerable public health risk due to its high infectivity and potential for bioterrorism. Francisella‐like lipoprotein (Flpp3), a key virulence factor unique to Francisella, plays critical roles in infection and immune evasion, making it a promising target for therapeutic development. However, the lack of well‐defined binding pockets and structural information on native interactions has hindered structure‐guided ligand discovery against Flpp3. Here, we used a combination of physics‐based and deep‐learning methods to design high‐affinity miniprotein binders targeting two distinct sites on Flpp3. We identified four binders for site I with binding affinities ranging between 24–110 nM. For the second site, an initial binder showed a dissociation constant ( K D ) of 81 nM, and subsequent site saturation mutagenesis yielded variants with sub‐nanomolar affinities. Circular dichroism confirmed the topology of designed miniproteins. The X‐ray crystal structure of Flpp3 in complex with a site I binder is nearly identical to the design model (Cα root‐mean‐square deviation (RMSD): 0.9 Å). These designed miniproteins provide research tools to explore the roles of Flpp3 in tularemia and should enable the development of new therapeutic candidates.

Gokce‐Alpkilic, Gizem [Molecular Engineering and S↗