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At least 1,207 records · Page 67

All sources NASA NTRS DOE OSTI

NASA NTRS2015

The Degradational History of Endeavour Crater, Mars

Endeavour crater (2.28 deg S, 354.77 deg E) is a Noachian-aged 22 km-diameter impact structure of complex morphology in Meridiani Planum. The degradation state of the crater has been studied using Mars Reconnaissance Orbiter and Opportunity rover data. Exposed rim segments rise approximately 10 m to approximately 100 m above the level of the embaying Burns Formation and the crater is 200-500 m deep with the southern interior wall exposing over approximately 300 m relief. Both pre-impact rocks (Matijevic Formation) and Endeavour impact ejecta (Shoemaker Formation) are present at Cape York, but only the Shoemaker crops out (up to approximately 140 m) along the rim segment from Murray Ridge to Cape Tribulation. Study of pristine complex craters Bopolu and Tooting, and morphometry of other martian complex craters, enables us to approximate Endeavour's pristine form. The original rim likely averaged 410 m (+/-)200 m in elevation and a 250-275 m section of ejecta ((+/-)50-60 m) would have composed a significant fraction of the rim height. The original crater depth was likely between 1.5 km and 2.2 km. Comparison between the predicted original and current form of Endeavour suggests approximately 100-200 m rim lowering that removed most ejecta in some locales (e.g., Cape York) while thick sections remain elsewhere (e.g., Cape Tribulation). Almost complete removal of ejecta at Cape York and minimal observable offset across fractures indicates current differences in rim relief are not solely due to original rim relief. Rim segments are embayed by approximately 100-200 m thickness of plains rocks outside the crater, but thicker deposits lie inside the crater. Ventifact textures confirm ongoing eolian erosion with the overall extent difficult to estimate. Analogy with degraded Noachian-aged craters south of Endeavour, however, suggests fluvial erosion dominated rim degradation in the Noachian and was likely followed by approximately 10s of meters modification by alternate processes. Such degradation is consistent with 1) the interpretation of a pediment on the rim flanks of Endeavour, 2) the formation of features such as Marathon Valley, 3) the nearly complete removal of ejecta at Cape York, 4) preservation of a thicker section of ejecta at Cape Tribulation and perhaps, 5) the origin of some gaps in the rim around the crater. A paucity of debris shed from the rim indicates most degradation occurred prior to embayment by the plains rocks.

Grant, J. A.↗

NASA NTRS1993

Mirror fusion propulsion system - A performance comparison with alternate propulsion systems for the manned Mars mission

The performance characteristics of several propulsion technologies applied to piloted Mars missions are compared. The characteristics that are compared are Initial Mass in Low Earth Orbit (IMLEO), mission flexibility, and flight times. The propulsion systems being compared are both demonstrated and envisioned: Chemical (or Cryogenic), Nuclear Thermal Rocket (NTR) solid core, NTR gas core, Nuclear Electric Propulsion (NEP), and a mirror fusion space propulsion system. The proposed magnetic mirror fusion reactor, known as the Mirror Fusion Propulsion System (MFPS), is described. The description is an overview of a design study that was conducted to convert a mirror reactor experiment at Lawrence Livermore National Lab (LLNL) into a viable space propulsion system. Design principles geared towards minimizing mass and maximizing power available for thrust are identified and applied to the LLNL reactor design, resulting in the MFPS. The MFPS' design evolution, reactor and fuel choices, and system configuration are described. Results of the performance comparison shows that the MFPS minimizes flight time to 60 to 90 days for flights to Mars while allowing continuous return-home capability while at Mars. Total MFPS IMLEO including propellant and payloads is kept to about 1,000 metric tons.

Deveny, M.↗

NASA NTRS1993

Mirror fusion propulsion system: A performance comparison with alternate propulsion systems for the manned Mars Mission

Schulze, Norman R.↗

DOE OSTI2022

Design optimization of an additively manufactured prototype recuperator for supercritical CO 2 power cycles

Supercritical CO 2 (sCO 2 ) power cycles are being developed due to their potential for high efficiency and reduced capital cost. It is necessary that these recuperators operate at high pressures and temperatures, up to 30 MPa and 900 K, with effectiveness values > 95% and pressure drops <1% to achieve high cycle efficiencies. Moreover, it is also necessary to have reasonable cost recuperators to control the capital costs of the sCO 2 power cycles. In this study, a Plate Pin-Fin (PPF) heat exchanger has been proposed as an sCO 2 recuperator. This preliminary recuperator design leverages capabilities enabled by additive manufacturing. Although the PPF design has characteristics similar to those of a plate heat exchanger, small diameter and relatively long fins are used to increase surface area, enhance heat transfer, and provide structural support for the partition plates that separate the fluid streams. Existing correlations for heat transfer and pressure drop were adapted for the PPF heat exchanger. These correlations were implemented in a 1D analytical model and used for the optimization of a 5-kW th high temperature recuperator for an indirect sCO 2 cycle by varying the design parameters to minimize the quantity of material required. A 3D conjugate heat transfer numerical simulations were conducted to validate the heat transfer and pressure loss correlations. A steepest descent method was used to minimize heat exchanger mass for a 5-kW prototype recuperator subject to a maximum specified pressure drop. Additionally, the design analysis indicated that an optimum PPF recuperator would be attained for the minimum allowable pin transverse spacing, minimum pin width, minimum pin height and near maximum cell aspect ratio. Moreover, at a low material requirement of 0.216 kg/kW and a pressure drop, which is almost five times lower than the allowable pressure drop design target, the optimized PPF heat exchanger has the high potential to be an alternative to a printed circuit heat exchanger, which is a conservative design basis for the current state-of-the-art sCO 2 recuperators.

42 ENGINEERING↗

DOE OSTI2022

High-performance all-solid-state Li–S batteries enabled by an all-electrochem-active prelithiated Si anode

The development of all-solid-state Li–S batteries has been greatly impeded by dendrite growth and dendrite penetration, which are both related to the Li metal anode. As a compromised alternative, we report lithium silicide (Li x Si) as a dendrite-free and high-capacity anode with Li source. Here, the as-synthesized Li x Si is relatively soft, highly electronically conductive, and with a high Li diffusivity. These distinctive properties make Li x Si anode viable as an “all-electrochem-active” electrode (consisted of 100 wt.% Li x Si). Compared with the typical composite electrode, the all-electrochem-active electrode not merely maximizes the electrode-level energy density but also minimizes the electrolyte-related interfacial degradation. Li x Si symmetric cell demonstrates a reversible cycling at 4 mA cm –2 for over 320 h. Stress change and morphological evolution of the Li x Si electrode are investigated upon dealloying/alloying. When paired with a S cathode (active mass loading of 3 mg cm –2 ), Li x Si–S full cell shows a good cycling behavior over 500 cycles and rate performance (69% capacity retained at 1.2C) even at 25 °C.

25 ENERGY STORAGE↗

DOE OSTI2022

Optimizing conformance control for gas injection EOR in unconventional reservoirs

Field observations have shown that interference between wells caused by connected fractures commonly exists in unconventional reservoirs. The well interference effect and conformance issues could lead to minimal enhanced oil recovery response (EOR) in actual operations if they are not properly controlled. A series of data analysis, modeling, and experimental activities were performed in this study to investigate the gas EOR strategies in the Bakken Formation. Employing the embedded discrete fracture modeling technology, a multiple-well, multiple-fracture model was developed to capture the well interference and conformance issues in the Bakken. The model made it possible to investigate the complex flow behavior between wells in the EOR (huff ‘n’ puff) processes. Alternative EOR and conformance control strategies using water and surfactant injections were studied to improve oil production performance based on experimental observations. Results showed that water injection could be used for conformance control in the Bakken because of its relatively low mobility compared to gas; however, water could also block oil flow around the conformance control wells because of the high interfacial tension between oil and water. Adding surfactant to the injection water is more effective for improving gas EOR performance since surfactant reduces the oil–water interfacial tension and contact angle effectively. Up to 9.4% more oil could be produced from the huff ‘n’ puff wells in 2 years of EOR operations when rich gas was injected at only 3 MMscf/d with 6000 psi of surfactant injection in the offset wells for conformance control.

42 ENGINEERING↗

DOE OSTI2016

An information theoretic approach to use high-fidelity codes to calibrate low-fidelity codes

For many simulation models, it can be prohibitively expensive or physically infeasible to obtain a complete set of experimental data to calibrate model parameters. In such cases, one can alternatively employ validated higher-fidelity codes to generate simulated data, which can be used to calibrate the lower-fidelity code. In this paper, we employ an information-theoretic framework to determine the reduction in parameter uncertainty that is obtained by evaluating the high-fidelity code at a specific set of design conditions. These conditions are chosen sequentially, based on the amount of information that they contribute to the low-fidelity model parameters. The goal is to employ Bayesian experimental design techniques to minimize the number of high-fidelity code evaluations required to accurately calibrate the low-fidelity model. We illustrate the performance of this framework using heat and diffusion examples, a 1-D kinetic neutron diffusion equation, and a particle transport model, and include initial results from the integration of the high-fidelity thermal-hydraulics code Hydra-TH with a low-fidelity exponential model for the friction correlation factor.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

DOE OSTI2021

Role of Inlet Boundary Conditions on Fuel-Air Mixing at Supercritical Conditions

Advanced engine design and alternative fuels present the possibility of fuel injection at purely supercritical conditions in diesel engines and gas turbines. The complex interactions that govern this phenomenon still need significant research, particularly the boundary conditions for fuel injection are critical for accurate simulation. However, the flow inside the injector itself is often omitted to reduce the computational efforts, and thus, velocity, mass flux, or total pressure is specified at the injector exit (or domain inlet), often with simplified velocity profiles and turbulence levels. This simplified inlet boundary treatment has minimal effects on results for conventional fuel injection conditions, however, the validity of this approach at supercritical conditions has not been assessed. Comprehensive real-gas and binary fluid mixing models have been implemented for computational fluid dynamics (CFD) analysis of fuel-air mixing at supercritical conditions. The model is verified using prior CFD results from the literature. The model is used to investigate the effects of the shape of axial velocity and mass fraction profiles at the inlet boundary with the goal to improve the comparison of predictions to experimental data. Results show that the boundary conditions have a significant effect on the predictions, and none of the cases match precisely with experimental data. Furthermore, the study reveals that the physical location of the inlet boundary might be difficult to infer correctly from the experiments and highlights the need for high-quality, repeatable measurements at supercritical conditions to support the development of relevant high-fidelity models for fuel-air mixing.

02 PETROLEUM↗

DOE OSTI2026

Unlocking the Future of Aircraft Manufacturing: The Environmental Benefits of Laser Patterning for Surface Enhancement of Aircraft-Certified Alloys

Surface protection and functional modification of aircraft-certified aluminum alloys are essential for corrosion resistance, durability, and long-term airworthiness. At the same time, increasingly restrictive environmental regulations motivate the development of alternatives to legacy wet-chemical surface treatments. This study presents an integrated assessment of ultrafast femtosecond laser surface texturing as a surface functionalization approach for Aluminum 6061 alloys within an aerospace manufacturing and sustainability context. Ultrashort-pulse laser processing enables controlled micro- and nano-scale surface topographical modification with limited thermal impact, allowing adjustment of wettability and surface functionality while preserving bulk material integrity. As a dry and contactless process, femtosecond laser treatment eliminates the use of hazardous chemicals, reduces consumable inputs, and generates minimal secondary waste. A streamlined cradle-to-gate life cycle assessment conducted in accordance with ISO 14040/14044 indicates a lower global-warming potential per functional unit compared with conventional surface treatments, including anodization, plasma-assisted coatings, and organic coating systems. Complementary qualitative analyses addressing environmental health and safety, supply-chain risk, and ESG alignment indicate potential advantages related to occupational safety, regulatory compliance, waste management, and end-of-life recyclability. The investigation is performed on planar Aluminum 6061 reference surfaces with a treated area of 25 mm 2 , providing a controlled laboratory-scale basis for analyzing process behavior, functional surface modification, and associated environmental metrics. Within this defined scope, the results support further evaluation of femtosecond laser surface texturing as a surface engineering option for future aerospace manufacturing.

corrosion resistance↗

DOE OSTI2023

Impact of Oxygen Storage Components in Prototype Pd-Based Three-Way Catalysts under Exhaust Conditions Relevant to Propane Engines

With increasing concerns about global warming, the push for sustainable and eco-friendly fuels is accelerating. Propane, recognized as liquefied petroleum gas or LPG, has garnered research interest as an alternative fuel due to its notable advantages, including a high-octane rating, reduced greenhouse gas emissions, and potential cost-effectiveness. However, to realize its full potential as an alternative fuel it is essential to develop catalysts that efficiently handle emissions at low temperatures. In our research, we investigated three distinct palladium (Pd)-based three-way catalyst (TWC) formulations (PdRh, Pd-only, and Pd-OSC) to investigate the influence of typical TWC components rhodium (Rh) and oxygen storage components (OSC) in exhaust scenarios relevant to propane-fueled engines. Among these, the formulation containing oxygen storage components (Pd-OSC) showed the highest reactivity for both NO and C 3 H 8 while minimizing performance degradation from hydrothermal aging (HTA). Notably, the temperature of 50% conversion (T50) for propane in the Pd-OSC fresh and HTA sample was lower by 30 °C and 13 °C, respectively, compared to the Pd-only sample, highlighting the role of oxygen storage materials in enhancing catalyst performance, even without dithering. Additionally, N 2 physisorption showed that the PdOSC sample has a higher surface area and increased pore volume. This underscores the idea that OSC materials not only augment the catalyst’s porosity but also optimize reactant accessibility to active sites, thus elevating catalytic efficiency. In addition to evaluating performance, we further explored the performance and characteristics of the catalysts using catalytic probe reactions, such as water–gas shift and steam reforming reactions.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

NASA NTRS1976

Experimental clean combustor program, phase 2

The alternate fuels investigation objective was to experimentally determine the impacts, if any, on exhaust emissions, performance, and durability characteristics of the hybrid and vorbix low pollution combustor concepts when operated on test fuels which simulate composition and property changes which might result from future broadened aviation turbine fuel specifications or use of synthetically derived crude feedstocks. Results of the program indicate a significant increase in CO and small NOX increase in emissions at idle for both combustor concepts, and an increase in THC for the vorbix concept. Minimal impact was observed on gaseous emissions at high power. The vorbix concept exhibited significant increase in exhaust smoke with increasing fuel aromatic content. Altitude stability was not affected for the vorbix combustor, but was substantially reduced for the hybrid concept. Severe carbon deposition was observed in both combustors following limited endurance testing with No. 2 home heat fuel. Liner temperature levels were insensitive to variations in aromatic content over the range of conditions investigated.

Roberts, R.↗

NASA NTRS2009

Space Systems - Safety and Compatibility of Materials - Method to Determine the Flammability Thresholds of Materials

Spacecraft fire safety emphasizes fire prevention, which is achieved primarily through the use of fire-resistant materials. Materials selection for spacecraft is based on conventional flammability acceptance tests, along with prescribed quantity limitations and configuration control for items that are non-pass or questionable. ISO 14624-1 and -2 are the major methods used to evaluate flammability of polymeric materials intended for use in the habitable environments of spacecraft. The methods are upward flame-propagation tests initiated in static environments and using a well-defined igniter flame at the bottom of the sample. The tests are conducted in the most severe flaming combustion environment expected in the spacecraft. The pass/fail test logic of ISO 14624-1 and -2 does not allow a quantitative comparison with reduced gravity or microgravity test results; therefore their use is limited, and possibilities for in-depth theoretical analyses and realistic estimates of spacecraft fire extinguishment requirements are practically eliminated. To better understand the applicability of laboratory test data to actual spacecraft environments, a modified ISO 14624 protocol has been proposed that, as an alternative to qualifying materials as pass/fail in the worst-expected environments, measures the actual upward flammability limit for the material. A working group established by NASA to provide recommendations for exploration spacecraft internal atmospheres realized the importance of correlating laboratory data with real-life environments and recommended NASA to develop a flammability threshold test method. The working group indicated that for the Constellation Program, the flammability threshold information will allow NASA to identify materials with increased flammability risk from oxygen concentration and total pressure changes, minimize potential impacts, and allow for development of sound requirements for new spacecraft and extravehicular landers and habitats. Furthermore, recent research has shown that current normal gravity materials flammability tests do not correlate with flammability in ventilated, micro- or reduced-gravity conditions. Currently, the materials selection for spacecraft is based on the assumption of commonality between ground flammability test results and spacecraft environments, which does not appear to be valid. Materials flammability threshold data acquired in normal gravity can be correlated with data obtained in microgravity or reduced-gravity experiments, and consequently a more accurate assessment of the margin of safety of the material in the real environment can be made. In addition, the method allows the option of selecting better or best space system materials, as opposed to what would be considered just acceptable from a flammability point of view and realistic assessment of spacecraft fire extinguishment needs, which could result in significant weight savings. The knowledge afforded by this technique allows for limited extrapolations of flammability behavior to conditions not specifically tested and that could potentially result in significant cost and time savings. The intent of this Technical Specification is to bring to the attention of International Aerospace Community the importance of correlating laboratory test data with real-life space systems applications. The method presented is just one of the possibilities that are believed will lead to better understanding the applicability of laboratory aerospace materials flammability test data. International feedback on improving the proposed method, as well as suggestions for correlating other laboratory aerospace test data with real-life applications relevant to space systems are being sought.

Hirsch, David↗

DOE OSTI2019

Test and Chemistry Plan for MEDE Treatment of Fermi-1 Blanket Materials

There exists approximately 34 metric tons of Fermi-1 nuclear power reactor blanket assemblies at the Idaho National Laboratory (INL). Contained in this material is about 365 kg of sodium metal. In 2000, the Final Environmental Impact Statement for the Treatment and Management of Sodium-Bonded Spent Nuclear Fuel was issued. In the EIS, the No Action Alternative was preferred for the Fermi-1 blanket material. Under the No Action Alternative, two options were analyzed: • Continued storage until 2035 or until development of a new or currently less mature technology to treat all or part of the sodium-bonded material. • Direct disposal of the sodium-bonded material in high-integrity cans. This report with document how the Melt-Drain-Evaporate (MEDE) process, developed by Argonne National Laboratory (ANL), can be used to treat full-length Fermi-1 blanket material to remove the sodium, eliminate the hazards associated with that metal, all while minimizing the effort needed. Previous work by ANL showed the process worked very well with chopped, shorter segments of this material. If successful, the removal of the sodium from the material may allow the Fermi-1 blanket material to be disposed via existing or future planned disposal pathways for similar materials. This document presents the test plan for the evaluation of sodium removal from intact Fermi-1 reactor blanket materials by the MEDE process. This test plan establishes the objectives for such testing, which includes the anticipated outcomes, a summary of the testing parameters, and an overview of the testing process. This test plan does not provide technical direction or work control guidance; that is the role of a Laboratory Instruction (LI) that will be issued to govern the work.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2024

Improved filters for angular filter refractometry

Angular filter refractometry is an optical diagnostic that measures the absolute contours of a line-integrated density gradient by placing a filter with alternating opaque and transparent zones in the focal plane of a probe beam, which produce corresponding alternating light and dark regions in the image plane. Identifying transitions between these regions with specific zones on the angular filter (AF) allows the line-integrated density to be determined, but the sign of the density gradient at each transition is degenerate and must be broken using other information about the object plasma. Additional features from diffraction in the filter plane often complicate data analysis. Here, in this paper, we present an improved AF design that uses a stochastic pixel pattern with a sinusoidal radial profile to minimize unwanted diffraction effects in the image caused by the sharp edges of the filter bands. We also present a technique in which a pair of AFs with different patterns on two branches of the same probe beam can be used to break the density gradient degeneracy. Both techniques are demonstrated using a synthetic diagnostic and data collected on the OMEGA EP (extended performance) laser.

47 OTHER INSTRUMENTATION↗

DOE OSTI2024

Dynamic embedding of effective harmonic normal mode vibrations in all-atomistic energy gap fluctuations: Case study of light harvesting 2 complex

Environmental effects in excitation energy transfer have mostly been modeled by baths of harmonic oscillators, but to what extent such modeling provides a reliable description of actual interactions between molecular systems and environments remains an open issue. Here, we address this issue by investigating fluctuations in the excitation energies of the light harvesting 2 complex using a realistic all-atomistic simulation of the potential energy surface. Our analyses reveal that molecular motions exhibit significant anharmonic features, even for underdamped intramolecular vibrations. In particular, we find that the anharmonicity contributes to the broadening of spectral densities and substantial overlaps between neighboring peaks, which complicates the meaning of mode frequencies constituting a bath model. Thus, we develop a strategy to construct a minimally underdamped harmonic bath that has a clear connection to all-atomistic dynamics by utilizing actual normal modes of molecules but optimizing their frequencies such that the resulting bath model can best reproduce the all-atomistic simulation results. By subtracting the underdamped contribution from the entire fluctuations, we also show that identifying a residual spectral density representing all other contributions with overdamped behavior is possible. We find that this can be fitted well with a well-established analytic form of a spectral density function or, alternatively, modeled as explicit time dependent fluctuations with muti-exponential or power law type correlation functions. We provide an assessment and the implications of these possibilities. The approach presented here can also serve as a general strategy to construct a simplified bath model that can effectively represent the underlying all-atomistic bath dynamics.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2014

TH-C-BRD-09: Successes and Limitations of Online Range Adaptive Spot Scanning Proton Therapy for NSCLC

Purpose: To determine the ability to adapt discrete spot-scanning proton therapy (SSPT) plans based on geometric changes of anatomy to minimize normal tissue dose and maintain target coverage. Methods: We developed and tested a range-correction algorithm to compensate for anatomy changes in SSPT with correction factors for target lateral size changes and energy scaling. This algorithm adjusts the energy of each spot from the original optimized treatment plan to match the new daily anatomy based on water equivalent path-length. To correct for the lateral target size changes, the peripheral spots were scaled based on phantom studies with variable target size. For energy change corrections, alternative cumulative scaling factor lookup tables were generated based on calculated central-axis and integral depth dose calculations for different energies. These various adaptive algorithms were performed on 7 lung cancer patients that were previously treated with proton therapy and who required at least one adaptive intervention. Single-field optimized SSPT plans were generated for these patients with clinical beam angles. Dose-volume histogram metrics were obtained for these patients for both the non-adaptive and the different adaptive plans applied to the last available weekly CT scan. Results: The doses to normal tissue were largely reduced for the spinal cord (Dmax), total lung (V20Gy), and contralateral lung (V20Gy) for all different methods of adaptive planning. With both corrections applied, the average changes for these metrics were −6.2Gy, −2.7%, and −4.9%, respectively. The same method generated unacceptably high target hot spots with average target V110% increase of 12.3%. Conclusion: Adaptive methods based on direct adjustments to proton range can reduce normal tissue doses under large anatomical changes but are insufficient in achieving clinically acceptable target doses and generate unacceptably sizeable hot spots. Adaptive planning methods for proton therapy will likely necessitate some aspect of reoptimization for acceptable clinical utility.

60 APPLIED LIFE SCIENCES↗

DOE OSTI2022

Cast Components for High Temperature Concentrated Solar Power Thermal Systems

Concentrating Solar-Thermal Power (CSP) components such as piping, valves fittings are required for use at temperatures up to 800°C. These are anticipated to be made using Nickel-based alloys such as Haynes ® 230 ® , Haynes ® 282 ® , or IN ® 740H ® and can contribute significantly to the cost of a CSP Gen 3 plant. Thus, there is a significant motivation to lower the cost of materials and components so that the capital costs can be minimized. In all these cases, the cost of the component has two contributions: 1. Materials cost, and 2. Manufacturing cost. Both materials cost and manufacturing costs must be kept low to attain the lowest possible cost. Materials cost can be lowered by using materials that have the ideal combination of properties at the lowest cost. Another avenue to lower cost is chose a manufacturing process that has the potential to lower the cost. Traditionally tubes are made from billets through a wrought process and can be expensive. An alternative process to consider is the centrifugal casting process where the tube is directly fabricated from molten metal. In this case, the molten metal is poured inside a cylindrical metallic mold with an insulating layer and is spun rapidly. A wide range of sizes (diameter, wall thickness, and length) can be cast using this process. The objective of this project was to develop the process for fabricating pipes and related components using a centrifugal casting process and to measure the properties of alloys fabricated using this process.

14 SOLAR ENERGY↗

DOE OSTI2021

Co-Design of a Fully Electric Hybrid Hydraulic-Electric Architecture (FE-HHEA) for Off-Road Mobile Machines

Off-road mobile machines, such as excavators and wheel-loaders, are typically actuated by hydraulics using internal combustion engines as their power sources. There is a trend towards fully electrifying these machines and improving their efficiencies due to environmental regulations and concerns. In this paper, a control co-design methodology is used to design a Fully Electrified Hybrid Hydraulic-Electric Architecture (FE-HHEA) for an excavator that drastically reduces energy consumption and minimizes the sizes of costly electric components. By optimizing both control operation and the physical design, the co-design methodology takes into account the interaction between these two aspects. The design methodology also illustrates how the system architecture evolves from the previously developed IC engine powered HHEA with the engine replaced by an electric motor to a seemingly very different architecture with fewer components. The optimized system reduces energy consumption by 71% over the baseline system and uses electrical components that are 1/3 the size of an alternate fully electric architecture.

33 ADVANCED PROPULSION SYSTEMS↗