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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 1,243 records · Page 69

Supervisory control and health monitoring framework for large-scale additive manufacturing systems. Final CRADA report

ORNL worked with National Instruments (NI) to develop a large-scale, complex additive manufacturing (AM) systems framework for remote health monitoring and supervisory control. We found the framework, based on the Lincoln Electric Metal AM system located at ORNL’s MDF, capable of controlling the process, leading to improved part quality and digital twin creation.

42 ENGINEERING↗

Thermal Management System of an Outer-Rotor-Motor-Based Traction Drive With Integrated Power Electronics in its Central Cavity

Increasing power densities of electric vehicle traction drive systems necessitates combining the electric motor and the power electronics into one unit. A compact, integrated traction drive unit with fewer components also drives production costs down, enabling wider adoption of electric vehicles. However, the integration of power electronics in the electric machine is associated with challenges of designing an effective thermal management solution for the combined traction drive system. This paper focuses on the thermal management approach selected for Oak Ridge National Laboratory’s outer-rotor-motor-based integrated traction drive and evaluates its potential performance. The outer-rotor-motor configuration provided an opportunity for integration of the six-phase inverter in the available space in the central cavity of the internal stator. A cylindrical inverter enclosure with integrated coolant (water-ethylene glycol) channels in its walls was designed to enable heat removal from the power electronics. Numerical thermal-fluid modeling and initial channel/fin optimization results for the cylindrical heat sink are presented here. As permanent magnets are integrated in a high-speed (20 000 RPM) outer rotor, forced air convection provides cooling for the magnets. The magnets were segmented axially to mitigate the eddy current losses. Heat generated in the stator windings and laminations is removed by water-ethylene glycol coolant circulating in interpolar T-shape ceramic heat exchangers inserted between windings. General design concepts and numerical thermal-fluid simulations illustrating the electric motor thermal management solution are also presented.

Kekelia, Bidzina↗

Studies on the compositional dependent structural and electrical properties of CaTiO3-modified K0.5Na0.5NbO3 piezoelectric system

Lead-free piezoelectric ceramics of (1 − x)K0.5Na0.5NbO3-xCaTiO3 were fabricated, and their crystal structure, microstructure, and electrical properties were systematically studied. Rietveld refinement of the x-ray diffraction data and Raman spectroscopic analyses revealed a composition-dependent structural phase transition: three phase transitions, namely, from a pure orthorhombic phase for x ≤ 0.02 to a mixed phase of orthorhombic and tetragonal phases (0.03 ≤ x ≤ 0.08) and finally another mixed phase of tetragonal + cubic for x = 0.10 and 0.15 at room temperature (RT). The morphological study reveals a decrease in grain size along with a more uniform distribution of grains as the concentration of CaTiO3 (CT) increases; notably, a homogeneous distribution of grains is observed for x = 0.05. The temperature-dependent dielectric properties show two phase transitions, from orthorhombic to tetragonal (TO-T) and tetragonal to cubic (TC), for unmodified K0.5Na0.5NbO3 (KNN). However, both the phase transition temperatures (TO-T and TC) decrease, and the transition peaks broaden with an increase in CT substitution, and for x > 0.06, the TO-T shifted below RT. The broadening of the transition peak at TO-T may be due to the relaxation behavior. Among the prepared samples, the 5 mol. % CT-modified KNN shows the optimum electrical properties (d33 = 114 pC/N, ɛr = 412, and 2Pr = 15.25 μC/cm2) at RT. The enhanced electrical properties for x = 0.05 are due to the coexistence of orthorhombic and tetragonal phases, facilitating easy polarization rotation and flattening of the free energy profile. A phase diagram has been constructed based on the information gathered from the temperature-dependent dielectric measurements, RT x-ray diffraction, and Raman spectroscopy data and is discussed in detail.

Physics↗

Consumer Guide to Small Wind Energy Systems

Learn how to use a small wind energy system to produce electricity to power your home. This fact sheet from Energy Saver includes information on how small wind energy systems can work for homes and how to determine whether your site is a good candidate for a small wind turbine.

small wind energy system, wind turbine, Energy Sav↗

The Value of Sharing and Consolidating Critical Community, Electricity, and Natural Hazard Information

The California Public Utilities Commission (CPUC) sought support for the development of database schema specifications for a bi-directional data portal that would foster cross-jurisdictional collaboration necessary to improve resilient energy infrastructure planning processes. This technical assistance activity involved Berkeley Lab researchers reviewing 34 local/tribal government hazard mitigation plans to assess (1) the natural hazards that communities are most concerned about; (2) the variety of–and terminology used to describe–critical community infrastructure; and (3) the availability of GIS information that could be incorporated into CPUC-mandated "Microgrid Planning Portals". In addition, we develop a common, but generic data taxonomy showing what fields to collect to encourage consolidating and sharing of this information in the future. Finally, we partnered with the Bishop Paiute tribal government to demonstrate the value of combining electricity infrastructure, natural hazard layers, and critical community infrastructure into a series of maps. The project demonstrated that a single system containing both electric utility and community infrastructure data—as well as information about natural hazards—will help the state of California, the IOUs, first responders, and long-term planners better prepare for—and thus lower their exposure to these ongoing and emerging hazards. The project also identified a number of challenges that will need to be overcome before it is possible to stand up a single system to display this information.

24 POWER TRANSMISSION AND DISTRIBUTION↗

Complex Electrical Conductivity of a Single‐Fractured Rock: Fracture‐and‐Matrix Coupling Mechanism and Aperture Size Predictions

Fractured rocks play a crucial role in myriad natural and engineered systems, including Earth's critical zone, oil/gas/geothermal reservoirs, and geological CO 2 /H 2 /waste storage systems. While complex electrical conductivity is extensively used to estimate the pore and grain sizes of conventional porous rocks and soils, it is rarely used to predict the aperture size of fractured rocks and this remains poorly understood. Here, integrating theory, simulations, and experiments, we show that under external fields, fractured rocks follow the fracture-and-matrix coupling to make the bulk complex conductivity non-linear with respect to water conductivity. We find that the relaxation time and quadrature conductivity for porous media do not apply to fractured rocks, but, instead, reasonably accurate predictions of aperture size can be made based on the true formation factor. This study unravels the fundamental mechanism governing conduction and polarization of fractured rocks and paves the way for the non-invasive investigation of global fractured rocks.

58 GEOSCIENCES↗

Opportunities for Integrating Electric and Gas Planning

Growing demand for electricity in buildings is creating new opportunities and challenges for electric and natural gas planning. To date, electric and gas planning processes have largely been siloed, and only a few jurisdictions have started to examine how these two processes could be linked together. The report explores the current state of electric and gas system planning, and the benefits and challenges of integrating these planning processes. We frame the characteristics of an integrated electric and gas distribution planning process and identify indicators of progress toward the characteristics.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

Opportunities and Challenges for Nuclear-Renewable Hybrid Energy Systems

Nuclear-renewable hybrid energy systems (also known as integrated nuclear-renewable systems) are conceptual systems that have two or more energy inputs and produce two or more products. They maximize profitability, and usually equipment utilization, by adjusting between the products depending upon the availability of resources and market value. For example a nuclear-renewable hybrid energy system that produces electricity and hydrogen would maximize sales of electricity when its price is high and shift to hydrogen production when the electricity price is low. This presentation summarizes the results of several economic analyses of nuclear-renewable hybrid energy systems and they key overall conclusions from those analyses.

ENERGY PLANNING, POLICY, AND ECONOMY,ENVIRONMENTAL↗

Opportunities and Challenges for Nuclear-Renewable Hybrid Energy Systems

Nuclear-renewable hybrid energy systems (also known as integrated nuclear-renewable systems) are conceptual systems that have two or more energy inputs and produce two or more products. They maximize profitability, and usually equipment utilization, by adjusting between the products depending upon the availability of resources and market value. For example a nuclear-renewable hybrid energy system that produces electricity and hydrogen would maximize sales of electricity when its price is high and shift to hydrogen production when the electricity price is low. This presentation summarizes the results of several economic analyses of nuclear-renewable hybrid energy systems and they key overall conclusions from those analyses.

economic analysis↗

Autonomous Fueling System for Heavy-Duty Fuel Cell Electric Trucks

The motivation for this project stemmed from the challenges associated with rapidly refueling heavy-duty hydrogen fuel cell electric trucks (FCETs). Current manual refueling processes for fast refueling involve large, heavy equipment (e.g., hoses three times heavier than standard) and pose ergonomic risks and potential for equipment damage. The goal was to develop and test an autonomous fueling system to improve ergonomics, enhance safety, increase equipment durability through design improvements, and potentially speed up the fueling process. This project aimed to add to the understanding of autonomous systems in the context of heavy-duty hydrogen refueling, evaluating the technical effectiveness of potential concepts. A successfully developed system would benefit the public by facilitating the adoption of zero-emission heavy-duty transport, reducing reliance on manual labor for a physically demanding task, and potentially improving the safety and efficiency of hydrogen refueling infrastructure. The major accomplishment during the project's active period was the completion of the system-level architecture task. This involved establishing a detailed list of system requirements covering interfaces, environmental conditions, regulatory compliance, industry standards, safety, security, performance capabilities, and optional features. Five key use cases for the autonomous system were also identified. However, due to internal restructuring at Nikola, the necessary resources could not be allocated to continue the project. Consequently, Nikola opted to discontinue the project. The award was mutually terminated by Nikola and the DOE.

08 HYDROGEN↗

Organic Rankine Cycle Integration and Optimization for High Efficiency CHP Genset Systems (Final Technical Report)

This project successfully advanced the integration of Organic Rankine Cycle (ORC) technology with reciprocating engine–based combined heat and power (CHP) systems to improve electrical efficiency, total CHP efficiency, and grid-responsive operation. Over three budget periods, the work progressed from high-temperature ORC component development and thermodynamic model validation to next-generation system design, working fluid transition, and techno-economic analysis. Key technical accomplishments include development and validation of a thermodynamic model capable of accurately predicting ORC performance across an expanded temperature and pressure envelope; successful identification and validation of low-global-warming-potential (GWP) working fluids—most notably R1233zd(E)—as viable replacements for R245fa; and demonstration of scalable ORC architectures suitable for integration with 1–20 MW class reciprocating engines. These advances enable flexible CHP configurations that can increase electrical output while maintaining high overall utilization of available thermal energy. The project also produced a clean-sheet design for a next-generation ORC system targeting substantially higher power output per unit, supported by detailed component selection, heat exchanger evaluation, and system-level modeling. Techno-economic analyses indicate that ORC-enabled flexible CHP systems can meet or exceed Department of Energy (DOE) efficiency targets while providing value to both facility operators and the electric grid.. Late-stage testing of the largest next-generation ORC prototype identified limitations related to pump net positive suction head (NPSH) requirements and condenser flooding under certain operating conditions. Although these issues constrained full validation of that configuration within the project timeframe, they provided clear and actionable design guidance for future system refinements. Importantly, validated modeling, smaller-scale testing, and working fluid evaluations confirmed the technical viability of the overall approach. In aggregate, this project met its core objectives by establishing validated design tools, de-risking key ORC technologies for CHP applications, and defining a credible pathway toward commercialization of flexible, high-efficiency CHP systems. The results form a strong foundation for continued development and deployment beyond the conclusion of the DOE-funded effort.

20 FOSSIL-FUELED POWER PLANTS↗

Oak Ridge National Laboratory Pilot Demonstration of an Attestation and Anomaly Detection Framework using Distributed Ledger Technology for Power Grid Infrastructure

This report summarizes the design and pilot demonstration of a framework called Grid Guard that was created to provide increased data and device trustworthiness to electric grid devices by leveraging distributed ledger technology (DLT), specifically blockchain. Grid Guard contains a combination of core cryptographic methods such as the secure hash algorithm (SHA), and asymmetric cryptography, private permissioned blockchain, baselining configuration data, consensus algorithm (Raft) and the Hyperledger Fabric (HLF) framework. The system implements a low energy, fast, and robust enhancement to system trustworthiness within and across electric grid systems such as substations, control centers and metering infrastructures. Blockchain is a distributed database structured that provides a practically unalterable (immutable) timeline of stored transactions. By relying on hashing and the Raft consensus algorithm, if an entity tries to illegitimately alter a record at one instance of the database the other ledger nodes are not altered. They work to cross-reference each other and easily locate any incorrectly added data and remove it. The bulk raw data is stored in an off-chain storage (outside of the blockchain ledger) and a hash of this baseline data is stored in the Blockchain ledger via hashing windows of time-series and configuration data, after aggregation and filtering. The bulk off-chain data repository is then considered to be trust-anchored using the hashes stored in the blockchain. To secure the electric grid testbed devices and data, device configuration baselines were compared to those baselines that had been previously stored in the ledger. Statistical baselines for device configurations, network communication patterns, and high-speed sensor data are calculated and then stored off-chain and hashes stored in the ledger. Measurements such as three-phase voltage and current, frequency, breaker status, protection scheme settings, network configuration settings (and other device configuration artifacts) and network traffic features (packet interarrival times) are compared every minute or other selected time windows. During phase 1 of the Grid Guard DLT project different DLT technologies were studies, and an assessment was performed on DLT technology vulnerabilities, uses, and key characteristics. DLT consensus protocols were studies (e.g., RAFT, named after Reliable, Replicated, Redundant, And Fault-Tolerant). Also, cryptography, public, private and permissioned or permissionless systems were assessed. Grid Guard implements a permissioned private DLT. Consensus algorithm selection and choice of DLT implementation depended heavily on the use-case. For this use-case, parameters were selected to measure performance and existing tools for assessment. Benchmarking was performed theoretically and practically. During phase 2 hashed transactions/blocks were inserted into the ledger every second. During phase 2 of the Grid Guard DLT project, a prototype framework was developed and demonstrated for attestation of critical substation devices and data using precision timing systems that use PTP and IRIG-B protocols) on a testbed of operational devices that emulated a distribution substation, control center, and power metering infrastructure using real Operational Technology (OT). The testbed includes OT devices such as protective relays, human machine interfaces (HMI), and power meters. To determine when to collect and compare system and network baselines, an initial examination of an anomaly detection capability to identify malicious manipulation of data streams was conducted. The resulting anomaly detection was demonstrated in a set of experiments and leveraged to trigger device artifact attestation checks. Attestation checks occur against device configuration baselines when compared with the immutable blockchain-stored baselines, which provided a cryptographically supported means by which to store baselines. The electrical substation-grid testbed was created to test the Grid Guard framework. The testbed emulates the operations of a portion of a power grid and SCADA systems as closely as possible. The testbed integrates real protocols, mainly IEC 61850 standard protocols, such as the Sampled Value (SV) and the GOOSE protocols. The testbed also supports DNP3 and other layer 2 and layer 3 protocols such as Telnet, SSH, SFTP/FTP and other proprietary protocols needed to connect to industrial control system equipment. The testbed emulates real power conditions using the OpalRT hardware-in-the-loop (HIL) device which can create fault situations that cannot be easily tested on real systems. The electrical substation-grid testbed was created using real measurement, communication, and protection devices that electrical utilities commonly use.

24 POWER TRANSMISSION AND DISTRIBUTION↗

A transmissive concentrator photovoltaic module with cells directly cooled by silicone oil for solar cogeneration systems

Hybrid concentrator photovoltaic-thermal systems can cogenerate electricity and heat by beam-splitting incoming concentrated light onto photovoltaic cells and a thermal receiver to increase total conversion efficiency and potentially reduce system cost. To demonstrate this, we have designed and prototyped a transmissive spectrum-splitting concentrator photovoltaic module that maximizes solar energy conversion by utilizing the entire solar spectrum. Visible light is collected using infrared-transmissive triple-junction photovoltaic cells to achieve an in-band module efficiency of 43.3% for light of wavelength λ < 873 nm, while 44.2% of out-of-band light with λ > 873 nm is transmitted through for collection by a thermal receiver. During testing on a dual-axis tracked parabolic concentrator dish at up to 166 suns, cell temperatures were maintained at 119 °C or below via a novel active cooling method. This cooling system strictly flows silicone oil directly across both sides of the cells, without inhibiting optical transmission, as verified through experimentation and simulation. The module was validated outdoors for 572 sun·hrs, and achieved a maximum thermal receiver temperature of 180 °C. 86.1% of incident solar power is collected at 166 suns average concentration collectively among the electrical, cooling, and thermal receiver subsystems. The remaining 13.9% is lost to mirror reflectivity, dish shadowing, receiver reflection, and thermal losses. The ability to directly cool the cells with an inert silicone oil offers the potential for reduced system cost relative to previous transmissive hybrid concentrator photovoltaic-thermal systems, including microfluidic-cooled designs. This solar cogeneration capability is valuable in a wide range of commercial and industrial applications.

14 SOLAR ENERGY↗

Distribution System Dataset Generator for AI Applications [SWR-24-75]

This software is a simple, light-weight python package to generate pytorch compatible machine learning graph dataset representing electric power distribution system. User is able to use these graph datasets to test their graph generation artificial intelligence (AI) models, link prediction AI models, graph classification AI models and so much more. This package uses grid-data-models (https://github.com/NREL-Distribution-Suites/grid-data-models) as input data format for power distribution system. NREL-Ditto (https://github.com/NREL-Distribution-Suites/ditto) tool can be leveraged to transform popular distribution system file formats such as opendss, cyme and synergi to grid-data-models.

Duwadi, Kapil↗

A Cryptographic Method for Defense Against MiTM Cyber Attack in the Electricity Grid Supply Chain

Critical infrastructures such as the electricity grid can be severely impacted by cyber-attacks on its supply chain. Hence, having a robust cybersecurity infrastructure and management system for the electricity grid is a high priority. This paper proposes a cyber-security protocol for defense against man-in-the-middle (MiTM) attacks to the supply chain, which uses encryption and cryptographic multi-party authentication. A cyber-physical simulator is utilized to simulate the power system, control system, and security layers. The correctness of the attack modeling and the cryptographic security protocol against this MiTM attack is demonstrated in four different attack scenarios.

Paul, Shuva↗

Advanced Fenestration Controller (AFC) v1.0

The Advanced Fenestration Controller is the result of 5+ years of R&D to develop an advanced control system for Dynamic Facades (e.g., automated shades, blinds, etc.), electric lighting, and HVAC system in buildings. It can dynamically control those technologies to reduce electricity cost while increasing comfort. The work in FY22 focused on open-sourcing our development, per agreement with DOE.

Gehbauer, Christoph↗

Energy Sector Position, Navigation, and Time Cybersecurity Profile

The Pacific Northwest National Laboratory has developed this positioning, navigation, and timing (PNT) profile for the Energy Sector at the request of the U.S. Department of Energy. The Department of Energy is the sector-specific agency for the Energy Sector and is responsible for providing guidance in the form of this PNT Profile, per Executive Order 13905, Strengthening National Resilience Through Responsible Use of Positioning, Navigation, and Timing Services (Executive Office of the President 2020) issued February 18, 2020. Executive Order 13905 directed the National Institute of Standards & Technology to develop a PNT Profile that is broadly applicable to all sectors and to serve as a foundation for sector-neutral guidance, NISTIR 8323 Foundational PNT Profile: Applying the Cybersecurity Framework for the Responsible Use of Positioning, Navigation, and Timing (PNT) Services. This document builds on NISTIR 8323 to identify and serve as the required Energy Sector specific guidance. For purposes of this PNT Profile, Energy Sector precise time is 0.5 µs (microseconds) to 1 µs accuracy. Currently, the electricity subsector has systems that use this level of precision time, but the oil and natural gas subsector currently does not. While the electricity subsector uses precision timing, it does not use positioning and/or navigation at this level of accuracy. For this reason, this PNT Profile will focus on only precise time for the electricity subsector.

24 POWER TRANSMISSION AND DISTRIBUTION↗