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DOE OSTI2025

Low Cost High-Performance HRE-Free 3-in-1 Electric Drive Unit

The project team completed work to expand upon American Axle & Manufacturing’s (AAM) baseline technology and develop a high-speed, AC induction electric drive unit (EDU) with total direct-oil-cooling and integrated power electronics. The project accelerated advancements in EDU technology by allowing AAM to build upon the progress made in developing the underlying baseline technologies. The following seven improvements to AAM’s baseline technology were implemented in this research and development program: 1) Increased speed (30k RPM) AC induction motor, 2) Silver-sintering of discrete silicon carbide (SiC) metal-oxide-semiconductor field-effect transistors (MOSFET) to heat sinks, 3) Electrically insulated rotor bars, 4) Optimized lamination steel, 5) EDU-integrated 650VDC inverter package, 6) Over-molded stator with molded liners, and 7) 650VDC power-dense stator design. The successful development of the technology resulted in a meaningful cost reduction for EDU systems in the market. Coupled with falling battery system costs, lower EDU costs will likely accelerate the market acceptance and related production scaling of battery electric vehicles. The objective of this project was to research, develop, and test a Heavy Rare Earth (HRE)-free 3-In-1 electric drive unit (EDU) that has class leading power density and cost. The key technologies to be developed were anticipated to meet or exceed the Department of Energy (DOE) targets of a cost ≤ $\$$7/kilowatt (kW), power density ≥ 12 kW/liter, and operating voltage ≥ 600 VDC.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2025

Multi-frequency progressive refinement for learned inverse scattering

Interpreting scattered acoustic and electromagnetic wave patterns is a computational task that enables remote imaging in a number of important applications, including medical imaging, geophysical exploration, sonar and radar detection, and nondestructive testing of materials. However, accurately and stably recovering an inhomogeneous medium from far-field scattered wave measurements is a computationally difficult problem, due to the nonlinear and non-local nature of the forward scattering process. We design a neural network, called Multi-Frequency Inverse Scattering Network (MFISNet), and a training method to approximate the inverse map from far-field scattered wave measurements at multiple frequencies. We consider three variants of MFISNet, with the strongest performing variant inspired by the recursive linearization method — a commonly used technique for stably inverting scattered wavefield data — that progressively refines the estimate with higher frequency content. MFISNet outperforms past methods in regimes with high-contrast, heterogeneous large objects, and inhomogeneous unknown backgrounds.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2016

Automatic outdoor monitoring system for photovoltaic panels

Long-term acquisition of solar panel performance parameters, for panels operated at maximum power point in their real environment, is of critical importance in the photovoltaic research sector. However, few options exist for the characterization of non-standard panels such as concentrated photovoltaic systems, heavily soiled or shaded panels or those operating under non-standard spectral illumination; certainly, it is difficult to find such a measurement system that is flexible and affordable enough to be adopted by the smaller research institutes or universities. We present here an instrument aiming to fill this gap, autonomously tracking and maintaining any solar panel at maximum power point while continuously monitoring its operational parameters and dissipating the produced energy without connection to the power grid. Here, the instrument allows periodic acquisition of current-voltage curves to verify the employed maximum power point tracking approach. At the same time, with hardware schematics and software code being provided, it provides a flexible open development environment for the monitoring of non-standard generators like concentrator photovoltaic systems and to test novel power tracking approaches. The key issues, and the corresponding solutions, encountered in the design are analyzed in detail and the relevant schematics presented.

14 SOLAR ENERGY↗

NASA NTRS1986

Evaluation of a surface/vegetation parameterization using satellite measurements of surface temperature

Ground measurements of surface-sensible heat flux and soil moisture for a wheat-growing area of Beauce in France were compared with the values derived by inverting two boundary layer models with a surface/vegetation formulation using surface temperature measurements made from NOAA-AVHRR. The results indicated that the trends in the surface heat fluxes and soil moisture observed during the 5 days of the field experiment were effectively captured by the inversion method using the remotely measured radiative temperatures and either of the two boundary layer methods, both of which contain nearly identical vegetation parameterizations described by Taconet et al. (1986). The sensitivity of the results to errors in the initial sounding values or measured surface temperature was tested by varying the initial sounding temperature, dewpoint, and wind speed and the measured surface temperature by amounts corresponding to typical measurement error. In general, the vegetation component was more sensitive to error than the bare soil model.

Taconet, O.↗

NASA NTRSDate not supplied

Testing and Application of Commercial Thermodynamics Software for Solid-Gas Equilibria in Planetary Science Applications

The ability to calculate chemical equilibria from thermochemical constants (e.g., H, S, Cp) or other experimental data is a tool widely employed by scientists. However, phase equilibria for planetary science problems is limited by easy access to libraries of thermochemical data, as well as the software to invert that data. Many academic software packages are focused on specific types of problems (e.g., aqueous solutions or melting and crystallization of magmas). This focus makes them excellent tools for specific uses, but poorer tools for other scenarios, especially those involving elements or chemical species that are less well-studied in that specific scientific field (e.g. NaCl vapor). Amongst the more general thermodynamic software tools, there are closed academic software packages, open-source options, as well as commercial software. We have explored the extent to which commercial chemistry/chemical engineering software may be able to satisfy the need for thermochemical modeling packages that can accommodate the diverse species and conditions of planetary science problems. Here we compare the output of software package HSC Chemistry™ (Metso Outotec) to published vapor-solid phase diagrams for a variety of major and minor elements. HSC Chemistry™ has been used in several recent geochemical studies of terrestrial volcanic systems [2- 4]. However, it has not to our knowledge been benchmarked against peer-reviewed model results for the conditions and compositions relevant to planetary science. We present one such comparison here, the low- pressure environment of the solar nebula, using literature data. In short, we find excellent agreement between HSC Chemistry™ and the well-regarded academic software package CONDOR. These preliminary results suggest that at least some commercial software packages are capable of robust thermochemical calculations for planetary science.

planetary science↗

DOE OSTI2022

Development of Fixtures and Methods to Assess the Durability of Balance of Systems Components

The degradation of photovoltaic (PV) balance of systems (BoS) components is not well studied, but the consequences include offline modules, strings, and inverters; system shutdown; arc faults; and fires. A utility provider experienced a ~30% failure rate in their power transfer chain, originally attributed to branch connectors. Field-failed specimen assemblies were, therefore, examined, consisting of cable connector, branch connector, and discrete fuse components. In this study, unused field-vintage specimens are examined using a benchtop prototype fixture to identify the most influential environmental stressors on BoS components as well as the effect of external mechanical perturbation. The prototype fixture was used to develop a perturbation capability for future use in the combined-accelerated stress testing chamber. The benchtop experiments were also used to develop the in-situ data acquisition of specimen current, voltage, and temperature. A significant increase in operating temperature (~100 °C from ~40 °C) and a different failure mode (arcing at the metal pins rather than overheating of the fuse filament) were observed promptly once periodic mechanical perturbation was applied. The current at failure was decreased from 35 A (measured for static specimens, with failure occurring in the fuses) to 15 A (for tests with mechanical perturbation, with failure at the male/female metal pin connection). After initial examination using X-ray computed tomography, the external plastic was machined away from failed specimens to allow for failure analysis, including the extraction of the internal convolute springs for morphological examination (optical and electron microscopy). Chemical composition analysis included energy-dispersive X-ray spectroscopy, differential scanning calorimetry, and Fourier transform infrared spectroscopy.

14 SOLAR ENERGY↗

NASA NTRS1979

A jet exhaust noise prediction procedure for inverted velocity profile coannular nozzles

Acoustic model tests have demonstrated that significant noise suppression can be obtained from inverted velocity profile coannular nozzles. An acoustic prediction procedure was developed for inverted velocity profile coannular nozzles that can be used to predict SPL spectra as a function of nozzle geometry and flow conditions. In the development of this prediction procedure, the noise spectrum at a given angle was decomposed into four noise components: a low frequency mixing noise component, a high frequency mixing noise component, an outer stream shock noise component, and an inner stream shock noise component. The physics of the inverted velocity flow field development was used to formulate noise generation models. Scaling laws for each noise component were defined based on these models. Comparisons of predictions from this procedure with experimental data were conducted to verify the prediction procedure.

Larson, R. S.↗

NASA NTRS1993

Design of power electronics for TVC EMA systems

The Composite Development Division of the Propulsion Laboratory at Marshall Space Flight Center (MSFC) is currently developing a class of electromechanical actuators (EMA's) for use in space transportation applications such as thrust vector control (TVC) and propellant control valves (PCV). These high power servomechanisms will require rugged, reliable, and compact power electronic modules capable of modulating several hundred amperes of current at up to 270 volts. MSFC has selected the brushless dc motor for implementation in EMA's. This report presents the results of an investigation into the applicability of two new technologies, MOS-controlled thyristors (MCT's) and pulse density modulation (PDM), to the control of brushless dc motors in EMA systems. MCT's are new power semiconductor devices, which combine the high voltage and current capabilities of conventional thyristors and the low gate drive requirements of metal oxide semiconductor field effect transistors (MOSFET's). The commanded signals in a PDM system are synthesized using a series of sinusoidal pulses instead of a series of square pulses as in a pulse width modulation (PWM) system. A resonant dc link inverter is employed to generate the sinusoidal pulses in the PDM system. This inverter permits zero-voltage switching of all semiconductors which reduces switching losses and switching stresses. The objectives of this project are to develop and validate an analytical model of the MCT device when used in high power motor control applications and to design, fabricate, and test a prototype electronic circuit employing both MCT and PDM technology for controlling a brushless dc motor.

Nelms, R. Mark↗

DOE OSTI2026

An SF 6 gas-insulated −500 kV DC conical insulator vacuum feedthrough

A test electrode was biased to −500 kV direct current (DC) by means of a novel SF 6 gas-insulated conical alumina insulator feedthrough. The design enables the extreme high vacuum conditions required by spin-polarized electron sources by reducing the photogun vacuum chamber volume compared to coaxial cylindrical insulators. In contrast to conventional inverted-insulator photogun designs that rely on solid dielectric interfaces for high-voltage terminations, the present design employs a pressurized SF 6 intervening volume between a conical alumina insulator and a modified commercial epoxy high-voltage cable receptacle. Here, this approach enables the use of commercially available cable hardware while extending the demonstrated operating voltage of solid feedthroughs. A maximum voltage of −500 kV was applied to a test electrode attached to the narrow end of the feedthrough inside a chamber filled with SF 6 at 170.3 kPa (10 psig) and later under vacuum to −259 kV, limited by field emission. The results demonstrate that a commercial high-voltage cable combined with a custom-designed SF 6 gas-insulated vacuum feedthrough can be used to bias photogun electrodes to −500 kV DC.

Palacios-Serrano, Gabriel [Thomas Jefferson Nation↗

DOE OSTI2022

Correcting for digital image correlation speckle inversion at high temperature using color cameras

Digital image correlation (DIC) is a popular, noncontacting technique to measure full-field deformation by using cameras to track the motion of an applied surface pattern. Because it is noncontacting, DIC can be performed for extreme temperature applications (e.g., hot-fire rocket testing of carbon composite rocket nozzles) under harsh conditions during which bonded gauges are damaged. Speckle pattern inversion is a phenomenon that sometimes occurs while performing high-temperature DIC. During speckle pattern inversion, portions of the surface pattern that were initially darker at room temperature (e.g., graphite) may emit more light due to blackbody radiation than the portions that were initially paler, thereby producing images in which the pattern appears inverted at high temperature relative to the initial pattern at room temperature. This phenomenon can prevent the correlation algorithm from being able to resolve the displacements between images. This work compares three methods to mitigate speckle pattern inversion: (A) the subtraction method, a recently-published technique in which two high-temperature images are subtracted to remove unwanted light; (B) the filtering method, a popular technique in which optical bandpass filters screen out unwanted light; and (C) the histogram rescaling method, a proposed new method that pairs a color camera with a blue light source and uses information from the green sensor of the camera to correct against inversion in the blue sensor through postprocessing. The histogram rescaling method is shown to successfully eliminate speckle pattern inversion and has the added advantages that it does not require quasi-static loading to be able to compensate for speckle pattern inversion, nor does it impose thick-glass distortions caused by the optical filter.

Rowley, Lindsey J.↗

DOE OSTI2018

Confronting Models with Regional CO 2 Observations

This research addressed an important DOE science area: the role of natural disturbances in carbon cycling. Our project included both (a) modeling and field measurements and (b) strengthened ties between DOE national laboratories and universities which continue after the project was completed. Our focus was on understanding the consequences of drought and emissions (fire and urban) to atmospheric trace gas composition (carbon dioxide, carbon monoxide, and methane), including both concentration and stable isotope composition. Measurements of these atmospheric gases were used to infer the spatial and temporal patterns of both sources and sinks in the carbon cycle. As part of this effort, we maintained two long-term monitoring networks along a geographic gradient in Utah and Colorado that spans montane forests, urban regions, and oil/gas fields. In this research, we expanded on a well-accepted atmospheric model (STILT-WRF) as a tool to evaluate fluxes in CLM/CESM-related models. We used the STILT model to provide a strong linkage between point atmospheric measurements and the surface parameterizations/emissions that are part of the CLM/CESM models. Overall, this project benefited and supported the DOE Long Term Mission and Goals in four distinct ways: (a) testing of carbon cycle models, (b) testing and evaluating model mechanisms whereby factors in CLM influence trace gas composition in CESM, (c) acquiring high-quality, long-term data on concentrations of carbon dioxide in western USA ecosystems, and (d) by reducing uncertainties associated with the representation of climate-carbon feedbacks in Earth System models through the development of new methods for evaluating model performance. One postdoctoral associate (Henrique Duarte) and one Ph.D. student (Darek Malia) were trained with this support. Nine peer-reviewed publications and 14 poster presentations were produced with support from this project. This proposal addresses a specific science area in the RFP: the role of natural disturbances in carbon cycling. In particular, we will focus on the consequences of drought and fire at landscape to regional scales for atmospheric trace gas concentration and stable isotope composition (CO 2 , CO, and CH 4 ). We seek to expand on the well accepted atmospheric Stochastic Time-Inverted Lagrangian Transport (STILT) model coupled to the Weather Research and Forecasting (WRF) model as a tool to evaluate stable isotope fluxes in CLM/CESM-related models through existing, long-term data sets and field campaigns where high-precision trace gas concentration and isotope measurements can be made along gradients and transects. Given the confounding impacts of anthropogenic trace gas emissions on landscape-to-regional atmospheric observations, we will also measure and parameterize isotopic characteristics of CO 2 , CO, and CH 4 from anthropogenic or forest sources in order to allow us the opportunity to partition atmospheric trace gases into natural and anthropogenic sources.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2023

Implementational Aspects for the Characterization of Low-Inertia in Power Systems

The replacement of conventional generating units with non-conventional renewable energy resources impacts the stability of the power system. While the general goal of supplying demand could be achieved from both generation resources, inverter-based energy resources are different from traditional synchronous machines in the sense that they do not inherently provide inertia to the system. The latter obviously worsen the system ability to maintain the balance between supply and demand after certain contingencies such as generator outages. With high integration of renewable-based generation resources, there is a reduction in total system inertia, which could lead to systems with less time to react for frequency restoration in case of such unexpected unit failures. While conceptually it is true, there is a missing gap in the field of power system stability community in terms of test-bed power systems for characterizing low-inertia conditions. In this paper, a framework for low-inertia power systems is presented. The purpose of the test-bed is to establish an environment for testing and conducting research on power systems experiencing low-inertia issues. The frequency nadir, the rate of change of frequency, and the under-frequency load shedding scheme are used as a measure of the healthiness of power grids.

Baquedano-Aguilar, Mario D.↗

NASA NTRS1993

Analysis of electromagnetic scattering from irregularly shaped, thin, metallic flat plates

This report describes an application of the method of moments to calculate the electromagnetic scattering from irregularly shaped, thin, metallic flat plates in free space. In the present technique, an irregularly shaped plate is enclosed by a rectangle on which the surface-current density is then expressed in terms of subdomain functions by dividing the rectangle into subsections. A shape function is introduced to ensure zero current outside the patch. The surface-current density is determined using the electric field integral equation (EFIE) approach in conjunction with the method of moments, and from a knowledge of the surface-current density, the electromagnetic scattering from a plate is calculated. Using this technique, the electromagnetic scattering from a hexagonal plate; an equilateral triangular plate; an equilateral triangular plate with a concentric, equilateral triangular hole and an inverted, equilateral triangular hole; and a diamond-shaped plate is computed and compared with the numerical results obtained by using the Electromagnetic Surface Patch (ESP) code developed by Ohio State University. The numerical results compare favorably with the measurements performed on these shapes in the Langley Experimental Test Range facility.

Deshpande, Manohar D.↗

DOE OSTI2025

Synchronous Machine Governor Upgrade

Conventional generation sources play a critical role in the stability and reliability of the electrical grid, particularly as we transition towards more renewable energy sources. To understand and accurately emulate their behavior for optimizing grid operations and ensuring seamless integration with renewable technologies, it is essential to better emulate the grid- and plant-level impacts of conventional generation sources, such as natural gas (NG) driven heat recovery steam generators (HRSGs) and combustion turbines (CTs). Therefore, a governor model is developed in a programmable logic controller (PLC) to investigate the performance of the conventional generator under various dynamic operating conditions and to identify the impact on grid stability in a controlled environment. The governor model aims to enable the hardware-in-the-loop (HIL) based emulation of these conventional generation sources using the existing 2 MVA synchronous machine/generator that is driven by a flexible 2.5 MW variable speed drive. This setup will allow us to replicate the dynamic characteristics and response behaviors of NG-driven HRSGs and CTs. The controls for the emulated conventional plants follow the industry standard and are adjustable, ensuring they accurately reflect the operational capabilities and limitations of real-world systems. These controls include load-following capabilities, ramp rates, startup and shutdown sequences, and emissions characteristics. By incorporating these adjustable controls, we aim to capture the nuanced impacts of conventional generation, such as their ability to provide ancillary services like frequency regulation, voltage support, and spinning reserve. In this report, we simulate two types of dynamic operations: grid-connected and islanding. For each dynamic operation, representative starting sequences are tested, including turbine purge, ignition, speed ramping up, generator excitation and synchronizing, and breaker close. The HIL based tests provides insights for field deployment, specifically the high-fidelity governor model provides results to predict the potential stability and reliability risk and suggest possible integration measures (e.g., generation and load balancing, tuning of governor control parameters). Ultimately, this enhanced emulation capability will be integrated into our Advanced Research on Integrated Energy Systems (ARIES), enabling us to conduct comprehensive studies on the interactions between conventional and renewable energy sources. By better understanding these interactions, we can develop strategies to optimize the overall performance and reliability of the grid. This will support the deployment of advanced grid management techniques, such as demand response, grid-forming inverters, and energy storage systems. The main contributions are summarized as follows: (1) This report introduces a PLC-based governor model for gas turbines. This model accurately simulates the dynamic behavior of conventional generation sources under various operational scenarios; (2) The model is integrated with an HIL testbed that includes a 2.5 MW variable speed drive and a 2 MVA synchronous machine. This setup enables realistic, real-time emulation of conventional power plants, particularly NG driven HRSGs and CTs; (3) The developed model is adaptable to various gas turbine configurations and allows for precise control over parameters such as MW ramp rates. This flexibility makes it a valuable tool for future research and industry collaboration; and (4) By incorporating the model into the National Renewable Energy Laboratory's Advanced Research on Integrated Energy Systems, the report lays the groundwork for future studies on interactions between conventional and renewable energy sources, enhancing the ability to develop advanced grid management strategies.

24 POWER TRANSMISSION AND DISTRIBUTION↗

NASA NTRS1994

Two-Dimensional Scramjet Inlet Unstart Model: Wind-Tunnel Blockage and Actuation Systems Test

This supplement to NASA TM 109152 shows the Schlieren video (10 min. 52 sec., color, Beta and VHS) of the external flow field and a portion of the internal flow field of a two-dimensional scramjet inlet model in the NASA Langley 20-Inch Mach 6 Tunnel. The intent of the overall test program is to study (both experimentally and computationally) the dynamics of the inlet unstart; this (phase I) effort examines potential wind-tunnel blockage issues related to model sizing and the adequacy of the actuation systems in accomplishing the start and unstart. The model is equipped with both a moveable cowl and aft plug. Windows in the inlet sidewalls allow limited optical access to the internal shock structure. In the video, flow is from right to left, and the inlet is oriented inverted with respect to flight, i.e., with the cowl on top. The plug motion is obvious because the plug is visible in the aft window. The cowl motion, however, is not as obvious because the cowl is hidden from view by the inlet sidewall. The end of the cowl actuator arm, however, becomes visible above the inlet sidewalls between the windows when the cowl is up (see figure 1b of the primary document). The model is injected into the tunnel and observed though several actuation sequences with two plug configurations over a range of unit freestream Reynolds number at a nominal freestream Mach number of 6. The framing rate and shutter speed of the camera were too slow to fully capture the dynamics of the unstart but did prove sufficient to identify inlet start and unstart. This series of tests indicated that the model was appropriately sized for this facility and identified operability limits required first to allow the inlet to start and second to force the unstart.

Holland, Scott D.↗

DOE OSTI2021

Measuring QCD Splittings with Invertible Networks

QCD splittings are among the most fundamental theory concepts at the LHC. We show how they can be studied systematically with the help of invertible neural networks. These networks work with sub-jet information to extract fundamental parameters from jet samples. Our approach expands the LEP measurements of QCD Casimirs to a systematic test of QCD properties based on low-level jet observables. Starting with an toy example we study the effect of the full shower, hadronization, and detector effects in detail.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗

DOE OSTI2016

Inverted initial conditions: Exploring the growth of cosmic structure and voids

We introduce and explore “paired” cosmological simulations. A pair consists of an A and B simulation with initial conditions related by the inversion δ A (x,t initial ) = –δ B (x,t initial ) (underdensities substituted for overdensities and vice versa). We argue that the technique is valuable for improving our understanding of cosmic structure formation. The A and B fields are by definition equally likely draws from ΛCDM initial conditions, and in the linear regime evolve identically up to the overall sign. As nonlinear evolution takes hold, a region that collapses to form a halo in simulation A will tend to expand to create a void in simulation B. Applications include (i) contrasting the growth of A-halos and B-voids to test excursion-set theories of structure formation, (ii) cross-correlating the density field of the A and B universes as a novel test for perturbation theory, and (iii) canceling error terms by averaging power spectra between the two boxes. Furthermore, generalizations of the method to more elaborate field transformations are suggested.

79 ASTRONOMY AND ASTROPHYSICS↗

NASA NTRS1987

Stability analysis of two coupled Lorenz lasers and the coupling-induced periodic to chaotic transition

A linear stability analysis of two Lorenz lasers coupled by their electric fields has been performed, and it is shown that the bad cavity condition becomes a function of coupling and that a good cavity instability may occur if the injected fields are inverted before injection. In addition, it is shown that the symmetrically coupled Lorenz system is isomorphic to the original Lorenz system with new parameters. The stability analysis also predicts a lowering of the second laser threshold with coupling for both the chaotic and self-pulsing regimes. Numerical integration of the equations is in agreement with these predictions and has revealed a coupling induced transition from self-pulsing to chaotic behavior. The classification of the behavior of the coupled system in the parameter space of the coupling constants has been investigated and shows that the results of symmetric coupling allow enough of a margin for an experimental test of the theory. This would allow experimentalists to observe the actual Lorenz instability at excitations as low as 4-5 times above threshold.

Lawandy, N. M.↗