Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “OEM”

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.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 127 records · Page 7
All sourcesNASA NTRSDOE OSTI
DOE OSTI2018

Consumer Behavior and the Plug-In Electric Vehicle Purchase Decision Process: A Research Synthesis

This report synthesizes consumer behavior research as it pertains to the plug-in electric vehicle (PEV) purchase decision process. The purpose is to clarify what is known about the vital role consumers play in the U.S. PEV market as it matures to become less policy-reliant and more representative of the U.S., both spatially and demographically. A more representative PEV market will: help OEMs recoup more of their R&D investments in PEVs; help American consumers access the economic and performance benefits of PEVs; and help the U.S. become more energy independent while improving air quality-related public health and reducing greenhouse gas emissions.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2018

Video-Based Dynamic Measurement & Analysis for Structural Health Monitoring

LANS has invented and holds patents for a unique platform/suite of tools and methods for the emerging Structural Health Monitoring (SHM) marketplace which may hold value within several industry market sectors. Los Alamos is seeking a commercialization partner for this SHM technology as an OEM or field services company operating in one or more of these markets that is capable of crafting and executing a savvy go to market plan that utilizes or leverages this novel suite of Structural Health Monitoring intellectual property and know-how that LANS has available for exclusive or non-exclusive licensing.

99 GENERAL AND MISCELLANEOUS↗
DOE OSTI2018

Energy Dense Batteries Based on Highly Conductive Solid Electrolyte and Cathode Materials

Solid Power’s Phase II program builds on promising Phase I results to further develop, scale, and integrate Oakridge National Laboratory’s (ORNL) material technologies into prototype cells relevant to electric vehicle applications. These cells will provide excellent energy density, specific energy, safety, and low cost compared to conventional Li-ion. The optimal material system is targeted for integration into >10 Ah pouch cells to demonstrate the ability to reach the United State Advanced Battery Consortium (USABC) performance targets and the specific targets of Solid Power’s automotive OEM stakeholders.

25 ENERGY STORAGE↗
DOE OSTI2018

Hydrogen Fuel-Cell Electric Hybrid Truck Demonstration (Final Technical Report)

The purpose of the project was to demonstrate three (3) fully developed, operational, advanced vehicle technology prototypes for ON-ROAD goods movement applications. The major vehicle OEM for this demonstration was Navistar International Trucks, with the fuel cell and power control hybrid technology provided and integrated by US Hybrid. CEM was to provide independent data collection and analysis, while EDF would provide education, outreach, and communication for the project. GTI managed the partnership and arranged for hydrogen fuel for the demonstration. The drayage truck is used to transfer the cargo container from/to ports in a warehouse or logistic yard. For port facilities in the Port of Houston Area, as well as virtually all other ports, drayage trucks often queue for long periods, inching along at slow speeds to await loading and unloading. During this process, the trucks are essentially idle, with conventional diesel engines continuously running and producing accompanying emissions. The ZECT would essentially power off during idle periods, or at least utilize minimal electric energy. As such, range limitation by using a gaseous fuel would be mitigated by the fact that the vehicle is not using fuel during much of its duty cycle. The project team expected the vehicle range to be about 200 miles which is well within the duty cycle requirements of the original fleet partner, Richardson Trucking. The project was intended to demonstrate commercialization and production potential, and to clearly illustrate the selected vehicle technology’s potential to reduce GHG emissions and petroleum use if implemented widely. To achieve this, the project team proposed a two-year demonstration project in the Port of Houston area to assess and track vehicle performance, and evaluate fuel savings, petroleum reduction, and emissions reduction benefits of the prototype technology. Additional time at the front end of the project was required for vehicle and support infrastructure preparation. In June 2017 the remaining project partners, which now included Air Liquide, agreed that the project would be unlikely to move forward with the vehicle demonstration, primarily due to the lack of a viable cargo truck fleet partner in the Port of Houston area willing to make a sufficient commitment of resources to operate the vehicles for the demonstration.

08 HYDROGEN↗
DOE OSTI2018

Texturizing Wind Turbine Towers to Reduce Bat Mortality

There is still a great need for the development of mitigation strategies that are economically viable and can be used alone or in combination with other options (e.g., operational minimization, acoustic deterrents) to ensure that bat fatalities are effectively reduced at wind facilities across the U.S. Our goal was to develop a wind turbine tower coating that 1) bats show little or no interest in approaching, 2) can be applied to currently deployed wind turbine towers and to towers as they are constructed, 3) is economically feasible to produce and apply, and 4) ultimately contributes to a reduction in bat mortality at utility-scale wind facilities. Wind turbine tower monopoles are large, smooth surfaces and numerous studies have reported bats making close investigative approaches at turbine tower surfaces that are suggestive of drinking and foraging behavior. We therefore hypothesized that such activity could be contributing to bat-wind turbine fatalities by increasing the amount of time that bats spend in or around the rotor-swept zone. We further hypothesized that a texturizing the tower might minimized bat activity at the towers and therefore reduce fatality risk. To explore this, we designed a series of experiments to characterize how bats interact with smooth and texture-treated surfaces in a controlled environment. We conducted 64 behavioral trials in a flight facility from 10 June to 25 September 2015 and an additional 76 behavioral trials from 9 June to 30 August 2016. The first set of trials showed that while bats did make contact with smooth surfaces, they did not make contact with textured surfaces. We ascertained that bat activity occurred at 0 to 1 m distances from surfaces, suggesting that the bats (used in this study) may need to be this close to a surface to accurately discern its texture. From the results were developed a texture coating. For the second set of trials, we tested the texture coating. Bats showed a >40% reduction in activity within 1 m of the textured surfaces in comparison to the smooth surfaces. Following these controlled experiments, we conducted field tests at Wolf Ridge Wind, LLC. We applied the texture coating to the midsection of turbine monopoles. The texture coating was manually applied to 2 turbine towers, although we noted during the application there was variation in texture coating between turbines. We considered that this variation could potentially impact bat behavior. We then conducted bat activity surveys at both texture-treated towers and 2 nearby control towers, over 55 nights from 24 June to 22 September, 2017. All species of bats known to be present at the site were detected in the acoustic recordings at these turbine towers. We found no significant differences in overall numbers of bats observed and levels of acoustic activity at the smooth and texture-treated towers. When we analyzed the experimental pairs separately, however, we found that a greater proportion of the close range bat activity within Pair 1 occurred at the texture-treated tower and that much of this activity could be attributed to foraging behavior. In contrast at turbine Pair 2, we observed no difference in the proportion of close range bat activity between the smooth and texture-treated tower, with no clear differences in behavior at the two tower types. When we examined acoustic bat activity at the tower pairs separately, we found species-specific differences in activity that differed between the smooth and texture-treated towers within the pairs. For example, hoary bat acoustic activity was significantly higher at the texture-treated tower in Pair 1, but significantly lower at the texture-treated tower in Pair 2. Given the observational nature of the field test, our limited sample size (2 turbine pairs), variation in the texture-coating between the 2 turbine pairs, and different patterns of bat activity observed at the 2 turbine pairs, inferences from this one field test are limited at best. In conclusion, the results from the flight facility experiments were promising (i.e., we observed a significant decrease in bat activity at smooth compared to texture-treated surfaces); however, due to coating installation and application challenges prior to our field test, we were unable to collect sufficient information to understand how these coatings affect bat activity at operational wind turbine towers. Although the results from the field test are inconclusive, the lessons learned will be informative for future research into turbine surface materials that can modify the surface of the turbine tower and therefore alter how bats perceive wind towers. Thus, the outcomes of this research project may have a significant impact on wind energy operators, wind developers, and OEMs by contributing to future impact mitigation strategies. In future research we will test new ideas to improve the development, application, and evaluation of this mitigation technique.

17 WIND ENERGY↗
DOE OSTI2019

Ultra Efficient Light Duty Powertrain with Gasoline Low Temperature Combustion (Final Report)

This document details the work completed during Project DE-EE0006839 ‘Ultra Efficient Light Duty Powertrain with Gasoline Low Temperature Combustion’. All tasks from the project’s Statement of Project Objectives are discussed. Final demonstration data is also presented and discussed. Further project details can be found in the Quarterly Technicial Reports that were submitted during the course of the project and are stored on the EERE Project Management Center Website. The goal of this project was to develop, implement and demonstrate a low temperature combustion approach called Gasoline Direct Injection Compression Ignition (GDCI) that provides high thermal efficiency with low NOx and PM emissions. The project target was to demonstrate a 35% fuel economy improvement over the baseline vehicle while meeting Tier 3 emissions levels. At the start of this project, GDCI was a moderately mature combustion technology, due in large part to advances made during a Delphi Technologies program funded through an earlier Department of Energy Advanced Technology Powertrains (ATP) opportunity; under that earlier contract, DE-EE0003258, Delphi Technologies assembled a team with complementary industrial and academic experience, and led this team to advance the technology from the original fundamental work to the state of art embodied by a first-generation (Gen 1) multi-cylinder GDCI engine. Key activities during that project centered on engine and combustion chamber design, and development of fuel injection equipment, valvetrain and advanced controls. Performance results with the Gen 1 engine in a development vehicle demonstrated that GDCI had the capability to operate using Low Temperature Combustion (LTC) over a broad speed-load range. Based on benchmarking work, efficiency for the Gen 1 GDCI engine compared favorably overall to production light-duty diesel engines. The second DOE funded project, DE-EE0006839, focused on a number of technical risks and issues that were left to be resolved for GDCI to become a production-viable technology. These risks were:GDCI combustion system refinement to achieve near-ideal air/fuel mixture preparation for high efficiency and low HC and CO emissions; Transient control development for low temperature combustion with high EGR levels during real-world transient driving maneuvers and over a broader range of ambient conditions; Aftertreatment system design that is effective in dealing with the low-temperature challenges of a highly efficient engine. The project was executed in two phases. Phase 1 leveraged the development vehicle from the Advanced Technologies Powertrain 1 (ATP1) project, DE-EE0003258. That vehicle was used as an initial test bed in the development of a high performance low temperature exhaust aftertreatment system. The vehicle was also used to develop calibration refinements for improved exhaust emissions and fuel efficiency. Samples of a new GDCI development level engine, called Gen2 GDCI (and developed outside of the first DOE funded project), were also used during Phase 1 to develop refined controller hardware and control algorithms, as well as improved sensors and actuators. The Gen2 engine was then retrofitted into the development vehicle from the ATP1 project and used for controls refinement and calibration of GDCI to achieve improved cold start, drivability and robustness to real world environments and fuel variations. During Phase 2 of the project, Gen3 versions of the GDCI engine were designed and built specifically for this project based on experience from the earlier engines. These engines were designed to be production-like in construction and, when combined with refined control systems and project specific low temperature exhaust aftertreatment, were intended to support the goal of meeting Tier 3 emissions levels at a vehicle level. Though great progress had been made advancing the GDCI combustion process, and despite extensive presentations of our work on the technology at various conferences and in direct meetings with automotive companies, none of the US domestic automotive OEMs had shown an interest in adopting this combustion process as part of their technology planning as the project approached the Go/No-Go point at the end of Budget Period 3. As a result of this low-level of interest both the US Department of Energy and Delphi Technologies received in this technology from domestic auto manufactures, Delphi Technologies elected a ‘No-Go’ status for the gate between Budget Period 3 and Budget Period 4 which terminated the project without spending any Budget Period 4 funds. The project team concluded that the dynamometer mapping of the most recent level of hardware, combined with the vehicle level simulation by Argonne National Laboratory, was sufficient to document the capabilities and potential of the combustion process without spending the time and money to do the controls development and full calibration necessary for a demonstration vehicle.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2019

US Hybrid Northeast Demonstration and Deployment of FCRxNV200 (DE-EE0007276 Final Report)

In this project, US Hybrid and other strategic project partners, collaborated to build a fuel cell range extended plug-in hybrid utility vehicle and demonstrate it in real-world operation. The base vehicle platform to be modified to the hybrid platform was the Nissan e-NV200, which is an all-electric version of the NV200 commercial cargo van. This is a Class 1 vehicle with a GVWR of approx. 4,900 lbs., wheelbase of 115 inches, and cargo capacity of approx. 122ft. The 80kW/254N-m electric powertrain is the same as Nissan’s LEAF, but with a revised final drive ratio (9.301 vs. 8.194) to accommodate higher payloads with lower top speed. US Hybrid utilized a purpose built, freeze capable, integrated fuel cell engine FCe™10 to hybridize and range-extend the existing e-NV200 vehicle with OEM drivetrain. The eNV200 has the same size battery as the LEAF with a different rear axle ratio. Fuel cell stack size and balance of plant (BOP) configuration were designed for compact under the hood vehicle packaging. Engine design took into consideration the need for high efficiency (>50% at all loads & up to 62% at partial power), optimal heat recovery for cabin heating, and low maintenance. The technology of the isolated DC-DC converter operating at >100kHz enables extremely high efficiency (ZVS and SIC power devices) and robust performance while reducing system complexity, weight, and volume. This enables an extended vehicle range of up to 250 miles and an operational life that should provide lower total cost of ownership (TCO) to the end user.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2018

Securing Vehicle Charging Infrastructure APR

Cybersecurity is essential for interoperable power systems and transportation infrastructure in the US. As the US transitions to transportation electrification, cyber attacks on vehicle charging could impact nearly all US critical infrastructure. This is a growing area of concern as more charging stations communicate to a range of entities (grid operators, vehicles, OEM vendors, etc.), as shown in Figure I.1.1.1. The research challenges are extensive and complicated because there are many end users, stakeholders, and software and equipment vendors. Poorly implemented electric vehicle supply equipment (EVSE) cybersecurity is a major risk to electric vehicle (EV) adoption because the political, social, and financial impact of cyberattacks—or public perception of such—ripples across the industry and has lasting and devastating effects. Unfortunately, there is no comprehensive EVSE cybersecurity approach and limited best practices have been adopted by the EV/EVSE industry. For this reason, there is an incomplete industry understanding of the attack surface, interconnected assets, and unsecured interfaces. Thus, comprehensive cybersecurity recommendations founded on sound research are necessary to secure EV charging infrastructure. This project is providing the automotive industry with a strong technical basis for securing this infrastructure by developing threat models, prioritizing technology gaps, and developing effective countermeasures. Specifically, the team is creating a cybersecurity threat model and performing a technical risk assessment of EVSE assets, so that automotive, charging, and utility stakeholders can better protect customers, vehicles, and power systems in the face of new cyber threats.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2019

Carbon Fiber Reinforced Polyolefin Body Panels

This project addresses an automotive industry desire for a cost-effective, lightweight material for body panels that offers mass reduction compared to steel and aluminum body panels, and a cost savings compared to incumbent polymer body panels. Inexpensive polypropylene (PP) combined with <10 weight % reclaimed/recycled carbon fiber (rCF) have the potential to meet both performance and affordability targets for lightweight, paintable vertical body panels. This project supports DOE and IACMI technical goals of reducing production cost of CF composites >25% in 5 years on a path to >50% in 10 years and demonstrating technologies for >80% recyclability or reuse of fiber reinforced composites in 5 years on a path to >95% in 10 years. Alternative body panel materials must meet all fit and surface finish requirements, and match the appearance of metal body panels adjacent to them. The PP/rCF materials must maintain exterior dimensional requirements with a low co-efficient of thermal expansion, excellent paintability, and mechanical performance. Thermoplastic injection molding offers significant reduction in tooling costs as injection molding dies are typically less than half the cost of stamping dies. This project utilized rCF compounded with special formulations of PPs to produce automotive components that meet requirements for fit, finish, mechanical performance, and paintability while offering significant mass savings over incumbent metal panels. It will also offer a cost savings versus other composite solutions. Fenders were molded at the IACMI – Corktown facility using an existing fender tool. Ford Motor Company was the industry lead for this project and provided project management, testing, painting and adhesion testing, and developed the cost-model/business case. Ford engaged and aggregated cost share with Borealis who provided materials, technical support for process trials, and participated in coordination meetings. Vehicles Technology Area staff in Corktown assisted in project management, process trials, molded fenders, and benchmarked physical characteristics. Over 450 plaques were molded with two different gating systems to look at processing conditions and specimens were excised for mechanical testing. Plaques were also used for paint trials, surface analysis, and dimensional analysis. Subsequently, over 200 fenders were molded at IACMI – Corktown. These fenders were used for paint trials, surface analysis, and dimensional analysis. The PP/rCF systems met all of the requirements except for paint appearance. Additional development of paint primer and top coat is necessary to fulfill automotive OEM paint surface requirements.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2020

Evaluation of Steam Cycle Upgrades to Improve the Competitiveness of U.S. Coal Power Plants (Final Scientific / Technical Report)

Increasing the competitiveness of the existing pulverized-coal utility fleet in the United States may be achieved by decreasing heat rate, via increases in steam cycle efficiency through upgraded steam temperatures and use of latest technology available in steam turbine and blading design. The average net plant efficiency of the US coal-fired fleet is approximately 33% (HHV). Plant efficiency increases to approximately 41.4% (HHV) at 1,350°F (732°C) steam temperature. However, achieving these Advanced Ultra-Super Critical (AUSC) steam conditions requires the use of advanced high-temperature materials. While there has been a significant amount of DOE-funded materials R&D, most of the related design work has focused on new (greenfield) units, rather than on opportunities to retrofit this advanced technology to the existing utility fleet. If technology, based upon the advanced materials required for AUSC steam conditions, may be applied to the existing fleet, using an economically viable retrofit, a higher capacity factor can be expected as a result of the increased plant competitiveness. The Electric Power Research Institute (EPRI) was awarded a project by the US Department of Energy to examine the technical and economic feasibility of a series of steam cycle upgrades to the two most prevalent types of U.S. coal power plants: 2,400 psig (16.6 MPa) subcritical and 3,500 psig (24.1 MPa) supercritical pulverized coal units. The nine upgrade options that were originally being considered included increasing the main and reheat steam temperatures from 1,000°F (538°C) to 1,100°, 1,200°, and 1,350°F (593°C, 649°C, and 732°C) while holding the steam pressures constant at their original design values, and cases where just the main steam or reheat steam temperatures were increased. The objective was to minimize the modifications required to the existing power plant while still providing a significant improvement in heat rate. The upgrade options assumed that the boiler enclosure envelope remained unchanged from each base case, and that all applicable OEM design guidelines for normal commercial units were imposed. For the highest temperature supercritical case, an option of using a low-pressure molten salt loop to transfer heat from the furnace to the steam was examined. The first major task of the work scope was designed to examine the technical feasibility of various upgrade options, while the subsequent work determined economic viability of the technically feasible upgrade options. Prior to evaluating the effect of these increased temperatures, a “base case” model of a subcritical and supercritical PC boiler was created, which was used for comparative purposes. Upgrade options were evaluated at full-load, part-load and dynamic transient conditions. Once the technical feasibility of each upgrade option was evaluated, the economic value of the heat rate improvement of each feasible option was determined by detailed modeling of unit dispatch in several regional power markets. The dispatch model was used to estimate the amount of revenue from power sales the upgraded unit would receive in comparison to a non-upgraded version of the same power plant. As a parallel task to the dispatch analysis, the capital cost of implementing the upgrades was estimated. The capital cost estimates were then compared to the increased revenue estimated by the dispatch modeling to determine the economic attractiveness of each upgrade option. Several upgrade options were determined to be technically feasible. The net present value (NPV) of the costs for steam cycle upgrades considered in this study ranged from approximately $\$$111 to $\$$130 million. The economic modeling results show that the unit dispatch changes resulting from steam cycle upgrades are relatively small, due largely to heat rate (and operating cost) changes being relatively small. Additionally, the cost of each upgrade exceeds the net revenue increases associated with the upgrade case. Note that the breakeven values are higher for subcritical retrofits, but the capital costs for the subcritical upgrades are also slightly higher. In typical new pulverized coal plants, fuel accounts for approximately 25% of the cost of electricity (COE), while capital costs represent around 50% of the COE. Therefore, in order to improve the heat rate by 4% one can only afford to increase the capital cost by 2%, at the same cost of electricity. The conclusion of this study is that without a cost for emitting CO 2 , it will be difficult to pay for significant efficiency improvements on plants firing low cost coals.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2020

Energy Consumption and Cost Reduction of Future Light-Duty Vehicles through Advanced Vehicle Technologies: A Modeling Simulation Study Through 2050

The U.S. Department of Energy’s (DOE’s) Vehicle Technologies Office (VTO) and Hydrogen and Fuel Cell Technologies Office (HFTO) aim to develop sustainable, affordable and efficient technologies for transportation of goods and people. Translating investments in advanced transportation component technologies and powertrains to estimate vehicle-level fuel savings potential is critical for understanding DOE’s impact. In this work, we simulated technologies funded by VTO and HFTO for light duty vehicles. The simulations were performed across: Multiple powertrain configurations (i.e., conventional, power-split, extended-range electric vehicle, battery electric drive, and fuel-cell vehicles), Vehicle classes (i.e., compact car, midsize car, small sport utility vehicle [SUV], midsize SUV, and pickup trucks); and Fuels (i.e., gasoline, diesel, hydrogen, and battery electricity). These various technologies are assessed for six different timeframes: laboratory years 2015, 2020, 2025, 2030, and 2045. A delay of 5 years is assumed between laboratory year and model year (year technology is introduced into production). Finally, uncertainties are included for both technology performance and cost aspects by considering two cases: Low case, aligned with DOE technology manager estimates of expected original equipment manufacturer (OEM) improvements based on regulations, business as usual; and High case, aligned with aggressive technology advancements based on R&D targets developed through support by VTO & HFTO. These scenarios are not intended as predictions of future performances. The energy and cost impact of different technologies were estimated using Autonomie (www.autonomie.net), Argonne vehicle system simulation tool. Autonomie is a state-of-the-art vehicle system simulation tool used to assess the energy consumption, performance and cost of multiple advanced vehicle technologies across classes (from light to heavy duty), powertrains (from conventional to HEVs, FCEVs, PHEVs and BEVs), components and control strategies. Autonomie is packaged with a complete set of vehicle models for a wide range of vehicle classes, powertrain configurations and component technologies, including vehicle level and component level controls. These controls were developed and calibrated using dynamometer test data. Autonomie has been used to support a wide range of studies including analyzing various component technologies, sizing powertrains components for different vehicle requirements, comparing the benefits of powertrain configurations, optimizing both heuristic and route based vehicle energy control and predicting transportation energy use when paired with a traffic modeling tool such as POLARIS. This report documents the assumptions and estimates the vehicle-level energy consumption benefits and associated technology costs for the various types of light duty vehicles. All details of vehicle assumptions and simulation results are available in the spreadsheets accompanying this report.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2020

On-Road Heavy-Duty Low-NOx Technology Cost Study

The National Renewable Energy Laboratory (NREL) conducted a cost analysis for emission control technologies under contract to the California Air Resources Board (CARB). CARB sought incremental cost analysis for emission control technologies for on-road heavy-duty (HD) engines, used in vehicle greater than 14,000 pounds (lbs) gross vehicle weight rating (GVWR) to achieve oxides of nitrogen (NOx) emissions rates significantly lower than those required by current emissions standards. Specifically, incremental costs (without any retail price mark-up) were estimated for representative diesel, natural gas, and gasoline engine and emission aftertreatment systems that were selected to represent potential technology packages that could achieve 0.02 grams per brake horsepower hour (g/bhp-hr) NOx on certification test cycles, including a proposed updated certification test cycle that includes additional low load operating conditions. NREL surveyed stakeholders including industry association groups, Tier 1 suppliers, and engine original equipment manufacturers (OEMs) to estimate incremental direct and indirect costs. Incremental costs were considered for current engine full useful life (FUL) definitions, as well as with proposed increased FUL and warranty period. The incremental costs were subsequently incorporated in life-cycle cost analyses examining the incremental engine and aftertreatment costs along with life-cycle costs over the various engine FUL scenarios. Life-cycle costs analysis included the incremental upfront cost, fuel consumption changes (changes in fuel economy), diesel exhaust fluid (DEF) consumption changes, and the maximum FUL of the aftertreatment package (major overhaul intervals).

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2020

Application and Certification of Comparative Vacuum Monitoring Sensors for Structural Health Monitoring of 737 Wing Box Fittings

Multi-site fatigue damage, hidden cracks in hard-to-reach locations, disbonded joints, erosion, impact, and corrosion are among the major flaws encountered in today's extensive fleet of aging aircraft and space vehicles. The use of in-situ sensors for real-time health monitoring of aircraft structures are a viable option to overcome inspection impediments stemming from accessibility limitations, complex geometries, and the location and depth of hidden damage. Reliable, structural health monitoring systems can automatically process data, assess structural condition, and signal the need for human intervention. Prevention of unexpected flaw growth and structural failure can be improved if on-board health monitoring systems are used to continuously assess structural integrity. Such systems are able to detect incipient damage before catastrophic failures occurs. Condition-based maintenance practices could be substituted for the current time-based maintenance approach. Other advantages of on-board distributed sensor systems are that they can eliminate costly, and potentially damaging, disassembly, improve sensitivity by producing optimum placement of sensors and decrease maintenance costs by eliminating more time- consuming manual inspections. This report presents a Sandia Labs-aviation industry effort to move SHM into routine use for aircraft maintenance. This program addressed formal SHM technology validation and certification issues so that the full spectrum of concerns, including design, deployment, performance and certification were appropriately considered. The Airworthiness Assurance NDI Validation Center (AANC) at Sandia Labs, in conjunction with Boeing, Delta Air Lines, Structural Monitoring Systems Ltd., Anodyne Electronics Manufacturing Corp. and the Federal Aviation Administration (FAA) carried out a certification program to formally introduce Comparative Vacuum Monitoring (CVM) as a structural health monitoring solution to a specific aircraft wing box application. Validation tasks were designed to address the SHM equipment, the health monitoring task, the resolution required, the sensor interrogation procedures, the conditions under which the monitoring will occur, the potential inspector population, adoption of CVM into an airline maintenance program and the document revisions necessary to allow for routine use of CVM as an alternate means of performing periodic structural inspects. To carry out the validation process, knowledge of aircraft maintenance practices was coupled with an unbiased, independent evaluation. Sandia Labs designed, implemented, and analyzed the results from a focused and statistically-relevant experimental effort to quantify the reliability of the CVM system applied to the Boeing 737 Wing Box fitting application. All factors that affect SHM sensitivity were included in this program: flaw size, shape, orientation and location relative to the sensors, as well as operational and environmental variables. Statistical methods were applied to performance data to derive Probability of Detection (POD) values for CVM sensors in a manner that agrees with current nondestructive inspection (NDI) validation requirements and also is acceptable to both the aviation industry and regulatory bodies. This report presents the use of several different statistical methods, some of them adapted from NDI performance assessments and some proposed to address the unique nature of damage detection via SHM systems, and discusses how they can converge to produce a confident quantification of SHM performance An important element in developing SHM validation processes is a clear understanding of the regulatory measures needed to adopt SHM solutions along with the knowledge of the structural and maintenance characteristics that may impact the operational performance of an SHM system. This report describes the major elements of an SHM validation approach and differentiates the SHM elements from those found in NDI validation. The activities conducted in this program demonstrated the feasibility of routine SHM usage in general and CVM in particular for the application selected. They also helped establish an optimum OEM-airline-regulator process and determined how to safely adopt SHM solutions. This formal SHM validation will allow aircraft manufacturers and airlines to confidently make informed decisions about the proper utilization of CVM technology. It will also streamline the regulatory actions and formal certification measures needed to assure the safe application of SHM solutions.

42 ENGINEERING↗
DOE OSTI2020

Evaluating Energy Efficiency Opportunities from Connected and Automated Vehicle Deployments Coupled with Shared Mobility in California

Connected and Automated Vehicles (CAVs) can be considered to be a disruptive transportation technology, with the potential to significantly improve overall transportation system efficiency; however, CAVs may increase induce vehicle miles traveled (VMT) and bring on greater energy consumption. Further, shared mobility is another disruptive transportation event that is reshaping our travel patterns. The primary goal of this project was to extensively collect data from vehicles and associated infrastructure equipped with CAV technologies from both real-world experiments and simulation studies mainly deployed in California, and develop a comprehensive framework for evaluating energy efficiency opportunities from large-scale (e.g., statewide) introduction of CAVs and a wide deployment of shared mobility systems in a variety of scenarios. To quantify the combined impact of CAV and shared mobility on travel behavior, traffic performance, and energy efficiency, a unique mesoscopic simulation-based model was developed for mobility and energy efficiency evaluation considering these disruptive transportation technologies. As a complement to existing studies on nationwide evaluation of CAVs’ energy impacts, this project was focused on data collection efforts and CAV applications under congested traffic environments that are frequently experienced on a massive scale across the major metropolitan areas in California. Extensive real-world data collection supplemented with simulation studies were conducted to cover a variety of CAV and shared mobility scenarios, particularly on scenarios less-explored in the existing research. Another key component of this project was to consider the interaction between different CAV technologies and shared mobility models, and the compound effect on energy efficiency. A comprehensive modeling suite was developed to quantify the impact of new mobility technologies on travel behavior and traffic performance. The developed modeling framework includes an energy intensity module, mode choice module and activity generation module that are integrated into an agent-based BEAM simulation platform to perform impact analysis based on a variety of scenarios. In addition, the RouteE model has been upgraded to incorporate the impact of CAVs on traffic flow, VMT and energy intensity, using micro-simulation data collected from both freeways and urban arterials. A novel fundamental influencing factor (FIF) mode choice model was developed to link CAV and shared mobility components with travel behaviors, and adapted into the BEAM-centered model framework. A statewide energy inventory was constructed under various CAV technology deployment scenarios by incorporating datasets and models for predicting vehicle market share and vehicle usage, which are tightly associated with the penetration of shared mobility systems. Based applying this modeling suite to a calibrated network in Riverside California, it was found that cooperative automated driving in general will improve mobility, but automated vehicles, even when deployed in a shared autonomous fleet, will likely bring an increase of VMT (up to 36%) due to mode shifts and deadheading. Ride-hailing vehicles typically have better energy efficiency and a higher share of electric vehicles, which helps offset the negative impact from VMT increases when estimating the system-level energy consumption. In general, simulation results show a 6% increase in energy consumption for the scenarios with an increasing shift to ride-hailing modes. The statewide analysis based on the National Household Travel Survey (NHTS) sample data is consistent with the findings from the Riverside network and validate the developed clustering-prediction modeling methodology. The outcomes from this project will help close the knowledge gap on recognizing the potential performance and energy impacts of a broad deployment of CAV and shared mobility technologies across a wide range of roadway infrastructure with varying levels of congestion. Results from this project: 1) will support policymakers in steering CAV development and deployment towards an energy favorable direction; 2) reduce uncertainties in estimating energy saving opportunities from new mobility technologies and services; 3) increase the confidence of CAV technology investors both on the infrastructure side (i.e., transportation agencies) and on the vehicle side (i.e., OEMs); and 4) expedite the deployment of energy-efficient CAV and shared mobility applications.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2020

Securing Vehicle Charging Infrastructure

As the US electrifies the transportation sector, cyber attacks targeting vehicle charging could bring consequences to electrical system infrastructure. This is a growing area of concern as charging stations increase power delivery and must communicate to a range of entities to authorize charging, sequence the charging process, and manage load (grid operators, vehicles, OEM vendors, charging network operators, etc.). The research challenges are numerous and are complicated because there are many end users, stakeholders, and software and equipment vendors interests involved. Poorly implemented electric vehicle supply equipment (EVSE), electric vehicle (EV), or grid communication system cybersecurity could be a significant risk to EV adoption because the political, social, and financial impact of cyberattacks - or public perception of such - ripples across the industry and has lasting and devastating effects. Unfortunately, there is no comprehensive EVSE cybersecurity approach and limited best practices have been adopted by the EV/EVSE industry. There is an incomplete industry understanding of the attack surface, interconnected assets, and unsecured interfaces. Thus, comprehensive cybersecurity recommendations founded on sound research are necessary to secure EV charging infrastructure. This project is providing the power, security, and automotive industry with a strong technical basis for securing this infrastructure by developing threat models, determining technology gaps, and identifying or developing effective countermeasures. Specifically, the team is creating a cybersecurity threat model and performing a technical risk assessment of EVSE assets, so that automotive, charging, and utility stakeholders can better protect customers, vehicles, and power systems in the face of new cyber threats.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2020

PDRD Project 19039 - All metal vacuum scroll pump development for tritium

Currently the United States relies on a single source, foreign company, Eumeca (formerly Normetex) for the supply of an all metal vacuum scroll pump to process tritium. This “one of a kind”, all metal, vacuum scroll pump utilizes no “wetted”, polymeric materials that degrade prematurely when exposed to tritium. U.S. based vacuum scroll pump suppliers typically utilize a polymer, Teflon®, as a tip seal material at the edge of the scroll impellers for proper pump function. Teflon® is known to degrade within a relatively short time frame (approximately 1 year) when continually exposed to tritium gas. This degradation results in “flaking” of the Teflon® material which results in particulate contamination of the process gas stream. While filtration of the particulate is possible, doing so requires additional maintenance which is costly in a glovebox environment. In addition, filtration can degrade pumping system performance as particulate collects in the filter media over time. To date, all of the well established U.S and European based vacuum scroll pump manufacturers have been uninterested in developing an all metal vacuum scroll pump that does not use a polymeric scroll tip seal. This position is taken as the vacuum scroll pump manufacturers do not see a large enough market to make it profitable for them to develop and market an all metal vacuum scroll pump. In the mid 2000s, one company, Air Squared, Inc., a small Original Equipment Manufacturer (OEM) specializing in design and fabrication of custom scroll vacuum pumps and compressors, was willing to pursue the effort. The first design effort incorporated Vespel® as a polymeric tip seal material. Results of this effort led to realizing the affect that the Met-Bel MB-601 metal bellows pump has on performance when used as a backing pump for an all metal vacuum scroll pump without a scroll tip seal. As a result, Air Squared subsequently designed an all metal vacuum scroll pump without a tip seal material for evaluation. Although the initial, all metal version of the Air Squared pump was found deficient in regard to scroll impeller stiffness, which resulted in scroll contact, general design and pump performance was verified to be adequate. SRS PDRD Project 19039 was launched in 2019 as a 3rd attempt with Air Squared, Inc. in regard to development of an all metal vacuum scroll pump for consideration as an equivalent to the Eumeca/ Normetex pump. The effort specified 300 series stainless steel for the scroll impellers, all metal sealing, and design to meet tritium throughput and ultimate vacuum requirements. In addition, a 60 psig design pressure rating requirement was specified for the pump containment boundary. The 3rd generation Air Squared pump has been designed, fabricated, and has received preliminary testing. Preliminary testing has indicated proper leak tightness and pump performance. However, work continues regarding development of a pumping chamber containment bellows that can be subjected to 66 psig without damage to the bellows. Work will continue in 2020 and 2021 to pursue a pumping chamber containment bellows that meets the pressure rating requirement.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2018

Energy Storage Financing: Performance Impacts on Project Financing

Understanding performance is the key to risk management in energy storage project financing. Technical performance underlies both capital and operating costs, directly impacting the system's economic performance Since project development is an exercise in risk management, financing costs are the clearest view into how lenders' perceive a project's riskiness. Addressing this perception is the challenge facing the energy storage industry today. Growth in the early solar market was hindered until OEMs and project developers used verifiable performance to allay lenders' apprehension about the long-term viability of those projects. The energy storage industry is similarly laying the groundwork for sustained growth through better technical Standards and best practices. However, the storage industry remains far more complex than other markets, leading lenders to need better data, analytical tools, and performance metrics to invest not only to maximize returns, but also safely--through incorporating more precise performance metrics into the project's documents.

25 ENERGY STORAGE↗
DOE OSTI2021

New High-Energy & Safe Battery Technology with Extreme Fast Charging Capability for Automotive Applications (Final Technical Report)

Being able to refill a cars gas tank when low on fuel is incredibly convenient and is a lacking feature for battery elective vehicles. New High-Energy & Safe Battery Technology with Extreme Fast Charging Capability for Automotive Applications was a research project designed to help correct this lacking feature by developing automotive sized Li-ion battery cells and demonstrating their ability to charge in under 10-minutes. To address the technical challenges Microvast, a cell manufacturer, was joined by Argonne National Labs, battery technology innovator, and BMW, a renown OEM, worked together to define and validate materials and cells for this project. By projects end, Microvast had successfully built and demonstrated a 240 Wh/kg, 35 Ah pouch cell that was capable of over 800 10-minute charge, full discharge cycles. From the outset of the project the plan was to use large amp-hour cells (ie automotive relevant sizes) to ensure the project findings and outcomes were most relevant for electric vehicle applications. The manufacture of cells was done using test manufacturing lines at Microvast and BMW that closely resemble the procedures of a Li-ion battery cell factory.

25 ENERGY STORAGE↗