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Final Report for ARPA-E LOCOMOTIVES Advanced Locomotive Technology and Rail Infrastructure Optimization System (ALTRIOS) Project

The Advanced Locomotive Technology and Rail Infrastructure Optimization System (ALTRIOS) is a unique, fully integrated, open-source software tool used to evaluate strategies for cost-effectively deploying advanced locomotive technologies and associated infrastructure. ALTRIOS simulates freight-demand-driven train scheduling, mainline meet-pass planning, locomotive dynamics, train dynamics, energy conversion efficiencies, and energy storage dynamics of line-haul train operations. Because new locomotives represent a significant long-term capital investment and new technologies must be thoroughly demonstrated before deployment, this tool provides guidance on the risk/reward trade-offs and operation integration of different technology rollout strategies. An open, integrated simulation tool is valuable for identifying future research needs and making decisions on technology development, routes, and train selection. This final report details the ALTRIOS software architecture, major modules and components, and data validation process. It demonstrates the software's utility through a 30-year rollout case study targeting high penetration of advanced powertrain technologies by 2050 for two BNSF Railway routes: loaded taconite ore trains from Hibbing, Minnesota, to Superior, Wisconsin, and mixed-freight trains from Superior to Minneapolis, Minnesota.

33 ADVANCED PROPULSION SYSTEMS↗

Fast and programmable locomotion of hydrogel-metal hybrids under light and magnetic fields

The design of soft matter in which internal fuels or an external energy input can generate locomotion and shape transformations observed in living organisms is a key challenge. Such materials could assist in productive functions that may range from robotics to smart management of chemical reactions and communication with cells. In this context, hydrated matter that can function in aqueous media would be of great interest. Here, we report the design of hydrogels containing a scaffold of high–aspect ratio ferromagnetic nanowires with nematic order dispersed in a polymer network that change shape in response to light and experience torques in rotating magnetic fields. The synergistic response enables fast walking motion of macroscopic objects in water on either flat or inclined surfaces and also guides delivery of cargo through rolling motion and light-driven shape changes. The theoretical description of the response to the external energy input allowed us to program specific trajectories of hydrogel objects that were verified experimentally.

36 MATERIALS SCIENCE↗

Quantifying Annual Industrial Locomotive Energy Consumption in the United States

While US Class 1 railroad locomotive rosters and annual fuel consumption are well-documented, considerably less is known regarding the overall energy consumption of operations involving industrial locomotives. To determine the energy savings potential of this rail operating sector, the objective of this research is to develop an inventory of US industrial locomotives and a baseline estimate of their annual energy consumption. Creating an industrial locomotives roster from public data is challenging given their diverse ownership by shippers or leasing companies, and operating locales largely out of public view. By cross-referencing public data on locomotive reporting marks, serial numbers, online images and aerial images, the project team confirmed the age, model and horsepower of over one thousand industrial locomotives. Estimating energy consumption is complicated by the variability in industrial locomotive types and power ratings, and extreme differences in duty cycles and utilization. Given these limitations, using quantified case study examples and adjustments to standard EPA line-haul and switching duty cycles, bounds on the magnitude of annual US industrial locomotive energy consumption were estimated.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

Industrial Locomotive Inventory Analysis

Due to their captive and local operations, industrial locomotives present a unique potential to reduce energy consumption and associated costs through application of advanced locomotive technologies. However, until now, there has been no data source for the number, size (hp), usage, and energy consumption of these locomotives, which limits the ability to design and implement a research, development, and deployment strategy. This research addresses this gap by developing the first national inventory of locomotives in industrial use and provides a tool to explore the energy and emissions associated with this transportation segment.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

ALTRIOS - Advanced Locomotive Technology and Rail Infrastructure Optimization System

The Advanced Locomotive Technology and Rail Infrastructure Optimization System (ALTRIOS) is a unique, fully integrated, open-source software tool to evaluate strategies for deploying advanced locomotive technologies and associated infrastructure for cost-effective decarbonization. ALTRIOS simulates energy conversion and storage dynamics, locomotive and train dynamics, meet-pass planning (detailed train timetabling), and freight-demand-driven train scheduling in a Pareto optimization. Because new locomotives represent a significant long-term capital investment and new technologies must be thoroughly demonstrated before deployment, this tool provides guidance on the risk/reward tradeoffs of different technology rollout strategies. An open, integrated simulation tool will be invaluable for identifying future research needs and making decisions on technology development, routes, and train selection. ALTRIOS development is a collaboration between NREL, the University of Illinois Urbana-Champaign (UIUC) RailTEC, Southwest Research Institute (SwRI), and BNSF.

ADVANCED PROPULSION SYSTEMS,MATHEMATICS AND COMPUT↗

Elastic-instability–enabled locomotion

Locomotion of an organism interacting with an environment is the consequence of a symmetry-breaking action in space-time. Here we show a minimal instantiation of this principle using a thin circular sheet, actuated symmetrically by a pneumatic source, using pressure to change shape nonlinearly via a spontaneous buckling instability. This leads to a polarized, bilaterally symmetric cone that can walk on land and swim in water. In either mode of locomotion, the emergence of shape asymmetry in the sheet leads to an asymmetric interaction with the environment that generates movement––via anisotropic friction on land, and via directed inertial forces in water. Scaling laws for the speed of the sheet of the actuator as a function of its size, shape, and the frequency of actuation are consistent with our observations. The presence of easily controllable reversible modes of buckling deformation further allows for a change in the direction of locomotion in open arenas and the ability to squeeze through confined environments––both of which we demonstrate using simple experiments. Our simple approach of harnessing elastic instabilities in soft structures to drive locomotion enables the design of novel shape-changing robots and other bioinspired machines at multiple scales.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

ALTRIOS (Advanced Locomotive Technology and Rail Infrastructure Optimization System) [SWR-22-54]

The Advanced Locomotive Technology and Rail Infrastructure Optimization System (ALTRIOS) is a unique, fully integrated, open-source software tool to evaluate strategies for deploying advanced locomotive technologies and associated infrastructure for cost-effective decarbonization. ALTRIOS simulates freight-demand driven train scheduling, mainline meet-pass planning, locomotive dynamics, train dynamics, energy conversion efficiencies, and energy storage dynamics of line-haul train operations. Because new locomotives represent a significant long-term capital investment and new technologies must be thoroughly demonstrated before deployment, this tool provides guidance on the risk/reward tradeoffs of different technology rollout strategies. An open, integrated simulation tool is invaluable for identifying future research needs and making decisions on technology development, routes, and train selection. ALTRIOS was developed as part of a collaborative effort by a team comprising the National Renewable Energy Laboratory (NREL), University of Illinois Urbana-Champaign (UIUC), Southwest Research Institute (SwRI), and BNSF Railway. Python Package: https://pypi.org/project/altrios/ Rust Crate: https://crates.io/crates/altrios-core

Baker, Chad↗

Assessment of Potential Failure Modes and Effects for On-Board Components for Hydrogen-Powered Locomotives

Hydrogen fuel sources offer alternatives to conventional fuels in the rail transportation industry. Hydrogen powered locomotive designs utilizing either a fuel cell or an internal combustion engine can make migration to alternative fuels possible for rail transportation. Codes and standards are still in development for rail application of hydrogen and safety risks must be assessed for hydrogen locomotive applications. This report utilizes a failure mode & effects analysis framework to help qualitatively understand possible risks from a hydrogen locomotive system. Findings illustrate how a combination of three mitigations greatly reduces the risks from a hydrogen locomotive system.

08 HYDROGEN↗

LOCOMOTIVES - Comprehensive Impact and Cost Assessment Framework of Carbon Lowering Approaches for the US Rail Freight System

The goal of this project is to develop a tool to aid railroads and other stakeholders assess and approach the decarbonization of freight rail operations by identifying new, viable low-carbon energy storage and conversion systems for future locomotive systems and how they should be deployed on the existing US freight rail network. In the first quarter, the project focused on collecting data, establishing a simulation workflow, and engaging industry through the creation of the Industry Advisory Board (IAB). In the second quarter, the project focused on selecting fuel pathways and powertrain technologies, setting performance targets, conducting a techno-economic analyses, and developing the simulation framework that would serve as the backbone of the future toolhead. The third quarter involved developing an industry-oriented interactive dashboard powered by a five-step sequential framework, as well as holding industry advisory board meetings as per the initial technology-to-market plan. In the remaining project quarters, the NUFRIEND dashboard were fine-tuned with the help of IAB member feedback and in-depth scenario analyses were conducted to support the techno-economic analysis of energy sources. Additionally, dashboard documentation, project insights, and open-source code on GitHub were prepared and released. Throughout the project, the team completed testing and analysis of all model components, integrated all initial test scenarios, and conducted stakeholder engagement. Lower-carbon drop-in fuels can be deployed as admixtures and are considered uniform across the network at a desired penetration rate, while hydrogen and battery-electric technology deployment poses a more complex problem as they require significant investments to be made in the siting of refueling/charging facilities and the replacement of locomotive fleets. Thus, strategies for locating and sizing refueling/charging facilities on a railroad’s network to meet their energy demands were developed to inform deployment decisions. To address this challenge, the Northwestern University Freight Rail Infrastructure & Energy Network Decarbonization (NUFRIEND) framework presents a five-step sequential framework to select O-D paths, locate facilities, reroute flows, size facilities, and evaluate the deployment for alternative energy sources that require locomotive powertrains to be converted and new refueling infrastructure to be deployed. The NUFRIEND Framework is an industry-oriented tool for simulating the deployment of new energy technologies across the US freight rail network. The framework provides a comprehensive network-level optimization and scenario simulation tool for decarbonizing the freight rail sector, addressing the uncertainties surrounding technological developments by supporting sensitivity analyses for different operational and technological parameters through a transparent and flexible input module. It offers practical alternatives to diesel locomotives and can be applied for any railroad considering the specific network structure and freight demand, outputting evaluation metrics for the associated emissions and costs relative to diesel operations. A number of relevant simulation scenarios were run and analyzed for key insights on the value of different alternative technologies for freight rail decarbonization. The project developments and findings have been presented at numerous conferences and events.

08 HYDROGEN↗

Design of Multi-Engine Freight Locomotive

This final report documents the completed engineering design of a modular, multi-engine renewable natural gas (RNG) hybrid freight locomotive. The project delivered a full systems design, component selection, and production and test plans for a near-zero-emission, Tier 5–capable line-haul locomotive, but did not proceed to fabrication or field testing due to withdrawal of the designated engine supplier.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

A buckling-sheet ring oscillator for electronics-free, multimodal locomotion

Locomotion of soft robots typically relies on control of multiple inflatable actuators by electronic computers and hard valves. Soft pneumatic oscillators can reduce the demand on controllers by generating complex movements required for locomotion from a single, constant input pressure, but either have been constrained to low rates of flow of air or have required complex fabrication processes. Here, we describe a pneumatic oscillator fabricated from flexible, but inextensible, sheets that provides high rates of airflow for practical locomotion by combining three instabilities: out-of-plane buckling of the sheets, kinking of tubing attached to the sheets, and a system-level instability resulting from connection of an odd number of pneumatic inverters made from these sheets in a loop. This device, which we call a “buckling-sheet ring oscillator” (BRO), directly generates movement from its own interaction with its surroundings and consists only of readily available materials assembled in a simple process—specifically, stacking acetate sheets, nylon film, and double-sided tape, and attaching an elastomeric tube. A device incorporating a BRO is capable of both translational and rotational motion over varied terrain (even without a tether) and can climb upward against gravity and downward against the buoyant force encountered under water.

Robotics↗

Techno-Economic Analysis and Life Cycle Assessment of Alternative Fuels for Locomotives in the U.S. Freight Rail Sector

Freight rail is more energy-efficient than truck transport over long-haul distances, offering a low-energy and emissions-intensive option for transporting freight. This study evaluates techno-economic analysis and life cycle assessment of seven alternative unblended fuels for freight locomotive engines─biodiesel, renewable diesel (RD), bio-oils, methanol, dimethyl ether (DME), ethanol, and ammonia─across 16 fuel pathways utilizing soybean, corn, woody biomass, renewable hydrogen, and waste sources, e.g., sludge, manure, and industrial CO 2 , and compares these to conventional diesel. The minimum fuel selling price (MFSP) ranged from $\$2.05$ to $\$8.27$ per diesel gallon equivalent (2020 US dollars), with biocrude and RDs produced from hydrothermal liquefaction (HTL) of sludge having the lowest MFSPs due to coproduct credits and avoided waste treatment cost. Life cycle GHG emissions ranged from −41 to 53 g of CO 2 e/MJ. RD from waste via HTL achieves negative emissions by diverting sludge/manure from GHG-intensive conventional management. Few pathways such as biocrude, methanol, and DME require additional control for SO X emissions in the refinery, while ethanol, FT-diesel, and bio-oil require additional control for particulate matter emissions. Bio-oil and RD from sludge have lower marginal abatement cost or MAC (–$\$38$/tonne CO 2 lowest) while methanol and ammonia with renewable hydrogen have higher MAC ($\$490$/tonne CO 2 maximum).

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

Identifications and classifications of human locomotion using Rayleigh-enhanced distributed fiber acoustic sensors with deep neural networks

Abstract This paper reports on the use of machine learning to delineate data harnessed by fiber-optic distributed acoustic sensors (DAS) using fiber with enhanced Rayleigh backscattering to recognize vibration events induced by human locomotion. The DAS used in this work is based on homodyne phase-sensitive optical time-domain reflectometry (φ-OTDR). The signal-to-noise ratio (SNR) of the DAS was enhanced using femtosecond laser-induced artificial Rayleigh scattering centers in single-mode fiber cores. Both supervised and unsupervised machine-learning algorithms were explored to identify people and specific events that produce acoustic signals. Using convolutional deep neural networks, the supervised machine learning scheme achieved over 76.25% accuracy in recognizing human identities. Conversely, the unsupervised machine learning scheme achieved over 77.65% accuracy in recognizing events and human identities through acoustic signals. Through integrated efforts on both sensor device innovation and machine learning data analytics, this paper shows that the DAS technique can be an effective security technology to detect and to identify highly similar acoustic events with high spatial resolution and high accuracies.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

Out-of-equilibrium interactions and collective locomotion of colloidal spheres with squirming of nematoelastic multipoles

Many living and artificial systems show similar emergent behavior and collective motions on different scales, starting from swarms of bacteria to synthetic active particles, herds of mammals, and crowds of people. What all these systems often have in common is that new collective properties like flocking emerge from interactions between individual self-propelled or driven units. Such systems are naturally out-of-equilibrium and propel at the expense of consumed energy. Mimicking nature by making self-propelled or externally driven particles and studying their individual and collective motility may allow for deeper understanding of physical underpinnings behind collective motion of large groups of interacting objects or beings. Here, in this work, using a soft matter system of colloids immersed into a liquid crystal, we show that resulting so-called nematoelastic multipoles can be set into a bidirectional locomotion by external oscillating electric fields. Out-of-equilibrium elastic interactions between such colloidal objects lead to collective flock-like behaviors emerging from time-varying elasticity-mediated interactions between externally driven propelling particles. Repulsive elastic interactions in the equilibrium state can be turned into attractive interactions in the out-of-equilibrium state under applied external electric fields. We probe this behavior at different number densities of colloidal particles and show that particles in dense dispersions collectively select the same direction of a coherent motion due to elastic interactions between near neighbors. In our experimentally implemented design, their motion is highly ordered and without clustering or jamming often present in other colloidal transport systems, which is promising for technological and fundamental-science applications, like nano-cargo transport, out-of-equilibrium assembly, and microrobotics.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

Investigating the Combustion Performance of Dual Fuel Combustion with Diesel and Port Injected Hydrogen in a Large Bore Locomotive Engine

The heavy-duty transportation sector has primarily relied on conventional diesel combustion engines given their reliability and high thermal efficiency relative to spark ignition engines, but increased focus on reducing greenhouse gas emissions has led to investigation into alternative fuels. Gaseous hydrogen fuel has garnered a great deal of recent interest in the engine community given it has zero carbon, but hydrogen is not available at the scale and cost that petroleum fuels are currently available, and this is a barrier to adoption for industries that are looking to decarbonize their operations. Because of the fuel flexibility provided, dual fuel technology offers a pathway for some industries to adopt hydrogen as a fuel source while maintaining sufficient flexibility in times and locations where the new fuel is not yet available. This computational study investigates dual fuel combustion in a large bore locomotive engine architecture using direct injected diesel and port injected gaseous hydrogen fuel. With an optimal port fuel injection configuration from previous work, simulations of varying substitution ratio, compression ratio, manifold air temperature, diesel injection timing, and diesel injection pressure were performed to understand their effect on combustion performance. Results indicated that both increased substitution ratio and higher intake air temperature accelerates hydrogen flame propagation and can result in high peak cylinder pressures. Additionally, diesel injection timing and injection pressure were demonstrated as effective methods for controlling dual fuel combustion heat release rates.

ODonnell, Patrick Christopher↗

Quantitative Risk Assessment for Hydrogen-Powered Locomotive Refueling

Hydrogen powered locomotives are being explored to reduce emissions in rail applications. The risks of operations like refueling should be understood to ensure safe environments for workers and members of the public. Sensitivity analyses were conducted using HyRAM+ to identify major drivers of risk and compare effects of system parameters on individual risk. The consequences of jet fires from full-bore leaks dominated the risk, compared to explosions or smaller leaks. Pipe size, leak detection capability, and leak frequencies of system components greatly affected risk while overpressure modeling parameters and ambient conditions had little effect. The effects of personal protective equipment (PPE) materials on individual risk were quantified by reducing the individual’s exposure time or absorbed thermal dose. PPE only showed a risk reduction in low-risk cases. This study highlighted target areas for risk mitigation, including leak detection equipment and component maintenance, and indicated that the minimal effects of other parameters on risk may not justify prescriptive requirements for refueling operators.

08 HYDROGEN↗

Piezoelectric-triboelectric heel charger to generate electricity from locomotion using level mechanism and mechanical SSHI boosting circuit

The disclosure provides an electricity generating insert for a piece of footwear, the insert can be removably placed in the heel portion, e.g. under the insole. The insert comprises a multilayer piezoelectric stack that alternatively flexes under the compression-decompression that occurs during locomotion, which flexing causes friction in the stack to generate electricity capable of charging electronic devices and the like, e.g. via a port on the footwear.

Wang, Ya↗