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All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

Development of Integrated Mechanical Pods

This presentation highlights early wins, updated progress, and upcoming developments on ‘national-scale shared development platform’ for rapid prototyping, testing and validation of various integrated Mechanical Pod solutions and form factors. Such pod solutions consist of a set of all-electric heat pump mechanical equipment that have integrated functionalities through built-in controls, with heating, cooling, hot water, ventilation (including energy recovery), electrical management, and battery storage within a single package. The presentation draws inspiration from the success of bathroom pods in the US modular construction industry, UK’s efforts with unitizing mechanical systems as ‘utility cupboards’, and VEIC’s early wins in design-build of all-electric Mechanical Pod solutions in Vermont. The presentation includes researchers and partners involved with NREL in Design for Manufacturing and Assembly (DfMA), Virtual Design and Construction (VDC), and digital twin based process optimization modeling of integrated Mechanical Pod solutions. The presentation aims to highlight early wins from such a platform and how various physical and virtual tools are currently being employed as part of NREL’s ongoing multi-year project funded by US DOE. Streamlined procurement, coordination, installation, and O&M of Mechanical Pods such that the majority of work is delegated to the off-site modular factory implies monetary savings. Such a seemingly basic shift in location of the construction process leads to great reduction in complexity, first cost, lead time, and waste, and greater opportunities for innovative compartmentalization and integration of mechanical systems appropriately sized for each apartment or hotel guest room. However, past studies on unitized combination systems show that high installation costs, maintenance issues, challenges with system integration, limitations in existing electrical infrastructure, and lack of architecturally appealing solutions are key barriers. NREL and partners aim to address key barriers through DfMA approach, rapid prototyping and testing, and digital twin process optimization modeling. The presentation is also a call for interested entities to partner with NREL as part of the national-scale development platform, help drive both product and process innovation, and encourage open source sharing of learnings. Learning objectives include (1) learn about the vision of national-scale shared development platform for process-product innovation on integrated mechanical pod solutions and how to get involved, (2) gain an understanding of the components of an all-electric, high performance home, design characteristics and equipment included in an all-electric mechanical pod, integration of mechanical systems within a modular factories’ assembly line, and the system’s commissioning, operation and maintenance. The pre-planning and coordination with the factory and sub-contractors are also highlighted, (3) gain an understanding of using process modeling tools to quantify resource-constrained performance of operations (such as integration of energy efficiency strategies) to manufacture modules of varying design, (4) gain insights on virtual design, rapid prototyping, and emulated testing of various form factors across different climatic conditions. The need for such preliminary testing with open source sharing of learnings will also be highlighted.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2022

Integrated Mechanical System Pods (CRADA Final Report)

LBNL provided input to setting the requirements related to indoor air quality and contributed to the development of metrics and test plans to evaluate prototypes of the mechanical pods, which were developed by other members of the project team. The testing of prototypes was conducted by and at Syracuse University, another project partner. LBNL also collaborated with RMI to develop a basic plan for data collection when the pods are deployed for field testing in Phase 2.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2025

A Recipe for ABC Multifamily Retrofits: Technologies, Financing, and Project Delivery

This report documents the final technical accomplishments and outcomes of Rocky Mountain Institute’s project under the U.S. Department of Energy (DOE) Award DE-EE0009064. The project aimed to develop, validate, and scale whole building retrofit solutions for multifamily buildings, including two configurations of Integrated Mechanical System Pods (IMSP-C and IMSP-U), in alignment with DOE Advanced Building Construction (ABC) initiative's decarbonization and energy efficiency goals. While the project made significant progress in Budget Period 1 (Phase 1) and throughout Budget Period 2 (Phase 2), activities were discontinued as of March 26, 2025, following a Stop Work Order issued by DOE. As such, this report reflects all completed work through that date. The project did not enter Budget Periods 3 and 4 (Phase 2), and demonstration site implementation, field M&V, and final commercialization execution were not conducted.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2022

The Energy in Modular (EMOD) Buildings Method: A Guide to Energy-Efficient Design for Industrialized Construction of Modular Buildings

Industrialized construction has immense potential to address the growing need globally to build and upgrade the building stock to be affordable, energy-efficient, and resilient. It can also help achieve the United States' goal of a 50% reduction in U.S. greenhouse gas (GHG) emissions by 2030. Despite this potential, and the ever-increasing push for electrification and decarbonization of households in the United States, industrialized construction has not yet been leveraged specifically to help address these challenges and accelerate the pathway to meet these goals. The National Renewable Energy Laboratory (NREL) aims to claim this missed opportunity by focusing on delivering affordable, grid-efficient net-zero energy (NZE) modular buildings for underserved communities to ensure an equitable transition to the future of clean energy, accelerate decarbonization of the built environment, and support the development of a high-productivity construction and energy efficiency workforce. The Energy in Modular (EMOD) method is our approach to designing, producing, and delivering affordable, net-zero energy, low-carbon, and healthier buildings at scale. The following energy efficiency strategies are part of the scope of this guide: envelope thermal control, envelope infiltration control, mechanical, electrical, and plumbing systems, smart controls, and solar plus storage. We draw synergies between design for manufacturing and assembly, process optimization, retrofit technologies, and digitization. Our goal is to influence the improvement and production of buildings to increase performance, enhance energy efficiency, and reduce GHG emissions. This guide documents the research and development efforts initiated by a set of design objectives to "modularize" a set of energy efficiency and low-carbon strategies into a housing unit while preserving and enhancing energy efficiency benefits and decarbonization pathways. This guide is intended to serve as a framework for housing developers, housing agencies, architects, energy experts, and process engineers or factory operator personnel who are critical to today's modular builder teams. This guide focuses on specific energy efficiency strategies, decarbonization pathways, and associated processes as part of NREL's research efforts. Stakeholders may substitute other means, methods, and technologies for the ones evaluated in this study.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
NASA NTRSDate not supplied

Should Astronauts throw out their Trash? And if so, How?

We don’t think much about taking out the trash on Earth, but in space, it requires some thought. Should it even be thrown overboard? Besides the implications of littering in space, there are also practical considerations of whether waste materials can be reused for other purposes onboard or do they reduce mission efficiency. In a previous study, gasifying and venting trash along the way to Mars was found to noticeably reduce propellant needs and launch mass of the spacecraft, whereas keeping processed trash on board in the form of radiation shielding tiles would significantly lower the crew’s radiation dose during a solar particle event. The latest human exploration mission proposals will be considered with an eye toward answering the questions, “Should Astronauts throw out their Trash?” and “If so, what is the best way?” Besides reviewing the propulsion and radiation shielding aspects of the question, equivalent system mass factors of mass, power, volume, and crew time, as well as human factors, like smell, will be studied. Disposal options include jettison of an entire module containing waste, regular disposal of trash via an airlock, or gasifying waste products for easier disposal or reuse. Jettison via an airlock could take many forms, from “taking out the trash” on a spacewalk to launching trash tiles or pods with different mechanisms. Likewise, the “trash-to-gas” concept, which would allow for overboard venting via a pipe, has many thermochemical processes to choose from, each with their own pros and cons. Unraveling these various tradeoff studies is the goal of this paper.

trash↗
DOE OSTI2022

Flow structures of the cross-flow over a five-layer helically coiled steam generator geometry

The helically-coiled heat exchanger (HCSG) offers advantages over straight tubes such as compactness in geometry, increased heat transfer coefficients, and capability to absorb thermal expansion. In this study, the time-resolved velocity field data of shell-side crossflow over a five-layer helically coiled steam generator geometry was obtained using Particle Image Velocimetry (PIV) between adjacent rods in four regions with up to 5000 frames per second (5 kHz) at approximately Re u = 3600. The slant rod bundle created different flow patterns in different regions. Proper Orthogonal Decomposition (POD) revealed high-energy-mode flow structures. Due to the confined flow channel geometry, the large flow structures were not advected resulting in no strong POD mode paring. Continuous Wavelet Transform (CWT) visualized the characteristics of flow fluctuation in time and frequency domain simultaneously, which ranged in Strouhal number, S u , between 0.03 and 1.17. In the wake regions of the rods, flows changed in both pattern and magnitude over time. Once a pattern formed, it continued for relatively shorter than straight tube arrays, before changing the pattern again. The histograms of the POD time coefficients presented this multimodal flow characteristics. The current study focuses more on whole flow field analyses in the selected regions rather than local point-wise analyses. Finally, this study revealed that various Strouhal numbers can exist in the helically coiled heat exchanger geometry, which was not observed in straight tube arrays. In particular, Strouhal numbers smaller than 0.1 do not seem to be caused by vortex shedding but seem to be the result of the combination of complex geometry and possible multimodal trends. Based on the current observation, further works would involve intensive instantaneous point-wise analyses on the interactions between important locations such as separation points, stagnation points, shear layers, etc.

42 ENGINEERING↗
NASA NTRS1996

Structure Identification Within a Transitioning Swept-Wing Boundary Layer

Extensive measurements are made in a transitioning swept-wing boundary layer using hot-film, hot-wire and cross-wire anemometry. The crossflow-dominated flow contains stationary vortices that breakdown near mid-chord. The most amplified vortex wavelength is forced by the use of artificial roughness elements near the leading edge. Two-component velocity and spanwise surface shear-stress correlation measurements are made at two constant chord locations, before and after transition. Streamwise surface shear stresses are also measured through the entire transition region. Correlation techniques are used to identify stationary structures in the laminar regime and coherent structures in the turbulent regime. Basic techniques include observation of the spatial correlations and the spatially distributed auto-spectra. The primary and secondary instability mechanisms are identified in the spectra in all measured fields. The primary mechanism is seen to grow, cause transition and produce large-scale turbulence. The secondary mechanism grows through the entire transition region and produces the small-scale turbulence. Advanced techniques use Linear Stochastic Estimation (LSE) and Proper Orthogonal Decomposition (POD) to identify the spatio-temporal evolutions of structures in the boundary layer. LSE is used to estimate the instantaneous velocity fields using temporal data from just two spatial locations and the spatial correlations. Reference locations are selected using maximum RMS values to provide the best available estimates. POD is used to objectively determine modes characteristic of the measured flow based on energy. The stationary vortices are identified in the first laminar modes of each velocity component and shear component. Experimental evidence suggests that neighboring vortices interact and produce large coherent structures with spanwise periodicity at double the stationary vortex wavelength. An objective transition region detection method is developed using streamwise spatial POD solutions which isolate the growth of the primary and secondary instability mechanisms in the first and second modes, respectively. Temporal evolutions of dominant POD modes in all measured fields are calculated. These scalar POD coefficients contain the integrated characteristics of the entire field, greatly reducing the amount of data to characterize the instantaneous field. These modes may then be used to train future flow control algorithms based on neural networks.

Chapman, Keith↗
NASA NTRS2009

Engine Conceptual Design Studies for a Hybrid Wing Body Aircraft

Worldwide concerns of air quality and climate change have made environmental protection one of the most critical issues in aviation today. NASA's current Fundamental Aeronautics research program is directed at three generations of aircraft in the near, mid and far term, with initial operating capability around 2015, 2020, and 2030, respectively. Each generation has associated goals for fuel burn, NOx, noise, and field-length reductions relative to today's aircrafts. The research for the 2020 generation is directed at enabling a hybrid wing body (HWB) aircraft to meet NASA's aggressive technology goals. This paper presents the conceptual cycle and mechanical designs of the two engine concepts, podded and embedded systems, which were proposed for a HWB cargo freighter. They are expected to offer significant benefits in noise reductions without compromising the fuel burn.

Tong, Michael T.↗
NASA NTRS2009

Engine Conceptual Design Studies for a Hybrid Wing Body Aircraft

Worldwide concerns of air quality and climate change have made environmental protection one of the most critical issues in aviation today. NASA s current Fundamental Aeronautics Research program is directed at three generations of aircraft in the near, mid and far term, with initial operating capability around 2015, 2020, and 2030, respectively. Each generation has associated goals for fuel burn, NOx, noise, and field-length reductions relative to today s aircrafts. The research for the 2020 generation is directed at enabling a hybrid wing body (HWB) aircraft to meet NASA s aggressive technology goals. This paper presents the conceptual cycle and mechanical designs of the two engine concepts, podded and embedded systems, which were proposed for a HWB cargo freighter. They are expected to offer significant benefits in noise reductions without compromising the fuel burn.

Tong, Michael T.↗
DOE OSTI2023

Effect of Phosphorus Modulation in Iron Single‐Atom Catalysts for Peroxidase Mimicking

Abstract Fe–N–C single‐atom catalysts (SACs) exhibit excellent peroxidase (POD)‐like catalytic activity, owing to their well‐defined isolated iron active sites on the carbon substrate, which effectively mimic the structure of natural peroxidase's active center. To further meet the requirements of diverse biosensing applications, SAC POD‐like activity still needs to be continuously enhanced. Herein, a phosphorus (P) heteroatom is introduced to boost the POD‐like activity of Fe–N–C SACs. A 1D carbon nanowire (FeNCP/NW) catalyst with enriched Fe–N 4 active sites is designed and synthesized, and P atoms are doped in the carbon matrix to affect the Fe center through long‐range interaction. The experimental results show that the P‐doping process can boost the POD‐like activity more than the non‐P‐doped one, with excellent selectivity and stability. The mechanism analysis results show that the introduction of P into SAC can greatly enhance POD‐like activity initially, but its effect becomes insignificant with increasing amount of P. As a proof of concept, FeNCP/NW is employed in an enzyme cascade platform for highly sensitive colorimetric detection of the neurotransmitter acetylcholine.

Ding, Shichao↗
DOE OSTI2022

Parametric model-order-reduction development for unsteady convection

A time-averaged error indicator with POD- h Greedy is developed to drive parametric model order reduction (pMOR) for 2D unsteady natural convection in a high-aspect ratio slot parameterized with the Prandtl number, Rayleigh number, and slot angle with respect to the gravity. The error indicator is extended to accommodate the energy equation and Leray regularization. Despite being two-dimensional and laminar, the target flow regime presents several challenges: 1) there is a bifurcation in the angle parameter space; 2) the solution can be multivalued, even at steady state; and 3) the solution exhibits spatio-temporal chaos at several points in the parameter space. The authors explore several reduced-order models (ROMs) and demonstrate that Leray-regularized Galerkin ROMs provide a robust solution approach for this class of flows. They further demonstrate that error-indicated pMOR can efficiently predict several QOIs, such as mean flow, mean Nusselt number and mean turbulent kinetic energy, even in the presence of a bifurcation. Finally, they show that spatio-temporal chaos can lead to lack of reproducibility in both the full-order model and the reduced-order model and that the variance in the full-order model provides a lower bound on the pMOR error in these cases.

leray regularization↗
DOE OSTI2022

Numerical investigation of the influence of shear and thermal stratification on the wind turbine tip‐vortex stability

Summary The interaction between wind turbine wakes and atmospheric turbulence is characterised by complex dynamics. In this study, two major components of the atmospheric boundary layer dynamics have been isolated, namely, the mean velocity profile shear and the thermal stratification, to examine their impact on the near‐wake development by undertaking a series of highly resolved large‐eddy simulations. Subsequently, instantaneous flow fields are extracted from the simulations and used to conduct Fourier analysis and proper orthogonal decomposition (POD) and compute the mean kinetic energy fluxes by different POD modes to better understand the tip‐vortex instability mechanisms. Our findings indicate that shear can significantly affect the breakup of the wind turbine tip‐vortices and the shape and stable length of the wake, whereas thermal stratification seems to only have limited contribution to the spatial development of the near‐wake field. Finally, our analysis shows that the applied perturbation frequency determines the tip‐vortex breakup location as it controls the onset of the mutual inductance instability.

17 WIND ENERGY↗
NASA NTRS2003

Shuttle Systems 3-D Applications: Application of 3-D Graphics in Engineering Training for Shuttle Ground Processing

This project illustrates an animation of the orbiter mate to the external tank, an animation of the OMS POD installation to the orbiter, and a simulation of the landing gear mechanism at the Kennedy Space Center. A detailed storyboard was created to reflect each animation or simulation. Solid models were collected and translated into Pro/Engineer's prt and asm formats. These solid models included computer files of the: orbiter, external tank, solid rocket booster, mobile launch platform, transporter, vehicle assembly building, OMS POD fixture, and landing gear. A depository of the above solid models was established. These solid models were translated into several formats. This depository contained the following files: stl for sterolithography, stp for neutral file work, shrinkwrap for compression, tiff for photoshop work, jpeg for Internet use, and prt and asm for Pro/Engineer use. Solid models were created of the material handling sling, bay 3 platforms, and orbiter contact points. Animations were developed using mechanisms to reflect each storyboard. Every effort was made to build all models technically correct for engineering use. The result was an animated routine that could be used by NASA for training material handlers and uncovering engineering safety issues.

Godfrey, Gary S.↗
DOE OSTI2022

Implications of Shear and Thermal Stratification on Wind Turbine Tip-Vortex Stability

The interaction between wind turbines in a wind farm through their wakes is a phenomenon that has been studied for decades and is still relevant today. Turbines clustered together in arrays will often operate in the wake of other upstream turbines which may lead to significant power losses and fatigue loads. For modern large-scale wind turbines, the mean shear velocity profile and thermal stratification are major components of the atmospheric boundary layer so it is important to understand their impact on near-wake development. Additionally, veer is present due to the rotation of the Earth. The impact of shear, thermal stratification and veer on the stable wake length of turbines with a dynamic control strategy is studied numerically in this work using a suite of highly resolved large-eddy simulations. Instantaneous flow fields are extracted from the simulations and used to conduct proper orthogonal decomposition (POD) and compute the mean kinetic energy fluxes by different POD modes to better understand the tip-vortex instability mechanisms. Our findings show that the dynamic pitch control scheme is able to shorten the stable wake length to about 1.5R in uniform flow. Shear can significantly affect the break up of wind turbine tip-vortices as well as the shape and stable length of the wake, whereas thermal stratification seems to only have limited contribution to the spatial development of the near-wake field. Veer causes the wake boundary to skew but has a limited impact on the wake length.

length thermal stratification↗
NASA NTRS2005

Stability-Augmentation Devices for Miniature Aircraft

Non-aerodynamic mechanical devices are under consideration as means to augment the stability of miniature autonomous and remotely controlled aircraft. Such aircraft can be used for diverse purposes, including military reconnaissance, radio communications, and safety-related monitoring of wide areas. The need for stability-augmentation devices arises because adverse meteorological conditions generally affect smaller aircraft more strongly than they affect larger aircraft: Miniature aircraft often become uncontrollable under conditions that would not be considered severe enough to warrant grounding of larger aircraft. The need for the stability-augmentation devices to be non-aerodynamic arises because there is no known way to create controlled aerodynamic forces sufficient to counteract the uncontrollable meteorological forces on miniature aircraft. A stability-augmentation device of the type under consideration includes a mass pod (a counterweight) at the outer end of a telescoping shaft, plus associated equipment to support the operation of the aircraft. The telescoping shaft and mass pod are stowed in the rear of the aircraft. When deployed, they extend below the aircraft. Optionally, an antenna for radio communication can be integrated into the shaft. At the time of writing this article, the deployment of the telescoping shaft and mass pod was characterized as passive and automatic, but information about the deployment mechanism(s) was not available. The feasibility of this stability-augmentation concept was demonstrated in flights of hand-launched prototype aircraft.

Wood, RIchard M.↗
NASA NTRS2013

Small Projects Rapid Integration and Test Environment (SPRITE): Application for Increasing Robutness

Over the past few years interest in the development and use of small satellites has rapidly gained momentum with universities, commercial, and government organizations. In a few years we may see networked clusters of dozens or even hundreds of small, cheap, easily replaceable satellites working together in place of the large, expensive and difficult-to-replace satellites now in orbit. Standards based satellite buses and deployment mechanisms, such as the CubeSat and Poly Pico-satellite Orbital Deployer (P-POD), have stimulated growth in this area. The use of small satellites is also proving to be a cost effective capability in many areas traditionally dominated by large satellites, though many challenges remain. Currently many of these small satellites undergo very little testing prior to flight. As these small satellites move from technology demonstration and student projects toward more complex operational assets, it is expected that the standards for verification and validation will increase.

Lee, Ashley↗
NASA NTRS2013

Small Project Rapid Integration and Test Environment (SPRITE) An Innovation Space for Small Projects Design, Development, Integration, and Test

Over the past few years interest in the development and use of small satellites has rapidly gained momentum with universities, commercial, and government organizations. In a few years we may see networked clusters of dozens or even hundreds of small, cheap, easily replaceable satellites working together in place of the large, expensive and difficult-to-replace satellites now in orbit. Standards based satellite buses and deployment mechanisms, such as the CubeSat and Poly Pico-satellite Orbital Deployer (P-POD), have stimulated growth in this area. The use of small satellites is also proving to be a cost effective capability in many areas traditionally dominated by large satellites, though many challenges remain. Currently many of these small satellites undergo very little testing prior to flight. As these small satellites move from technology demonstration and student projects toward more complex operational assets, it is expected that the standards for verification and validation will increase.

Lee, Ashley↗