Exact THD Calculations Applied to Minimize Space Harmonic Content of Winding and Rotor Magnetic Fields
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Results for “Electric Machine”
Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.
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Design and Verification of An Open-Circuit Electro-Hydraulic Actuator System with An Integrated Electro-Hydraulic Unit
This paper proposes an electro-hydraulic actuator (EHA) system, and two novel-designed electro-hydraulic units (EHU) consisting of a fixed-displacement hydraulic pump and a variable-speed electric motor. Both the novel EHU designs integrate an electric machine and a hydraulic machine in a single unit, featuring compactness and power density. However, they differ for salient aspects such as power and electric machine cooling system. The EHA system features an open circuit design, where hydraulic hoses connect the EHU with a tank, a valve manifold, and the hydraulic cylinder. In this way, the proposed EHA technology can be used to implement distributed hydraulic actuation in a vehicle without requiring changes to the hydraulic actuators or at the overall layout of the hydraulic components with respect to the original vehicle design. A dedicated test rig is developed to verify the performance of the proposed EHA system. The efficiency of the EHA is measured in a steady state and under a realistic duty cycle of a commercial compact loader. The measured efficiency of the system can reach 54% with up to 20kN load and 6kW power level.
42 ENGINEERING↗
Analytical Design and Performance Estimation Methods for Aircraft Permanent Magnet Synchronous Machines
The design of an electric motor drivetrain is a complex multiphysics problem. Low fidelity motor drivetrain sizing can be a key tool in the design cycle of an electric motor drivetrain and for system level studies of aircraft configurations. However, low fidelity sizing can lead to misleading results if all the physics involved in a motor design are not properly accounted for. This paper provides details on modeling approaches for initial design and sizing of permanent magnet synchronous electric machines. The goal of this paper is to provide the reader an understanding of the key principles of motor design and some modeling approaches to perform initial sizing of an electric motor and its inverter.
Thomas F. Tallerico↗
Exploration of the Versatile Electrically Augmented Turbine Engine Gearbox Concept
Integration of electric machines with the shafts of gas turbine engines is implied in various electrified aircraft propulsion concepts. This includes implementation of the Turbine Electrified Energy Management (TEEM) concept, a motivator for the Versatile Electrically Augmented Turbine Engine (VEATE) gearbox. The VEATE gearbox is a mechanical power transmission concept that seeks to interface electric machines with a gas turbine engine in a synergistic manner. It enables a hybrid electro-mechanical approach for managing power in a gas turbine engine. It is hypothesized that the mechanical design of the VEATE gearbox could be leveraged to enhance the versatility of the present electrical hardware. The VEATE gearbox concept is first introduced and applied to an electrified two-spool advanced geared turbofan meant for powering a single-aisle commercial aircraft. A modeling approach for the gearbox is presented and studies are conducted to investigate the potential application to TEEM and power extraction. There is evidence that the VEATE gearbox could help to reduce the size of the TEEM power system, provide flexibility in power extraction implementation, and exhibit fail-safe design attributes.
Electrified Aircraft Propulsion↗
Exploration of the Versatile Electrically Augmented Turbine Engine Gearbox Concept
Integration of electric machines with the shafts of gas turbine engines is implied in various electrified aircraft propulsion concepts. This includes implementation of the Turbine Electrified Energy Management (TEEM) concept, a motivator for the Versatile Electrically Augmented Turbine Engine (VEATE) gearbox. The VEATE gearbox is a mechanical power transmission concept that seeks to interface electric machines with a gas turbine engine in a synergistic manner. It enables a hybrid electro-mechanical approach for managing power in a gas turbine engine. It is hypothesized that the mechanical design of the VEATE gearbox could be leveraged to enhance the versatility of the present electrical hardware. The VEATE gearbox concept is first introduced and applied to an electrified two-spool advanced geared turbofan meant for powering a single-aisle commercial aircraft. A modeling approach for the gearbox is presented and studies are conducted to investigate the potential application to TEEM and power extraction. There is evidence that the VEATE gearbox could help to reduce the size of the TEEM power system, provide flexibility in power extraction implementation, and exhibit fail-safe design attributes.
Versatile Electrically Augmented Turbine Engine Ge↗
Electrical and acoustical resonances of vibrators
The basic sources of vibration in electrical machines are identified as: (1) unbalanced masses of the rotor, (2) condition of the bearings, and (3) the electromagnetic field gap. Methods for improving the vibration characteristics of electrical machines are proposed. A mathematical model is developed for calculating the damping elements located between the bearings and the mounts.
Khvingiya, M. V.↗
Electrified Aircraft Propulsion Controls Hardware Testing
Electrified Aircraft Propulsion (EAP) systems hold potential for the reduction of aircraft fuel burn and emissions. To realize this potential for single-aisle aircraft, control technology challenges associated with EAP designs are increasing the demand for Hardware-In-the-Loop (HIL) studies that address the tightly coupled electrical powertrain and turbofan propulsion systems. Reconfigurable HIL testbeds enable the study of integrated supervisory control and control approaches that augment engine shaft torques to improve performance. This paper presents an overview of conceptual EAP controls architecture testing in two HIL testbeds. The NASA Electric Aircraft Testbed provides the ability for megawatt class electric powertrain testing for technology maturation. A 100 kilowatt testbed, the Hybrid Propulsion Emulation Rig, allows for rapid controls technology trade studies. In both testbeds, controls testing is performed by implementing the electrical power system in hardware while turbomachinery is emulated via electric machines that are commanded by a real-time model and controls. A novel scaling algorithm is applied to emulate the inertial loads of the turbomachinery that causes the electric machines to respond in a fashion similar to that of the full-scale propulsion system they represent. Results demonstrate desired control performance at both testbed scales for the conceptual EAP architecture.
Electrified Aircraft Propulsion↗
Electrified Aircraft Propulsion Controls Hardware Testing
Electrified Aircraft Propulsion (EAP) systems hold potential for the reduction of aircraft fuel burn and emissions. To realize this potential for single-aisle aircraft, control technology challenges associated with EAP designs are increasing the demand for Hardware-In-the-Loop (HIL) studies that address the tightly coupled electrical powertrain and turbofan propulsion systems. Reconfigurable HIL testbeds enable the study of integrated supervisory control and control approaches that augment engine shaft torques to improve performance. This paper presents an overview of conceptual EAP controls architecture testing in two HIL testbeds. The NASA Electric Aircraft Testbed provides the ability for megawatt class electric powertrain testing for technology maturation. A 100 kilowatt testbed, the Hybrid Propulsion Emulation Rig, allows for rapid controls technology trade studies. In both testbeds, controls testing is performed by implementing the electrical power system in hardware while turbomachinery is emulated via electric machines that are commanded by a real-time model and controls. A novel scaling algorithm is applied to emulate the inertial loads of the turbomachinery that causes the electric machines to respond in a fashion similar to that of the full-scale propulsion system they represent. Results demonstrate desired control performance at both testbed scales for the conceptual EAP architecture.
Electrified Aircraft Propulsion↗
NASA’s Electric Aircraft Propulsion Research: Yesterday, Today and Tomorrow
NASA has been making investments since ~2015 in technologies related to electric aircraft propulsion. These investments span all-electric with our four passenger X-plane and electric vertical lift studies, to regional flight demonstrators and targeted technology maturation programs. These latter two areas are focused ultimately on reducing fuel burn and overall energy use in transport-class aircraft, with the goal of reducing carbon impact of aviation on our planet. Key technology contributions include such as electric machines, power electronics, cables/bus bars, fault management systems, controls and systems studies, and enabling materials. Today we are seeing the fundamental technology investments manifest themselves in flight demonstrations, that are aimed at impacting aircraft entering service 2035-2040 time range. These efforts have largely been aimed at megawatt scale technologies that can enable hybrid electric or mildly distributed airplane concepts. While these concepts offer benefits to regional and single isle aircraft it is thought that a more fully electrified propulsion system requiring greater than 10 MW of distributed power offers more possible pathways to configure the propulsion-airframe system to gain new efficiencies. A few examples of this are NASA’s SUSAN distributed electrofan concept and NASA University Leadership Initiatives such as CHEETA and IZEA that champion turbo-electric concepts. These concepts utilize combination of advanced technologies such as, fuel cells, power dense electronics and power dense electric machines and superconducting technologies. How much or which of these concepts will be adopted by industry is unclear, however another step function in electrifying aircraft propulsion is now on the horizon.
Electric Aircraft Propulsion↗
Methods and systems for coordinating predictive cruise control, engine-off coasting, and hybrid power split
The enclosed disclosure relates to hybrid vehicles and systems with an engine, a drivetrain with a clutch and a transmission, an electric machine, and a controller. The controller receives lookahead information within a lookahead window and present state information of the hybrid vehicle. The controller determines a predicted coasting opportunity exceeding a predetermined threshold within the lookahead window and determines a cruise control reference speed, a power split between the engine and the electric machine, and a timing of enabling engine-off coasting during the coasting opportunity. The controller deactivates the engine and disengages the clutch at a start of the coasting opportunity when the engine-off coasting is enabled.
Gupta, Rohinish↗
Electric Motor Thermal Management
During FY 2022, NREL efforts focused on supporting collaborations with external research partners within the Electric Drive Technologies research consortium. The poster highlights collaborations with SNL, ORNL, and Georgia Tech. The collaboration with SNL utilized NREL's experimental capabilities to mechanically characterize SNL-provided material samples for motor applications. The collaboration with ORNL supported efforts to refine the design of a high-speed, non-heavy-rare-earth outer-rotor motor. The collaboration with Georgia Tech focused on a novel cooling technique for electric machines. NREL supported the effort by leading the thermal analysis and design of advanced machines.
ADVANCED PROPULSION SYSTEMS↗
Turbine Electrified Energy Management for Single Aisle Aircraft
Electrified aircraft propulsion technology is being developed to reduce the environmental impacts of the aviation industry. This is prompting the exploration of potential uses and benefits of hybrid systems in which electric powertrains are integrated with more traditional gas turbine propulsion systems. Turbine Electrified Energy Management (TEEM) is an energy management approach for hybrid-electric architectures in which electric machines are connected to the turbofan shafts and used to suppress the off-design operation naturally associated with engine transients. This reduces the need to maintain a large amount of compressor operability margin, thus allowing further exploration of the engine design space. In this study, a 19,000 lbf engine within a parallel hybrid propulsion system is considered along with a 30,000 lbf standalone engine. Data from prior TEEM applications are used to approximate the electric machine sizing required to achieve operability benefits. The TEEM controller is shown to improve operability during transients through the reduction of stall margin undershoots and the decrease of transient variations in component performance maps by over 29%.
Controls↗
Turbine Electrified Energy Management for Single Aisle Aircraft
Electrified aircraft propulsion technology is being developed to reduce the environmental impacts of the aviation industry. This is prompting the exploration of potential uses and benefits of hybrid systems in which electric powertrains are integrated with more traditional gas turbine propulsion systems. Turbine Electrified Energy Management (TEEM) is an energy management approach for hybrid-electric architectures in which electric machines are connected to the turbofan shafts and used to suppress the off-design operation naturally associated with engine transients. This reduces the need to maintain a large amount of compressor operability margin, thus allowing further exploration of the engine design space. In this study, a 19,000 lbf engine within a parallel hybrid propulsion system is considered along with a 30,000 lbf standalone engine. Data from prior TEEM applications are used to approximate the electric machine sizing required to achieve operability benefits. The TEEM controller is shown to improve operability during transients through the reduction of stall margin undershoots and the decrease of transient variations in component performance maps by over 29%.
EAP↗
A Control Strategy for Turbine Electrified Energy Management
Hybrid electric propulsion architectures provide the infrastructure to enable additional benefits to the propulsion system that are otherwise unrealizable with the sole use of the current, state-of-the-art, gas-driven, turbine engines. The presence of electric machines (EMs) coupled to the shaft(s) of the turbine engine provide the ability to actively alter the operation of the engine to the benefit of the propulsion system and the aircraft it propels. This is the goal of the Turbine Electrified Energy Management (TEEM) concept, which at its broadest level addresses the management of energy across the electrified propulsion system. Prior work has demonstrated the use of this concept to alter steady-state operation and improve transient operability of a hybrid-electric propulsion system. The main benefits previously illustrated include the elimination of stability bleeds and expansion of the turbomachinery design space in order to enable more efficient designs. This paper focuses on the development of control strategies to implement the TEEM concept, and it explores several possible architecture variants for applying this concept. Comparison studies are conducted between a purely gas-driven turbofan (baseline engine configuration) and TEEM augmented variants of the baseline engine. The variants are distinguished by the shaft(s) that possess an EM. The configurations consider EMs on both shafts, an EM on the high pressure spool (HPS) only, and an EM on the low pressure spool (LPS) only. These configurations are referred to as the dual-spool configuration, the HPS configuration, and LPS configuration, respectively. The studies expose several options in configuring and controlling the system, including the use of a single EM coupled to a single shaft of a two-spool engine to positively impact the operability of both shafts. The studies also demonstrate the use of independently designed controllers for the electric machine(s) that allow for a decoupled control design process.
Electrified↗
A Control Strategy for Turbine Electrified Energy Management
Hybrid electric propulsion architectures provide the infrastructure to enable additional benefits to the propulsion system that are otherwise unrealizable with the sole use of the current, state-of-the-art, gas-driven, turbine engines. The presence of electric machines (EMs) coupled to the shaft(s) of the turbine engine provide the ability to actively alter the operation of the engine to the benefit of the propulsion system and the aircraft it propels. This is the goal of the Turbine Electrified Energy Management (TEEM) concept, which at its broadest level addresses the management of energy across the electrified propulsion system. Prior work has demonstrated the use of this concept to alter steady-state operation and improve transient operability of a hybrid-electric propulsion system. The main benefits previously illustrated include the elimination of stability bleeds and expansion of the turbomachinery design space in order to enable more efficient designs. This paper focuses on the development of control strategies to implement the TEEM concept, and it explores several possible architecture variants for applying this concept. Comparison studies are conducted between a purely gas-driven turbofan (baseline engine configuration) and TEEM augmented variants of the baseline engine. The variants are distinguished by the shaft(s) that possess an EM. The configurations consider EMs on both shafts, an EM on the high pressure spool (HPS) only, and an EM on the low pressure spool (LPS) only. These configurations are referred to as the dual-spool configuration, the HPS configuration, and LPS configuration, respectively. The studies expose several options in configuring and controlling the system, including the use of a single EM coupled to a single shaft of a two-spool engine to positively impact the operability of both shafts. The studies also demonstrate the use of independently designed controllers for the electric machine(s) that allow for a decoupled control design process.
Energy management↗
Spaced Orthocyclic Winding Pattern for Improved Die Compressed Coils
Winding fill, coil fill, or packing factor, is critical to the performance of many types of electromagnetic devices from electric machines to actuators, transformers, inductors, etc. One technique to increase the packing of conductors in the winding area is to compress round magnet wire conductors in a die, so that they deform and air voids between coil turns are removed. The winding layout of the coil turns on a bobbin before compression has a direct impact on the achievable coil fill and the damage to the coil insulation or conductors after compression. It is thought that winding the turns in an orthocyclic pattern on the bobbin before compression would minimize damage to the turns. This however causes turns to displace during the winding compression process. A new pre-compression winding pattern is proposed, a spaced orthocyclic winding, to minimize turn displacement and damage. A design of experiments study has been carried out to optimize this winding method and to compare it to the traditional orthocyclic winding.
33 ADVANCED PROPULSION SYSTEMS↗
A Novel Single-Turn Permanent Magnet Synchronous Machine for Electric Aircraft
Explore the source record for details and available documents.
Zeyu Cheng↗
Inert-Gas Electrical Discharge Machining
Holes in complicated hardware successfully drilled by dry EDM process that uses tubular copper electrode and argon or helium gas as dielectric medium.
Ramani, V.↗