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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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At least 253 records · Page 14
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

Magneto-Structural Combined Dimensional and Topology Optimization of Interior Permanent Magnet Synchronous Machine Rotors

A magneto-structural combined dimensional and topology optimization approach for interior permanent magnet synchronous machine (IPMSM) rotor design is proposed using the Solid Isotropic Material Penalization (SIMP) density-based topology optimization method. This method optimizes the location and dimensions of the permanent magnets (PMs) embedded in the rotor, while simultaneously optimizing the lamination flux barriers using topology optimization.To allow for the location and dimensions of the PMs to change while retaining the same number of mesh elements and connectivity, the mesh must be deformed. Mesh deformation is accomplished using a Laplace smoothing technique. To increase the range of PM displacement and size changes, the non-PM areas of the rotor design domain are divided into sub-regions along whose boundaries the mesh nodes are redistributed also using a Laplace smoothing algorithm. Three examples of IPMSM rotor optimizations are presented to demonstrate the proposed approach.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2022

Investigation of Cycle-to-Cycle Variations in Internal Combustion Engine Using Proper Orthogonal Decomposition

The understanding, modeling and control of the cycle-to-cycle variation (CCV) in the modern internal combustion engine (ICE) is a key scientific challenge to achieve stable engine operation. High CCV in the engine combustion chamber may contribute to partial burn, misfire and knock, which adversely affects the engine performance and may potentially damage the engine. The objective of the current study is to leverage high-fidelity numerical simulations to improve the understanding of the causes of CCV. Using the massively parallel code, Nek5000, multi-cycle, wall-resolved large-eddy simulations (LES) were performed for the General Motors (GM), Transparent Combustion Chamber (TCC-III) optical engine under motored operating conditions. Further, the large-scale structures of the in-cylinder flow were investigated using a triple proper orthogonal decomposition (POD) technique to explore the characteristics of different parts of the flow and their contributions to CCV. The kinetic energy of the subset of flow structures were determined and correlated between the intake and compression strokes. The insights from the analysis of the large-scale flow structures will be used to assist the development of improved engine designs with reduced CCV and enhance the engine performance.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2026

Cobalt-Free Lithium and Manganese Rich Cathodes for Electric Vehicle Applications: Influence of Inherent Properties on Temperature-Dependent Performance

Lithium- and manganese-rich (LMR) oxides are attractive options as next-generation, earth-abundant cathodes. Despite inherent properties that result in less-than-ideal performance, advancements in this class of cathodes toward commercialization have been steady. Herein, we report a benchmark study on the influence these inherent properties exert on the discharge rate of Co-free, LMR//graphite (Gr) cells as a function of temperature. Because low-temperature performance is an essential consideration in the design of electric vehicle cells, understanding the limitations of current LMR systems is essential in understanding their current applicability as well as strategies for improvement. This work identifies two major limitations in the rate performance of LMR//Gr cells and suggests several areas of focus where practical strategies may provide improvements.

25 ENERGY STORAGE↗
DOE OSTI2022

Application of Frequency Division Multiplexing and Neural Networks in the Operation and Diagnosis of the Stator Current and Shaft Position Sensors Used in Electric/Hybrid Vehicles

Fast, precise and robust sensing of currents and motor shaft angle is essential for the excellent performance of electric and hybrid vehicles (EV/HEV). Multiplexing techniques are commonly applied in data acquisition systems (DAQs) to digitize the signals sensed in EV/HEV drives. Frequency-division multiplexing (FDM) applied to get the signals from current sensors and resolver angular position sensor has advantages over conventional multiplexing approaches. However, problems such as aging and mechanical imperfections distort the outputs of those sensors, producing measurement errors of the angular position and currents. Conventional techniques designed to compensate for those errors cannot be applied in signals multiplexed in frequency. This paper proposes online techniques to detect and compensate for the distortions in the resolver sensor and current sensors. The demultiplexing process was adjusted to allow distortion detection and compensation. An auto-associative neural network (ANN) compensates for the current measurement error, while an energy-based technique is applied to compensate for the distortions in the resolver outputs. The obtained results show that the distortions were compensated, allowing a more accurate estimation of stator currents and angular position when FDM is applied in EV/HEV DAQs.

Pereira Pinto, Joao↗
DOE OSTI2023

Gradient-Descent-Based Learning Gain for Backstepping Controller and Disturbance Observer of Nonlinear Systems

This paper proposes a gradient-descent-based learning (GL) gain for backstepping controller and disturbance observer (DOB) of nonlinear system. The proposed method consists of the GL gain update law, controller, and DOB. The GL gain update law is proposed to adapt the control gain and DOB gain according to the direction that minimizes the cost function. The mathematical analysis reveals that the GL gain always has a positive sign and upper bound. The controller is designed via a backstepping procedure to track the desired output with GL control gain. The DOB is designed to estimate the unknown external disturbance with the GL DOB gain. Because the control and DOB gains are simultaneously tuned to achieve improved performance, the time consumption for tuning can be reduced. In addition, the peaking phenomenon can be avoided initially by a small initial value of GL gains. The stability of the closed-loop system is guaranteed using the input-to-state stability property. The performance of the proposed method was validated via simulations and experiments using a DC motor.

42 ENGINEERING↗
DOE OSTI2021

Electric Vehicle Basics

Electric vehicles (EVs) use electricity as their primary fuel or to improve the efficiency of conventional vehicle designs. EVs include all-electric vehicles, also referred to as battery electric vehicles (BEVs), and plug-in hybrid electric vehicles (PHEVs). In colloquial references, these vehicles are called electric cars, or simply EVs, even though some of these vehicles still use liquid fuels in conjunction with electricity. EVs are known for providing instant torque and a quiet driver experience. Other types of electric-drive vehicles not covered here include hybrid electric vehicles, which are powered by a conventional engine and an electric motor that uses energy stored in a battery, and fuel cell electric vehicles, which use a propulsion system similar to electric vehicles, where energy stored as hydrogen is converted to electricity by the fuel cell.

47 OTHER INSTRUMENTATION↗
DOE OSTI2023

Leak Detection and Sensor Importance Within a Solvent Extraction Process Abstract

In anticipation of the Special Nuclear Material test bed (Beartooth), Idaho National Laboratory has developed a smaller, multi-sensor system for analyzing the solvent extraction process. These systems will allow for research into nuclear fuel processing operations. The multi-sensor system consists of a row of centrifugal contactors and allows for measurement sources that are not traditionally used in the solvent extraction process to be explored including temperature, vibration, acoustics, pH, color, flow, and motor current. Currently, the solvent extraction process is very labor intensive and requires vigilant operators to identify the occurrence of leaks, which can be common during startup or after any change to the system. This study aims to locate leaks using non-traditional measurement sources then to identify which signals were of greatest importance in making this classification using Local Interpretable Model-agnostic Explanations. These results can be used to help solvent extraction process operators detect leaks and to inform future test beds designers to which sensors contain relevant, actionable information in this scenario.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2023

Electric Vehicle Basics

Electric vehicles (EVs) use electricity as their primary fuel or to improve the efficiency of conventional vehicle designs. EVs include all-electric vehicles, also referred to as battery electric vehicles (BEVs), and plug-in hybrid electric vehicles (PHEVs). In colloquial references, these vehicles are called electric cars, or simply EVs, even though some of these vehicles still use liquid fuels in conjunction with electricity. EVs are known for providing instant torque and a quiet driver experience. Other types of electric-drive vehicles not covered here include hybrid electric vehicles, which are powered by a conventional engine and an electric motor that uses energy stored in a battery that is charged by regenerative braking, not by plugging in, and fuel cell electric vehicles, which use a propulsion system similar to electric vehicles, where energy stored as hydrogen is converted to electricity by the fuel cell.

ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2025

Electric Vehicle Basics (French Translation)

Electric vehicles (EVs) use electricity as their primary fuel or to improve the efficiency of conventional vehicle designs. EVs include all-electric vehicles, also referred to as battery electric vehicles (BEVs), and plug-in hybrid electric vehicles (PHEVs). In colloquial references, these vehicles are called electric cars, or simply EVs, even though some of these vehicles still use liquid fuels in conjunction with electricity. EVs are known for providing instant torque and a quiet driver experience. Other types of electric-drive vehicles not covered here include hybrid electric vehicles, which are powered by a conventional engine and an electric motor that uses energy stored in a battery that is charged by regenerative braking, not by plugging in, and fuel cell electric vehicles, which use a propulsion system similar to electric vehicles, where energy stored as hydrogen is converted to electricity by the fuel cell. This is the French translation of NREL/FS-5400-87125.

ADVANCED PROPULSION SYSTEMS,DIRECT ENERGY CONVERSI↗
DOE OSTI2022

Accelerated Lifetime Test of the SRF Dressed Cavity/Tuner System for LCLS II HE Project

The off-frequency detune method is being considered for application in the LCLS-II-HE superconducting linac to produce multi-energy electron beams for supporting multiple undulator lines simultaneously [1]. Design of the tuner has been changed to deliver roughly 3 times larger frequency tuning range. Working requirements for off-frequency operation (OFO) state that cavities be tuned at least twice a month. This specification requires the in-crease of the tuner longevity by 20 times compared with LCLS-II demands. Accelerated longevity tests of the LCLS-II HE dressed cavity with tuner were conducted at FNAL's HTS. Detail analysis of wearing and impacts on performances of the tuner's piezo and stepper motor actuators will be presented. Additionally, results of longevity testing of the dressed cavity bellow, when cooled down to 2 K and compressed by 2.6 mm for roughly 2000 cycles, will be presented.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗
DOE OSTI2025

Spike-Free Adaptive Sliding Mode Control: Application to Permanent Magnet Synchronous Motors

A new methodology for adaptive sliding mode control (ASMC) has been widely used to improve the control performance in various systems. This method exhibits several advantages, including low sliding mode control (SMC) chattering, no knowledge of the system disturbance bound, and no overestimation of the control gain. Despite its advantages, this method can be hampered by the spike phenomenon, slow control gain convergence, and difficulty in achieving optimal performance under varying disturbances. Consequently, this article proposes a spike-free ASMC method with a disturbance observer (DOB) to address these problems. Previous ASMC methods have been analyzed via simulations to verify the aforementioned problems. Here, this analysis highlights the need for disturbance compensation and improvements in the SMC gain adaptation law. Therefore, a DOB is designed to mitigate the spike phenomenon by compensating for disturbances. Subsequently, an SMC gain adaptation law based on disturbance error estimation is designed to eliminate the spike phenomenon completely. The proposed adaptation law makes the SMC gain to converge to a slightly higher value than the disturbance estimation error. Consequently, the proposed method not only eliminates the spike phenomenon, but also ensures optimal performance under varying disturbances. The performance of the proposed method is experimen tally validated through a comparative study.

42 ENGINEERING↗
DOE OSTI2026

World’s First Vertical GaN based High Power (200 kW) Multi-level Traction Electric Drive Design

Vertical GaN (vGaN) technology leverages a fully conductive 3D semiconductor structure, enabling superior power density compared to GaN-on-Si and other wide bandgap devices. It offers a pathway to surpass cost and efficiency limitations of Si and SiC devices in traction applications. However, scaling for high-voltage, high-power systems remains challenging. This paper presents the design of an 800V, 200kW traction inverter utilizing vertical GaN devices. The inverter achieves ultra-high efficiency (> 99.5%) through advanced power module integration and employs multilevel neutral-point-less X-type (NPL.X) inverter topology to ensure optimal traction drive system performance. These innovations demonstrate the potential of vGaN for next￾generation electric propulsion systems.

Alam, Khorshed [General Motors LLC, Detroit, MI (U↗
DOE OSTI2023

Designing an Intrusion Detection for an Adjustable Speed Drive System Controlling a Critical Process

In this article, we address the cyber-security problem of industrial control systems (ICSs) when their sensor measurements may be compromised due to an attacker who has intercepted those measurements via a network. We introduce a general-purpose method “Dynamic Watermarking (DW)” to detect potential cyber-intrusions on speed sensor measurements within industrial control systems, which deploy an adjustable speed drive (ASD) to control a critical process. The DW method is injecting a random private low-amplitude signal with a zero mean Gaussian distribution, “watermark”, into one of the input phase voltages powering the ASD system. The watermark signal propagates through the system including pulse width modulation (PWM) power conversion stage and motor, then ultimately appears in the speed sensor measurements. By deploying two statistical DW tests with two proper thresholds, the system can detect potential cyber-intrusions or unobservable cyber-attacks such as replay attacks and false data injection attacks (FDIA). The DW method tested on a laboratory-scale ASD system experimentally to protect the system against cyber-intrusions. This system, powered by a commercial PWM drive operating at 208 V, 3-phase, and 3.7 kW, served as our experimental platform.

42 ENGINEERING↗
DOE OSTI2025

CalCharge CRADA000008852 Master Agreement Amendment 1, Battery Consortium – Proprietary Activities

Lawrence Berkeley National Laboratory (LBNL) is partnering with the California Clean Energy Fund to launch CalCharge, an energy storage innovation accelerator, comprised of emerging and established California companies and related organizations developing battery technologies for the electric/hybrid vehicle transportation, the electric grid and consumer electronics markets. The vision of CalCharge is to accelerate the pace of technology innovation, business growth, and cluster development. Calcharge programs will deliver technology acceleration and technical expertise to the energy storage industry, as well as policy and market development support to strengthen the regional economy. LBNL shall collaborate with CalCharge members on the analysis and testing of battery and energy storage technologies. LBNL’s work will include analysis and testing of external design, examination of materials and components either separately or as a whole, and providing data and observations resulting from each collaboration. LBNL shall maintain and provide access to LBNL specialized facilities for research activities performed by or for CalCharge members. In addition, LBNL will provide expertise for short-term consultation, interpretation of testing data, or to clarify technical obstacles if requested by a Member. Over this time frame, Calcharge partnered with several start-ups to provide analytical resources. Those companies include Halotechnics, ZAF Energy Systems, Volkswagen Group of America, Toyota Motor Corporation, and Ensor Inc.

25 ENERGY STORAGE↗
DOE OSTI2024

Enhanced tunable cavity development for axion dark matter searches using a piezoelectric motor in combination with gears

Most search experiments sensitive to quantum chromodynamics (QCD) axion dark matter benefit from microwave cavities, as electromagnetic resonators, that enhance the detectable axion signal power and thus the experimental sensitivity drastically. As the possible axion mass spans multiple orders of magnitude, microwave cavities must be tunable and it is desirable for the cavity to have a tunable frequency range that is as wide as possible. Since the tunable frequency range generally increases as the dimension of the conductor tuning rod increases for a given cylindrical conductor cavity system, we developed a cavity system with a large dimensional tuning rod in order to increase this. Here we, for the first time, employed not only a piezoelectric motor, but also gears to drive a large and accordingly heavy tuning rod, where such a combination to increase driving power can be adopted for extreme environments as is the case for axion dark matter experiments: cryogenic, high-magnetic-field, and high vacuum. Thanks to such higher power derived from the piezoelectric motor and gear combination, we realized a wideband tunable cavity whose frequency range is about 42% of the central resonant frequency of the cavity, without sacrificing the experimental sensitivity too much.

47 OTHER INSTRUMENTATION↗
DOE OSTI2023

Combined Dimensional and Topology Optimization of Synchronous Machine Rotors Using a Material Density Interpolation Method

This article presents a magneto-structural combined dimensional and topology optimization technique for interior permanent magnet synchronous machine (IPMSM) and wound field synchronous machine (WFSM) rotors. Dimensional changes to the permanent magnet (PM) and rotor winding location or size are accomplished by interpolating or projecting a smoothed Heaviside rectangular function representing the presence of PM material onto the IPMSM rotor design domain mesh, whereas the presence of copper material for WFSM rotor is interpolated in the same manner. A density based Solid Isotropic Material with Penalization (SIMP) topology optimization approach is then used to vary the presence of electrical steel in mesh elements to form flux barriers around the PM. The proposed method enforces a defined shape for the PM without requiring the mesh in the design domain to be deformed. Four examples are presented to demonstrate the technique: Two flat bar IPMSM, one V-shaped IPMSM, and a WFSM. Here, a comparative study is performed on one of the flat bar IPMSMs using Metamodel of Optimal Prognosis (MOP) based method.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2023

Process Capability Study on the Volume Manufacturing of a Complex Rotating Automotive Component in Laser Powder Bed Fusion Additive Manufacturing

Oak Ridge National Lab (ORNL) and Ford Motor Company used an AddUp FormUp 350 to print a turbo wheel geometry to show feasibility of laser powder bed fusion (L-PBF) additive manufacturing (AM) in producing cost-effective components for automotive industries. L-PBF AM has potential to disrupt traditional manufacturing techniques by introducing novel materials and geometries that cannot otherwise be produced. Fundamental challenges associated with L-PBF include limitations on printing overhang geometries and resulting surface finish. In this collaboration, ORNL and Ford partnered with AddUp to show the viability of using L-PBF for an AM design turbine wheel while reducing as-fabricated surface roughness. A cost model associated with mass production was produced to analyze benefits of pursing LPBF AM compared to investment casting.

36 MATERIALS SCIENCE↗