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At least 307 records · Page 17

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↗

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↗

An Integrated Electric Vehicle Drive Motor and Wireless Charger

This work proposes an in-wheel electric vehicle-motor in which the motor windings also act as receiver coils in a wireless charging system. Vehicle wireless charging systems normally include a receiver coil, compensation network, rectifier and battery charger. The proposed concept would eliminate the need for a separate receiver coil. Studies based on two-dimensional finite element analysis are carried out to verify the feasibility of the concept. An external rotor Halbach array rotor with single layer fractional slot concentrated wingdings is found to be a suitable motor topology which would enable the use of one or more motor coils as a receiver coil. The paper also discusses the design modifications and considerations required to enable this.

Rallabandi, Vandana↗

Machine finishes balls to high degree of roundness

Machine was developed to finish ball to roundness within 12.5 nm (half a microinch) from any types of hard material. Grinding and polishing to this tolerance is accomplished by lapping elements on four to six motor-driven spindles. Spindles are adjustably spring-loaded to ensure constant contact pressure on ball and are driven by variable speed electric motors.

Angele, W.↗

Magnetostrictive direct drive motor

Highly magnetostrictive materials such as Tb.3Dy.7Fe2, commercially known as TERFENOL-D, have been used to date in a variety of devices such as high power actuators and linear motors. The larger magnetostriction available in twinned single crystal TERFENOL-D, approx. 2000 ppm at moderate magnetic field strengths, makes possible a new generation of magnetomechanical devices. NASA researchers are studying the potential of this material as the basis for a direct microstepping rotary motor with torque densities on the order of industrial hydraulics and five times greater than that of the most efficient, high power electric motors. Such a motor would be a micro-radian stepper, capable of precision movements and self-braking in the power-off state. Innovative mechanical engineering techniques are juxtaposed on proper magnetic circuit design to reduce losses in structural flexures, inertias, thermal expansions, eddy currents, and magneto-mechanical coupling, thus optimizing motor performance and efficiency. Mathematical models are presented, including magnetic, structural, and both linear and nonlinear dynamic calculations and simulations. In addition, test results on prototypes are presented.

Naik, Dipak↗

High-Temperature Magnetic Bearings Being Developed for Gas Turbine Engines

Magnetic bearings are the subject of a new NASA Lewis Research Center and U.S. Army thrust with significant industry participation, and cooperation with other Government agencies. The NASA/Army emphasis is on high-temperature applications for future gas turbine engines. Magnetic bearings could increase the reliability and reduce the weight of these engines by eliminating the lubrication system. They could also increase the DN (diameter of bearing times the rpm) limit on engine speed and allow active vibration cancellation systems to be used, resulting in a more efficient, "more electric" engine. Finally, the Integrated High Performance Turbine Engine Technology (IHPTET) program, a joint Department of Defense/industry program, identified a need for a high-temperature (1200 F) magnetic bearing that could be demonstrated in their Phase III engine. This magnetic bearing is similar to an electric motor. It has a laminated rotor and stator made of cobalt steel. Wound around the stator's circumference are a series of electrical wire coils which form a series of electric magnets that exert a force on the rotor. A probe senses the position of the rotor, and a feedback controller keeps it centered in the cavity. The engine rotor, bearings, and casing form a flexible structure with many modes. The bearing feedback controller, which could cause some of these modes to become unstable, could be adapted to varying flight conditions to minimize seal clearances and monitor the health of the system.

Kascak, Albert F.↗

Speed Sensorless Induction Motor Drives for Electrical Actuators: Schemes, Trends and Tradeoffs

For a decade, induction motor drive-based electrical actuators have been under investigation as potential replacement for the conventional hydraulic and pneumatic actuators in aircraft. Advantages of electric actuator include lower weight and size, reduced maintenance and operating costs, improved safety due to the elimination of hazardous fluids and high pressure hydraulic and pneumatic actuators, and increased efficiency. Recently, the emphasis of research on induction motor drives has been on sensorless vector control which eliminates flux and speed sensors mounted on the motor. Also, the development of effective speed and flux estimators has allowed good rotor flux-oriented (RFO) performance at all speeds except those close to zero. Sensorless control has improved the motor performance, compared to the Volts/Hertz (or constant flux) controls. This report evaluates documented schemes for speed sensorless drives, and discusses the trends and tradeoffs involved in selecting a particular scheme. These schemes combine the attributes of the direct and indirect field-oriented control (FOC) or use model adaptive reference systems (MRAS) with a speed-dependent current model for flux estimation which tracks the voltage model-based flux estimator. Many factors are important in comparing the effectiveness of a speed sensorless scheme. Among them are the wide speed range capability, motor parameter insensitivity and noise reduction. Although a number of schemes have been proposed for solving the speed estimation, zero-speed FOC with robustness against parameter variations still remains an area of research for speed sensorless control.

Elbuluk, Malik E.↗

Pressure feedback control of electro-hydraulic actuators using fixed displacement hydraulic machines

This paper presents the development of a control strategy for Electro-Hydraulic Actuator (EHA) systems based on fixed displacement hydraulic machines. Although some previous studies on EHAs show benefits in terms of energy efficiency and regeneration capability compared to conventional hydraulic systems, few studies focus on the dynamic performance of EHAs. Unlike traditional valve-controlled systems, an EHA based on a fixed displacement pump typically relies on variation of the electric motor shaft speed to control the actuator velocity. This study shows that pressure feedback can be used to control the speed of the electric machine, thus achieving the required actuator/machine dynamic response. A simulation model is developed by including the EM, the hydraulic system, and the actuation system, which can give a realistic prediction of the EHA performance for a typical duty cycle. An open-circuit EHA previously proposed by the authors is used to validate the control strategy, and the simulation results show superior dynamic performance, exhibiting a reduction in response time and oscillatory behavior, compared to a feedforward EHA controller. Following the method presented in this study, it is possible to design a controller with a pressure feedback strategy for EHA systems with different size and actuation requirements

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Co-Design of a Fully Electric Hybrid Hydraulic-Electric Architecture (FE-HHEA) for Off-Road Mobile Machines

Off-road mobile machines, such as excavators and wheel-loaders, are typically actuated by hydraulics using internal combustion engines as their power sources. There is a trend towards fully electrifying these machines and improving their efficiencies due to environmental regulations and concerns. In this paper, a control co-design methodology is used to design a Fully Electrified Hybrid Hydraulic-Electric Architecture (FE-HHEA) for an excavator that drastically reduces energy consumption and minimizes the sizes of costly electric components. By optimizing both control operation and the physical design, the co-design methodology takes into account the interaction between these two aspects. The design methodology also illustrates how the system architecture evolves from the previously developed IC engine powered HHEA with the engine replaced by an electric motor to a seemingly very different architecture with fewer components. The optimized system reduces energy consumption by 71% over the baseline system and uses electrical components that are 1/3 the size of an alternate fully electric architecture.

33 ADVANCED PROPULSION SYSTEMS↗

Alternating-Current Motor Drive for Electric Vehicles

New electric drive controls speed of a polyphase as motor by varying frequency of inverter output. Closed-loop current-sensing circuit automatically adjusts frequency of voltage-controlled oscillator that controls inverter frequency, to limit starting and accelerating surges. Efficient inverter and ac motor would give electric vehicles extra miles per battery charge.

Krauthamer, S.↗

Two-Stage Centrifugal Fan

Fan designs are often constrained by envelope, rotational speed, weight, and power. Aerodynamic performance and motor electrical performance are heavily influenced by rotational speed. The fan used in this work is at a practical limit for rotational speed due to motor performance characteristics, and there is no more space available in the packaging for a larger fan. The pressure rise requirements keep growing. The way to ordinarily accommodate a higher DP is to spin faster or grow the fan rotor diameter. The invention is to put two radially oriented stages on a single disk. Flow enters the first stage from the center; energy is imparted to the flow in the first stage blades, the flow is redirected some amount opposite to the direction of rotation in the fixed stators, and more energy is imparted to the flow in the second- stage blades. Without increasing either rotational speed or disk diameter, it is believed that as much as 50 percent more DP can be achieved with this design than with an ordinary, single-stage centrifugal design. This invention is useful primarily for fans having relatively low flow rates with relatively high pressure rise requirements.

Converse, David↗

Reciprocating piston pump system with screw drive

A pump system of the reciprocating piston type is described, which facilitates direct motor drive and cylinder sealing. A threaded middle potion of the piston is engaged by a nut connected to rotate with the rotor of an electric motor, in a manner that minimizes loading on the rotor by the use of a coupling that transmits torque to the nut but permits it to shift axially and radially with respect to the rotor. The nut has a threaded hydrostatic bearing for engaging the threaded piston portion, with an oil-carrying groove in the nut being interrupted. A fluid emitting seal located at the entrance to each cylinder, can serve to center the piston within the cylinder, wash the piston, and to aid in sealing. The piston can have a long stroke to diameter ratio to minimize reciprocations and wear on valves at high pressures. The voltage applied to the motor can be reversed prior to the piston reaching the end of its stroke, to permit pressure on the piston to aid in reversing the motor.

Perkins, Gerald S.↗

NASA Electric Vertical Takeoff and Landing (eVTOL) Aircraft Technology for Public Services – A White Paper

History has shown that our personal life is highly dependent on the technology that people have developed. A strategic scan of the aerospace environment at the beginning of the 21st century strongly suggests that the world might be approaching a new age of airpower—the era of electrified/hybrid aircraft propulsion. Undeniably, starting from the Montgolfier Brothers balloon flight in 1783, to the Wright Brothers piston engine flight in 1903, and the jet engine of the 1960s, or the space age of today, one can say that leaps in propulsion technology have marked the different ages of human flight. The technological advancements, brought at the beginning of 21st century by the revolution in data exchange, computational power, sensors, wireless communication, internet, and autonomy, contributed to the vision of this new age of propulsion we are approaching. Historically, conventional vertical takeoff and landing (VTOL) aircraft have been equipped with propulsion units relying on complex internal combustion machines (turbines, piston engines, for example), and complex mechanical arrangements (gearboxes, shafts, variable pitch propeller). By contrast, electric VTOL aircraft (eVTOL)1 rely on simpler propulsion units (electric motors and in some cases fixed-pitch propellers). This promotes redundancy and improves tolerance to failures, in turn improving safety. The use of simpler electric propulsion units should also allow significant acquisition and operating cost reductions. Whether full-electric (relying solely on batteries) or hybrid-electric (relying on a combination of batteries, fuel-powered engines, and generators.), eVTOLs are also expected to generate less noise and air pollution than conventional aircraft with similar payloads. According to the 2019 Annual Review of IATA (International Air Transport Association) [ref.1], due to an expected increase in air transport traffic by 5% every year and a doubling of air transport passenger numbers to 8.2 billion by 2037 significant challenges are posed to the aviation industry. Furthermore, this report does not factor in the expected demand for short-range (intra-city) air transportation, which is in development and yet to be operational. The increased demand to fly creates a responsibility to expand in a sustainable manner and an endeavor to develop more environmentally-friendly aircraft. eVTOL aircraft, either piloted or autonomous, is gathering considerable interest worldwide. Modern and novel full-electric or hybrid-electric eVTOL configurations enable a new paradigm shift in air transportation as the aviation industry remains committed to its goals of carbon-neutral growth from 2020 onwards and cutting CO2 emissions to half 2005 levels by 2050. While electric power has been used for decades, recent developments in mobile electric/hybrid propulsion coupled with advanced materials and autonomous systems may create the possibility to transition into the next age of air mobility propelled by electric/hybrid VTOL aircraft technology. Although eVTOL aircraft might seem like an incremental improvement or even a counterintuitive regression with regard to past VTOL development, it has in fact the potential to transform air mobility across a wide range of government applications. Previous transformations in aviation generated dramatic leaps in performance, but the cost was commensurate with performance, limiting quantity produced. This next age appears to take a different approach. Performance may not increase, but at this moment technology is poised for future urban mobility that will spawn commercial passenger drone services, that is, autonomous (pilotless) air taxis and thereby add a new dimension to the urban transportation mix of the future [ref. 2]. Advances in electric propulsion, autonomous flight technology, and 5G communication networks will enable this fast new-growing market to become a reality. It is now time to envision the introduction of electric/hybrid eVTOL aircraft for Public Services2. We believe that in the next decades eVTOL aircraft will have the potential to become an essential tool to Public Service agencies around the world in applications such as firefighting, public safety, search and rescue, disaster relief and law enforcement. This is due to several major factors. • First, with the increasing popularity of small, unmanned aircraft vehicles (UAVs) or drones, many companies today are focusing on the development of passenger UAVs designed to accommodate up to five passengers or equivalent cargo payload. Many such configurations are electric or hybrid-electric designs with VTOL capabilities. Several of these projects have started a flight test program and many more are expected to be in the experimental and development phase in 2020. Such revolutionary vehicles could be in commercial operations by 2030. These eVTOL systems could be ready for selected Public Services missions even sooner. • Second, although these advanced eVTOL vehicles under development still need access to fuel (hybrid) and/or electric charging capability, they can take off and land from almost anywhere. Therefore, such vehicles, both manned and unmanned can be successfully integrated for the critical missions of the Public Services with extra deployment flexibilities. • Third, advancement in electric propulsion systems in the automotive industry together with NASA’s leading efforts in electrification of aircraft propulsion systems, FAA’s ongoing active eVTOL certification programs, and EASA’s proposed framework for the certification of electric/hybrid small category VTOL aircraft in Europe [ref. 3] will help accelerate industry electric propulsion system development and integration. • Finally, eVTOL vehicles could be deployed for Public Services sooner than air taxi or other commercial applications, since Public Services missions may be more easily approved based on specific mission criteria, localized airworthiness authority for public-use aircraft3, and are normally operating under centralized airspace management and control by the theater command. Moreover, public perception and acceptance are generally less of a concern when operations save lives and benefit the wider community. The prioritized introduction of eVTOL aircraft in Public Services is ambitious, but we believe it is achievable in the coming decades if fundamental enablers (people and technologies) are engaged in defining the objectives and needs of these missions. The revolution that is currently taking place in eVTOL aircraft represents an unprecedented opportunity to develop a safer, more affordable, more available and more environmentally friendly future of vertical flight. To ensure that these novel aircraft meet the future expectations of Public Services, it is essential to take a collaborative and multi-disciplinary approach to their development, across engineering disciplines, policy-making, program management, business case development, manufacturing, and flight demonstrations. It should be noted that the term eVTOL (in the near term) used throughout this publication implies aircraft capable of transporting up to 5 persons which may or may not include a pilot if operated fully autonomously, assuming an average of 200 pounds (91 kg) per person or equivalent payload and a range up to 60 miles plus a suitable reserve. Hybrid or hydrogen powered eVTOLs would have greater range. For example, a “3-seat” eVTOL aircraft may only be able to carry two fully equipped firemen, and payload capacity is more relevant when used for the supply mission. Moreover, this paper concentrates on the “last-mile” solutions with a deployment time of no more than 6 hours. Although not specifically discussed in this document, it is understood that the future of Transformative Vertical Flight in general and Public Services, in particular, will also involve smaller UAVs that will undoubtedly play a crucial role in future aerial operations. For example, smaller unmanned aircraft may be used to dispatch medical supplies, portable filtration systems or perform the Search task of future Search and Rescue (SAR) operations. Close collaboration between the aircraft industry, the Civil Aviation Authorities (CAA), e.g., Federal Aviation Administration (FAA), European Aviation Safety Agency (EASA), Transport Canada Civil Aviation (TCCA) and the Department of Defense (DoD) certifiers, will help identify Public Services requirements, define expectations and limit development cost and timescales. Take the US Air Force Agility Prime as an example, the majority of the eVTOL application opportunities and mission elements identified are in line with the NASA TVF WG-4 objectives and use cases. Together, it forms a strong partnership to accelerate the development, certification, and practical deployment for public service missions. The US Air Force Agility Prime has been a collaboration partner on this white paper, and provided valuable input and recommendations. Most of the eVTOL public service mission elements discussed in this paper and additional use cases envisioned by the NASA TVF WG-4 team are shared by the Agility Prime program. The focus and efforts of the Agility Prime in product and system development, industry and government partnership, accelerated certifications as well as early test and deployment are totally in sync with the path forward recommended by this white paper. This kind of collaboration and partnership will help enable the practical use of the eVTOL for public service missions, benefit the eVTOL public acceptance, and accelerate the eVTOL industry revolution.

Johnny T. Doo↗

Two-Speed Gearbox Dynamic Simulation Predictions and Test Validation

Dynamic simulations and experimental validation tests were performed on a two-stage, two-speed gearbox as part of the drive system research activities of the NASA Fundamental Aeronautics Subsonics Rotary Wing Project. The gearbox was driven by two electromagnetic motors and had two electromagnetic, multi-disk clutches to control output speed. A dynamic model of the system was created which included a direct current electric motor with proportional-integral-derivative (PID) speed control, a two-speed gearbox with dual electromagnetically actuated clutches, and an eddy current dynamometer. A six degree-of-freedom model of the gearbox accounted for the system torsional dynamics and included gear, clutch, shaft, and load inertias as well as shaft flexibilities and a dry clutch stick-slip friction model. Experimental validation tests were performed on the gearbox in the NASA Glenn gear noise test facility. Gearbox output speed and torque as well as drive motor speed and current were compared to those from the analytical predictions. The experiments correlate very well with the predictions, thus validating the dynamic simulation methodologies.

Lewicki, David G.↗

Design and Development of a 200-kW Turbo-Electric Distributed Propulsion Testbed

The National Aeronautics and Space Administration (NASA) Armstrong Flight Research Center (AFRC) (Edwards, California) is developing a Hybrid-Electric Integrated Systems Testbed (HEIST) Testbed as part of the HEIST Project, to study power management and transition complexities, modular architectures, and flight control laws for turbo-electric distributed propulsion technologies using representative hardware and piloted simulations. Capabilities are being developed to assess the flight readiness of hybrid electric and distributed electric vehicle architectures. Additionally, NASA will leverage experience gained and assets developed from HEIST to assist in flight-test proposal development, flight-test vehicle design, and evaluation of hybrid electric and distributed electric concept vehicles for flight safety. The HEIST test equipment will include three trailers supporting a distributed electric propulsion wing, a battery system and turbogenerator, dynamometers, and supporting power and communication infrastructure, all connected to the AFRC Core simulation. Plans call for 18 high performance electric motors that will be powered by batteries and the turbogenerator, and commanded by a piloted simulation. Flight control algorithms will be developed on the turbo-electric distributed propulsion system.

distributed↗

High-Lift Propeller Noise Prediction for a Distributed Electric Propulsion Flight Demonstrator

Over the past several years, the use of electric propulsion technologies within aircraft design has received increased attention. The characteristics of electric propulsion systems open up new areas of the aircraft design space, such as the use of distributed electric propulsion (DEP). In this approach, electric motors are placed in many different locations to achieve increased efficiency through integration of the propulsion system with the airframe. Under a project called Scalable Convergent Electric Propulsion Technology Operations Research (SCEPTOR), NASA is designing a flight demonstrator aircraft that employs many "high-lift propellers" distributed upstream of the wing leading edge and two cruise propellers (one at each wingtip). As the high-lift propellers are operational at low flight speeds (take-off/approach flight conditions), the impact of the DEP configuration on the aircraft noise signature is also an important design consideration. This paper describes efforts toward the development of a mulit-fidelity aerodynamic and acoustic methodology for DEP high-lift propeller aeroacoustic modeling. Specifically, the PAS, OVERFLOW 2, and FUN3D codes are used to predict the aerodynamic performance of a baseline high-lift propeller blade set. Blade surface pressure results from the aerodynamic predictions are then used with PSU-WOPWOP and the F1A module of the NASA second generation Aircraft NOise Prediction Program to predict the isolated high-lift propeller noise source. Comparisons of predictions indicate that general trends related to angle of attack effects at the blade passage frequency are captured well with the various codes. Results for higher harmonics of the blade passage frequency appear consistent for the CFD based methods. Conversely, evidence of the need for a study of the effects of increased azimuthal grid resolution on the PAS based results is indicated and will be pursued in future work. Overall, the results indicate that the computational approach is acceptable for fundamental assessment of low-noise high-lift propeller designs. The extent to which the various approaches may be used in a complementary manner will be further established as measured data becomes available for validation. Ultimately, it is anticipated that this combined approach may be used to provide realistic incident source fields for acoustic shielding/scattering studies on various aircraft configurations.

Nark, Douglas M.↗

Novel Air System for 300 kW Heavy Duty Fuel Cell

Hydrogen fuel cell powered vehicles for heavy duty trucks is a potential path for reducing heavy duty vehicle emissions in the future. The air handling system delivers the proper amount of air (oxygen) to react with fuel (hydrogen) in the fuel cell to produce power. Air delivery requires significant power and is the largest parasitic loss for a 300 kW fuel cell. Today’s systems use an electric motor to power an air compressor that supplies oxygen to the fuel cell stack. In addition to parasitic power loss, hydrogen fuel cell systems often have reliability issues associated with the air handling system. Reliability is of significant concern for heavy duty applications (especially long-haul applications). This project aims to improve both the electrical power consumption and reliability of hydrogen fuel cell air handling systems to meet the needs of heavy duty on-highway vehicle applications. The air handling is provided by a twin vortices series (TVS) compressor in addition to adding a TVS expander to recover waste heat energy back into the compressor. The final configuration includes a 600 V, 39 kW motor connected with a single shaft to the compressor and expander. This configuration reduced the total electrical power consumption from 48.6 kW to 37 kW at full load, 27 kW to 9 kW at half load and 0.44 kW to 0.22 kW at idle. The response time requirement was to be less than 2 seconds while the final demonstration yielded 0.62 sec. The study includes additional technologies including water dosing into the compressor, a recuperator and elimination of the intercooler.

Reich, Evan [Eaton Corporation, Southfield, MI (Un↗

Straight and chopped dc performance data for a General Electric 5BT 2366C10 motor and an EV-1 controller

Performance data on the General Electric 5BT 2366C10 series wound dc motor and EV-1 Chopper Controller is supplied for the electric vehicle manufacturer. Data is provided for both straight and chopped dc input to the motor, at 2 motor temperature levels. Testing was done at 6 voltage increments to the motor, and 2 voltage increments to the controller. Data results are presented in both tabular and graphical forms. Tabular information includes motor voltage and current input data, motor speed and torque output data, power data and temperature data. Graphical information includes torque-speed, motor power output-speed, torque-current, and efficiency-speed plots under the various operating conditions. The data resulting from this testing shows the speed-torque plots to have the most variance with operating temperature. The maximum motor efficiency is between 86% and 87%, regardless of temperature or mode of operation. When the chopper is utilized, maximum motor efficiency occurs when the chopper duty cycle approaches 100%.

Edie, P. C.↗