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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 343 records · Page 19
All sourcesNASA NTRSDOE OSTI
NASA NTRS2021

Revolutionary Vertical Lift Technology (RVLT) Side-By-Side Hybrid Concept Vehicle Powertrain Dynamic Model

The Side-by-Side (SBS) Hybrid is one of several Revolutionary Vertical Lift Technology (RVLT) concept aircraft identified by NASA to investigate Urban Air Mobility (UAM) requirements. This paper presents a dynamic model of the SBS Hybrid powertrain built using the Toolbox for the Modeling and Analysis of Thermodynamic Systems (T-MATS) and the Electrical Modeling and Thermal Analysis Toolbox (EMTAT). The model consists of the rotors, electrical power system, and turboshaft engines connected through freewheeling clutches, gearboxes, and multiple shafts. This research effort models the complex behavior of the powertrain, including the operation of the freewheeling clutches and electrical power system at the simulation time scale of the shaft dynamics. Several simulations highlight the key features present in the model and demonstrate its operation.

powertrain↗
NASA NTRS2020

Efficient Thermal Management for Sampling Arm Actuators

An electric actuator incorporating novel features for thermal management is designed and analyzed. Reducing intra-actuator thermal resistance is not only beneficial for cold missions (helping to pre-heat the gearbox) but can also enable high power applications in benign environments. The proposed design increases the thermal conductance between the motor windings and the motor casing by at least two orders of magnitude over the state of practice actuator designs. The design leverages Additive Manufacturing (AM) to integrate a complex 3 dimensional Oscillating Heat Pipe (OHP) directly within the actuator structure. A baseline actuator without this thermal management feature was fabricated. Testing was conducted to evaluate the temperature difference between actuator components at a range of motor winding heat dissipations. An analysis of a proposed revised design incorporating OHPs into the input structure indicated an increase in the effective thermal conductivity of 8 and 22 times for the nominal and start-up modes respectively. In addition, the thermal conductance between the windings and the input structure is increased by a factor of 90, and the thermal conductance between the windings and the gear assembly is increased by a factor of 200 with the proposed design.

Odagiri, Kimihide↗
NASA NTRSDate not supplied

Preliminary Electric Motor Drivetrain Optimization Studies for Urban Air Mobility Vehicles

Abstract- Electric and hybrid electric aircraft require high performance and reliable electric motor drivetrains. These drivetrains, consisting of a motor, an inverter, a gearbox, and a thermal management system, are highly coupled systems where the design of individual components in the drivetrain will significantly affect the sizing and performance of the other components in the system. In this paper, a preliminary co-optimization tool for electric motor drivetrains for Urban Air Mobility vehicles is presented. An example study with the tool is completed for NASA’s RVLT quadrotor concept vehicle.

Thomas Tallerico↗
NASA NTRSDate not supplied

Preliminary Electric Motor Drivetrain Optimization Studies for Urban Air Mobility Vehicles

Electric and hybrid electric aircraft require high performance and reliable electric motor drivetrains. These drivetrains, consisting of a motor, an inverter, a gearbox, and a thermal management system, are highly coupled systems where the design of individual components in the drivetrain will significantly affect the sizing and performance of the other components in the system. In this paper, a preliminary co-optimization tool for electric motor drivetrains for Urban Air Mobility vehicles is presented. An example study with the tool is completed for NASA’s RVLT quadrotor concept vehicle.

Thomas Tallerico↗
NASA NTRSDate not supplied

Cryobotics: Extreme Cold Environment Testing

The extreme cold environment test chamber was designed to conduct research in cryobotics; an area of study that focuses on robotic systems and rotating machinery operating in extreme cold environments including Earth, low Earth orbit, Mars, Moon, asteroids, Solar orbit, planetary orbit, or those encountered during travel among these destinations. The test chamber incorporates a modular dynamometer, consisting of a variety of brakes, torque sensors and motors to be easily interchanged between tests. Each test employs a unique test profile that incorporates different setpoints of applied torques and velocities for a given period or number of revolutions. The modularity of the dynamometer setup allows for any combination of motor, gearbox to be tested. The chamber has been used to run tests for various projects including Bulk Metallic Glass Gears (BMGG), Volatiles Investigating Polar Exploration Rover (VIPER), Intelligent Payload Experiment (IPEX), and Pilot Excavator. Various upgrades have been made to the extreme cold environment test chamber for the use of cryobotic research. These upgrades greatly increased the autonomous capabilities of the test set up by providing redundancies in the hardware and software. The redundancies were primarily added to protect the integrity of the cryohead. A new strapping and insulation method was performed to create the thermal conductive path from the actuators to the cryohead. The software was upgraded to include temperature setpoint control, further increasing the autonomous capabilities of the test. This paper goes into detail regarding the upgrades made to the extreme cold environment test chamber, as well as highlights the results from a COLDArm acceptance test.

Jonathan Drew Smith↗
NASA NTRSDate not supplied

Designing A Coaxial Quadrotor for Urban Air Mobility

The NASA Revolutionary Vertical Lift Technology Project has created several Urban Air Mobility reference design vehicles to aid the burgeoning UAM industry. With over 700 conceptual designs already proposed, much interest has been generated across many unique configurations to bring vertical flight to the masses. The quadrotor configuration is one of the NASA reference vehicles, and does have some conceptual designs proposed in the industry. This study looks at the conceptual design of a coaxial quadrotor vehicle as an extension of the NASA RVLT quadrotor concept vehicle. The coaxial quadrotor has a similar layout to the quadrotor, but with a coaxial rotor at each of the four corners of the vehicle. Trade studies carried out using the NASA Design and Analysis of Rotorcraft (NDARC) tool analyzed the vehicle sizing, design gross weight, and performance for four design variants. The variants all use the baseline coaxial quadrotor layout, but analyze the effects of two major design choices: 1) variable pitch vs variable speed rotor control, and 2) motor to rotor power transmission via a gearbox vs direct-drive. The results indicate one design variant may have more benefits on some of the design objectives while another configuration may better satisfy the others.

UAM↗
NASA NTRS2024

Revolutionary Vertical Lift Technology Lift + Cruise Concept Vehicle Powertrain Dynamic Model

The Lift + Cruise (L+C) is one of several Revolutionary Vertical Lift Technology (RVLT) concept aircraft identified by NASA to investigate Urban Air Mobility (UAM) requirements. This six-passenger vehicle has a conventional tube-and-wing configuration, but with eight lift rotors (four on each wing) and a pusher rotor on the tail. This arrangement allows it to take off and land vertically as well as fly like an airplane. This report presents a novel dynamic model of the L+C powertrain built using the Toolbox for the Modeling and Analysis of Thermodynamic Systems (T-MATS) and the Electrical Modeling and Thermal Analysis Toolbox (EMTAT), both of which are NASA-developed toolboxes, and together are capable of modeling hybrid-electric powertrain architectures. This research effort models the complex behavior of the powertrain at the mechanical timescale (15 to 20 ms). The model consists of a turboshaft engine, generator, direct current bus, energy storage management system, gearboxes, and electric propulsor systems coupled together to create a dynamic model that mimics the operation of the multidomain powertrain. Two control algorithms, designed to equalize the power consumed to the power produced, are compared to assess their practicality: (1) independent proportional-integral (PI) control and (2) linear quadratic integral regulator (LQIR) control. Simulation results highlight the key features present in the model and demonstrate its operation under the two control schemes.

revolutionary vertical lift technology↗
NASA NTRS2024

Very High Cycle Fatigue Testing of AMS 6308 Steel

Lightweight and reliable gearboxes are required for helicopters and future electrical vertical take-off and landing aircraft. Mechanical gears in these applications experience more than 10 7 million fatigue cycles over their operating life and between maintenance intervals. Fatigue data for gear steels above 10 7 cycles is rare due to the testing time required to reach these cycle counts with traditional methods. In this paper, ultrasonic fatigue testing is used to collect mechanical fatigue data on AMS 6308 steel in the 10 7 to 1010 cycle regime.

Thomas Tallerico↗
DOE OSTI2021

Wind Turbine Drivetrain Reliability Assessment and Remaining Useful Life Prediction

This presentation describes a methodology for predicting probability of failure of wind turbine gearbox bearings failed by axial cracking. This methodology was applied to a commercial MW size wind plant and generated results were correlated with actual failures. This work is partnered with WindESCo and funded through DOE's Technology Commercialization Fund.

49 EE - Wind and Water Power Program - Wind (EE-4W↗
DOE OSTI2024

Paper #50 Preliminary Sizing of Active Magnetic Bearings for sCO2 Waste-Heat Recovery Application

The team of Southwest Research Institute (SwRI) and GE Vernova (GE) is executing a project developing conceptual designs of high-temperature active magnetic bearings (AMBs) for sCO2 machinery applications. The goals of the project are to develop conceptual designs for radial and thrust AMBs capable of operating in sCO2 environments up to 1000°F. A waste-heat recovery (WHR) application with hermetic machinery is used as a reference case to apply AMBs. This application was previously investigated to compare hermetic machinery enabled by process-lubricated bearings and high-speed motors/generators with traditional machinery configurations using oil-lubricated bearings, gearboxes, and grid-frequency electric machines. In this paper, AMBs are sized for the WHR application machinery. Load capacity estimates are made using first-principle-derived formulas that consider operation at elevated temperatures. Estimates of linearized AMB system coefficients are also made to aid future controller development. Rotor models are developed that account for AMB rotor geometry and housing space requirements. Rotordynamics studies are performed to identify reasonable target values for closed-loop AMB stiffness and closed-loop AMB damping. These target values will be used in future control studies.

Lipham, Robert↗
DOE OSTI2024

Axion Dark Matter EXperiment 2A Cavity Characterization

We cooled the ADMX 2A cavities down to 5K and found the Q-factors for various tunings, which were about a factor of five larger than the Q-factors from the previous cooldown. We also found that the tuning mechanism with the piezo motor and gearbox is not currently equipped to handle cryogenic temperatures. We created an experimental warm bead pull setup using piezo motors, an alumina bead, a pulley system, and a distance calibrating script. We found that the bead pull method can successfully show us the reflection-induced electric field mode structure. This technique allowed us to differentiate between different TE and TM modes near mode crossings. However, some bead pull sweeps produced noisy or asymmetrical results, possibly due to asymmetries in the tuning rod orientation or antenna. Future iterations of the bead pull method can help us estimate the cavity form factor and maximize our scan range near mode crossings.

Maglione, D.↗
DOE OSTI2024

Wind Turbine Maintenance Costs: Assessing the Potential of Gear Oil Improvements

Wind turbine operations & maintenance (O&M) costs constitute a sizable portion of total energy cost for wind power. There are many components in a utility-scale wind turbine that need to be lubricated with either oil or grease. This study uses gearbox oil as an example and assesses how lubricant technology improvements may impact wind turbine power production and levelized cost of energy. Using the modeling tools (i.e., WOMBAT, reV, and SAM) developed at National Renewable Energy Laboratory and lubrication oil technology scenarios defined based on inputs provided by ExxonMobil and industry stakeholders, we quantify the potential for increasing energy production and reducing maintenance costs across the current and future U.S. fleet of wind turbines as a result of improvements in lubrication technologies. The modeled improvements reduce the median levelized cost of energy by 1-2% across the U.S. fleet. Cumulative saving from gear oil technology improvements in 2050 for U.S. fleet is estimated to be approximately $6 billion. Extending the lubricant replacement interval has a larger impact on total cost and energy production than reducing lubricant cost.

costs↗
DOE OSTI2025

Cryogenic Gear System for ADMX Tuning Cavity

The Axion Dark Matter Experiment (ADMX) searches for axions by converting them into detectable photons using resonant microwave cavities at cryogenic temperatures. A precise tuning system is needed to adjust cavity frequency without adding thermal load or electromagnetic interference. This project developed and tested a 1000 to 1 gear reduction system made from PEEK, a low thermal conductivity plastic with good dimensional stability and self lubrication at low temperatures. A compound gear train design of five 3 to 1 stages and one 4 to 1 stage achieves high reduction within a 40 mm diameter compact housing. Prototypes were 3D printed and later CNC machined in PEEK using Fusion 360 and Bantam Tools to confirm manufacturability. Prototype testing showed smooth gear engagement and no slipping. The final gearbox improves cavity tuning precision for axion searches while protecting cryogenic conditions.

Ortega, Giancarlo [Marquette U.]↗
DOE OSTI2026

Grid and Wind Transient Ride Through Assessment of Type-5 Synchronous Wind Turbine

The integration of the inverter-based renewable energy resources is increasing and replacing conventional synchronous generators in the evolving bulk power system (BPS), impacting the system inertia along the way. Also, the limited over-current capability of power electronic converters continues to deteriorate the grid strength of the evolving power systems. Type-5 wind turbines have the potential to mitigate these problems because this configuration interfaces with the grid through a synchronous generator; hence, its operation and consequent grid impacts might mimic the conventional synchronous generator. The drivetrain of this type of turbines, however, is different from the more common Type-3 and Type-4 turbines. A hydraulic torque converter and gearbox with torque limiting feature are integral parts of a Type-5 wind turbine drivetrain, to isolate the wind speed variations at the wind turbine rotor from the grid connected generator side. This supports the synchronous operation of the generator. However, high fidelity models of Type-5 wind turbine drivetrain including these core components are not openly and widely available for grid integration and transient stability studies. Moreover, Type-5 turbines are not commonly deployed and hence its power generation and frequency stability characteristics are not widely publicized. This hinders appropriate assessment of Type-5 wind power plant's contribution to bulk grid resilience. This work provides transient stability assessment of a standalone Type-5 wind turbine. Normal operation and grid transient studies are performed to see the step load change and wind speed disturbance impacts on the Type-5 drivetrain and generation dispatch. Preliminary results show that Type-5 wind turbines can support load changes of between 0.6 p.u to 1.15 p.u. Beyond this point, the synchronization of the generator starts to deviate from its set point.

17 - WIND ENERGY↗
DOE OSTI2021

Gaining Insights in Loading Events for Wind Turbine Drivetrain Prognostics

Wind energy is one of the largest sources of renewable energy in the world. To further reduce the operations and maintenance (O&M) costs of wind farms, it is essential to be able to accurately pinpoint the root causes of different failure modes of interest. An example of such a failure mode that is not yet fully understood is white etching cracks (WEC). This can cause the bearing lifetime to be reduced to 5–10% of its design value. Multiple hypotheses are available in literature concerning its cause. To be able to validate or disprove these hypotheses, it is essential to have historic high-frequency measurement data (e.g., load and vibration levels) available. In time, this will allow linking to the history of the turbine operating data with failure data. This paper discusses the dynamic loading on the turbine during certain events (e.g., emergency stops, run-ups, and during normal operating conditions). By combining the number of specific events that each turbine has seen with the severity of each event, it becomes possible to assess which turbines are most likely to show signs of damage.

49 EE - Wind and Water Power Program - Wind (EE-4W↗
DOE OSTI2024

Wind Turbine Design Guideline DG03: Yaw and Pitch Bearings

This design guideline describes the design criteria, calculation methods, and applicable standards recommended for use in performance and life analyses of ball and roller (rolling) bearings for yaw and pitch motion support in wind turbine applications. The formulae presented here for rolling bearing analytical methods and bearing-life ratings are consistent with methods currently used by wind turbine designers and rolling bearing manufacturers. The original yaw and pitch bearing design guideline was first drafted in 1999 by industry members and finally published in 2009 by the National Renewable Energy Laboratory. It was conceived as the third in a series of design guidelines, but it was the only one actually published by NREL and since has been known by the name "DG03." Other design guidelines were started, but instead of being published by NREL, they eventually became some of the International Electrotechnical Commission wind turbine standards in use today. This updated design guideline includes advances in research and field experiences made between 2009 and 2023. A better understanding of the operating conditions and damage mechanisms, advances in computational design, and publicly available test results facilitate more reliable yaw and pitch bearing designs.

17 WIND ENERGY↗
NASA NTRS2014

Exploring Advanced Technology Gas Turbine Engine Design and Performance for the Large Civil Tiltrotor (LCTR)

A Large Civil Tiltrotor (LCTR) conceptual design was developed as part of the NASA Heavy Lift Rotorcraft Systems Investigation in order to establish a consistent basis for evaluating the benefits of advanced technology for large tiltrotors. The concept has since evolved into the second-generation LCTR2, designed to carry 90 passengers for 1,000 nautical miles at 300 knots, with vertical takeoff and landing capability. This paper explores gas turbine component performance and cycle parameters to quantify performance gains possible for additional improvements in component and material performance beyond those identified in previous LCTR2 propulsion studies and to identify additional research areas. The vehicle-level characteristics from this advanced technology generation 2 propulsion architecture will help set performance levels as additional propulsion and power systems are conceived to meet ever-increasing requirements for mobility and comfort, while reducing energy use, cost, noise and emissions. The Large Civil Tiltrotor vehicle and mission will be discussed as a starting point for this effort. A few, relevant engine and component technology studies, including previous LCTR2 engine study results will be summarized to help orient the reader on gas turbine engine architecture, performance and limitations. Study assumptions and methodology used to explore engine design and performance, as well as assess vehicle sizing and mission performance will then be discussed. Individual performance for present and advanced engines, as well as engine performance effects on overall vehicle size and mission fuel usage, will be given. All results will be summarized to facilitate understanding the importance and interaction of various component and system performance on overall vehicle characteristics.

vehicle sizing↗
NASA NTRS2015

Exploring Propulsion System Requirements for More and All-Electric Helicopters

Helicopters offer unique capabilities that are important for certain missions. More and all-electric propulsion systems for helicopters offer the potential for improved efficiency, reliability, vehicle and mission capabilities as well as reduced harmful emissions. To achieve these propulsion system-based benefits, the relevant requirements must be understood and developed for the various component, sub-component and ancillary systems of the overall propulsion system. Three representative helicopters were used to explore propulsion and overall vehicle and mission requirements. These vehicles varied from light utility (one to three occupants) to highly capable (three crew members plus ten passengers and cargo). Assuming 15 and 30 year technology availability, analytical models for electric system components were developed to understand component and ancillary requirements. Overall propulsion system characteristics were developed and used for vehicle sizing and mission analyses to understand the tradeoffs of component performance and weight, with increase in vehicle size and mission capability. Study results indicate that only the light utility vehicle retained significant payload for an arbitrary 100 nautical mile range assuming 15 year technology. Thirty year technology assumptions for battery energy storage are sufficient to enable some range and payload capabilities, but further improvements in energy density are required to maintain or exceed payload and range capabilities versus present systems. Hydrocarbon-fueled range extenders can be prudently used to recover range and payload deficiencies resulting from battery energy density limitations. Thermal loads for electric systems are low heat quality, but seem manageable. To realize the benefits from more and all-electric systems, technology goals must be achieved, as well as vehicles, missions and systems identified that are best suited to take advantage of their unique characteristics.

mission analysis↗