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DOE OSTI2022

Low Space Harmonic Content Windings (LSHWs) Applied to Improve the Pareto Front in Design Optimization of Electric Machines

In design optimization of high performance electric machines where the power density is increasingly a key metric, it is often desirable to maximize the average torque output within a given volume. However, if a smooth output is also required, the torque ripple may become a hurdle as it tends to increase with the average torque for conventional windings. A direct benefit of low space harmonic content windings (LSHWs), featuring the suppression or elimination of targeted non-working orders in the winding magnetomotive force (MMF), is the torque ripple reduction. This paper provides a detailed analysis of torque ripple pairs and the space-time harmonic order mapping, with concise results that applies to both distributed windings and fractionalslot concentrated windings (FSCWs) of any slot/pole combination. Metamodel-based optimizations are performed to compare two LSHWs with a conventional winding. Improved Pareto fronts are validated, which confirms higher torque producing capabilities at various torque ripple thresholds for LSHWs.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2024

Three-dimensional airgap electric machines employing winding embedded liquid cooling

Various examples are provided related to 3D airgap electric machines and winding embedded liquid cooling. In one example, an electric machine includes a stator assembly with stator windings supported by a stator core and an outer rotor assembly includes a radial plate surrounding the stator assembly and an endplate at a first end of the radial plate adjacent to the first end of the stator core. The stator windings can include a first portion extending along an axial length of the stator core and a second portion at a first end of the stator core that extends radially inward towards a shaft of the electric machine. The radial plate can include magnets distributed about the radial plate. In another example, a stator assembly includes stator windings supported by a stator core with a winding support including cooling channels distributed between the stator windings. The winding support can be nonmagnetic.

Islam, Md Sariful↗

DOE OSTI2022

Techno-Economic Implications of Electrical Machine Scaling for Wave Energy Converters

The sizing of an electrical machine for a Wave Energy Converter (WEC) can have a substantial impact on the overall sizing, cost, and rating of the device. An electrical generator is typically part of the power take-off (PTO) system, which is the mechanism by which the energy absorbed by the prime mover is transformed into useable electrical. For practically all WECs, the rate of change of actuation is predominantly determined by the wave resource (i.e., the wave height and frequency) and devices will see a sinusoidally varying velocity according to the wave conditions. The same can then be said for both directly and indirectly coupled PTOs with electrical generators. This techno-economic study investigates electrical machine scaling and associated cost implications through core machine design theory, manufacturer data, supporting literature, and the DOE sponsored Reference Model Project (RMP). The RMP was a partnered effort to develop open-source marine energy (ME) point designs as reference models (RMs) to benchmark ME technology performance and costs, methods for design and analysis of ME technologies, estimations for capital costs, operational costs, and levelized costs of energy (LCOE). The results from this study show torque is directly related to (1) the physical size of the machine required to increase the airgap sheer stresses, (2) the amount of active material, (3) the support structure, (4) bearing size and rating, and (5) offshore cable rating, all of which have a significant effect on overall system costs in terms of both CAPEX and OPEX. This paper aims to be a critical benchmark in helping determine an “optimal” nameplate rating for wave energy devices and their associated PTO. With an optimized rating and sizing process, WEC costs can be reduced, and overall performance can be improved.

cables↗

DOE OSTI2022

Techno-Economic Implications of Electrical Machine Scaling for Wave Energy Converters

The sizing of an electrical machine for a Wave Energy Converter (WEC) can have a substantial impact on the overall sizing, cost, and rating of the device. An electrical generator is typically part of the power take-off system, which is the mechanism by which the energy absorbed by the prime mover is transformed into usable electrical energy. For practically all WECs, the rate of change of actuation is predominantly determined by the wave resource (i.e., the wave height and frequency), and devices will see a sinusoidal varying velocity according to the wave conditions. The same can then be said for both directly and indirectly coupled power take-offs with electrical generators. This techno-economic study investigates electrical machine scaling and associated cost implications through core machine design theory, manufacturer data, supporting literature, and the Reference Model Project sponsored by the U.S. Department of Energy. The Reference Model Project was a partnered effort to develop open-source marine energy point designs as reference models to benchmark marine energy technology performance and costs, methods for design and analysis of marine energy technologies, estimations for capital costs, operational costs, and levelized cost of energy. The results from this study show torque is directly related to (1) the physical size of the machine required to increase the air-gap sheer stresses, (2)the amount of active material, (3) the support structure, (4) bearing size and rating, and (5) offshore cable rating, all of which have a significant effect on overall system costs in terms of both capital and operational expenditures. This paper aims to be a critical benchmark in helping determine an "optimal" nameplate rating for wave energy devices and their associated power take-offs. With an optimized rating and sizing process, WEC costs can be reduced and overall performance can be improved.

cables↗

DOE OSTI2021

Rotor for an electric machine

A rotor for an electric machine comprises a rotor core that defines a rotor slot having a central portion and an end portion. The end portion has a maximum width that is greater than a maximum width of the central portion immediately adjacent the end portion. A perimeter of the rotor slot at the end portion includes a plurality of segments extending between a first extremity at the maximum width of the end portion and a second extremity at the maximum width of the end portion. The plurality of segments include segments with different radii that decrease in magnitude from the center axis to the first extremity, and from the center axis to the second extremity.

Kim, Jihyun↗

DOE OSTI2022

A New Shape Optimization Approach for Lightweighting Electric Machines Inspired by Additive Manufacturing

Minimizing the mass in electric machines while maintaining superior performance is a new requirement for the advancement of drivetrains used in wind energy and electric mobility. Topology optimization (TO) for lightweighting electric machines using traditional approaches typically explores a restricted design space allowed by standard parametrizable geometry and manufacturing, while advanced methods, such as cell-based density approaches, suffer from a lack of robust manufacturability constraints during the optimization process. To overcome these drawbacks, we explore a grid-independent, boundary optimization where the outer shape of the magnet is parameterized using Bezier curves. We conduct a design of experiments (DOE) to study the effect of different magnet shapes on machine performance by varying the control points on the Bezier curves. A machine-learning-based surrogate model is constructed using the data from the DOE to quantify the relationship between the control points, air-gap torque, and mass. The control points are then optimized to maximize the torque density. The approach is used for minimizing electrical steel mass in the International Energy Agency (IEA) 15-MW radial flux direct-drive wind turbine generator. The new approach to shape optimization resulted in smooth and concise shapes that can be easily additively manufactured with up to a 20-ton reduction in electrical steel mass.

additive manufacturing↗

DOE OSTI2022

A Boundary Topology Optimization Approach for Lightweighting Electric Machines Inspired by Additive Manufacturing

Minimizing the mass in electric machines while maintaining superior performance has become a new requirement for the advancement of drivetrains used in wind energy and electric mobility. Topology optimization for light-weighting electric machines using traditional approaches typically explore a restricted design space allowed by standard parametrizable geometry and manufacturing, while advanced methods like cell-based density approaches suffer from a lack of robust manufacturability constraints during the optimization process. To overcome these drawbacks, we explore a grid-independent, boundary TO where the outer shape of the magnet is parameterized using Bezier curves. We conduct a design of experiments (DOE) to study the effect of different magnet shapes on machine performance by varying the control points on the Bezier curves. A machine-learning based surrogate model is constructed using the data from the DOE to quantify the relationship between the control points, air-gap torque and mass. The control points are then optimized to maximize the torque density. The approach is used for minimizing electrical steel mass in the IEA-15MW radial flux direct-drive wind turbine generator. The free-from boundary TO resulted in smooth and concise shapes that can be easily additively manufactured with upto 20-ton reduction in electrical steel mass.

additive manufacturing↗

DOE OSTI2022

Techno-Economic Implications of Electrical Machine Scaling for Wave Energy Converters: Preprint

cables↗

NASA NTRSDate not supplied

Thermal Vacuum Chamber Demonstration of a Cryocooled, HTS Rotor for a 1.4 MW Electric Machine for Electrified Aircraft Propulsion

Aircraft with electrified propulsion systems require electric machines that are very lightweight and highly efficient. Advancements to the state of the art are required to meet this demand. This is particularly true for large transport aircraft with more than about 150 passengers, which will require electric machines with power ratings in the 1 to 30+ MW range. At this scale of power, superconducting technology becomes attractive for electrified aircraft propulsion to increase efficiency and reduce mass [1]. A mass reduction relative to non-superconducting machines can result from an increase in the specific power of the machine and indirectly through a significant reduction in the amount of waste heat generated on the aircraft, which reduces the mass of the thermal management system [2]. NASA’s high efficiency megawatt motor (HEMM) is a 1.4 MW partially superconducting machine that is being developed to achieve an efficiency greater than 98% and electromagnetic specific power greater than 16 kW/kg. HEMM contains a copper stator operating at an average temperature around 423 K and a superconducting rotor composed of no-insulation 2nd generation high temperature superconducting (HTS) coils that operates around 60 K. The superconducting coils are conductively cooled by a pulse tube cryocooler embedded inside and rotating with the rotor shaft. This paper presents a full-scale demonstration of the rotor in a thermal vacuum chamber at the designed operating temperature. The test was designed to validate the design of HEMM’s rotor, namely the ability to operate the 2G HTS coils at their rated direct current in a relevant thermal environment while being conductively cooled.

high temperature superconductors↗

NASA NTRSDate not supplied

Potential of Materials to Impact Megawatt-Scale Electric Machines

High specific power density, megawatt-scale electric machines (motors and generators) are needed to enable megawatt-scale electric aircraft propulsion systems for single isle aircraft. Thermally insulating electrical insulation materials in the stator windings limits the ability to thermally manage the heat produced in these machines. Polymer-ceramic composites along with novel processing techniques offer viable options to improve the thermal conductivity of the electrical insulation system. This paper outlines current National Aeronautics and Space Administration’s Glenn Research Center efforts of developing several polymer-ceramic systems and processing techniques as they relate to electric machine insulation (including potting). There is also analysis of how these factors relate to machine performance.

electric macnhine↗

DOE OSTI2021

Jet Impingement Cooling of Electric Machines with Driveline Fluids

In the presentation thermal management of electric traction drives is discussed and capabilities of NREL's Advanced Power Electronics and Electric Machines group is reviewed. Emphasis is made on jet impingement cooling technique of electric machines with driveline fluids and experimental measurements of associated heat transfer coefficients.

47 OTHER INSTRUMENTATION↗

DOE OSTI2025

Power Electronics and Electric Machines for Advanced Aircraft

Power electronics and electric machines are critical components of efficient, high-performance aircraft - from fixed-wing turbine to electric vertical takeoff and landing aircraft and beyond. Improvements to these components create enormous energy efficiencies, enable cost savings, and ensure fail-safe operations. National Renewable Energy Laboratory researchers are developing innovative power electronics, electric motors, integrated electric traction drives, and thermal management systems to build highly efficient, lightweight, ultrareliable powertrains for aircraft.

42 ENGINEERING↗

DOE OSTI2022

A New Shape Optimization Approach for Lightweighting Electric Machines Inspired by Additive Manufacturing: Preprint

Minimizing the mass in electric machines while maintaining superior performance is a new requirement for the advancement of drivetrains used in wind energy and electric mobility. Topology optimization (TO) for lightweighting electric machines using traditional approaches typically explores a restricted design space allowed by standard parametrizable geometry and manufacturing, while advanced methods, such as cell-based density approaches, suffer from a lack of robust manufacturability constraints during the optimization process. To overcome these drawbacks, we explore a grid-independent, boundary TO where the outer shape of the magnet is parameterized using Bezier curves. We conduct a design of experiments (DOE) to study the effect of different magnet shapes on machine performance by varying the control points on the Bezier curves. A machine-learning-based surrogate model is constructed using the data from the DOE to quantify the relationship between the control points, air-gap torque, and mass. The control points are then optimized to maximize the torque density. The approach is used for minimizing electrical steel mass in the International Energy Agency (IEA) 15-MW radial flux direct-drive wind turbine generator. The free-form boundary TO resulted in smooth and concise shapes that can be easily additively manufactured with up to a 20-ton reduction in electrical steel mass.

additive manufacturing↗

DOE OSTI2022

Advanced Power Electronics and Electric Machines [Slides]

The presentation provides an overview of NREL's Advanced Power Electronics and Electric Machines (APEEM) group and its research activities. Power electronics thermal management systems for electric-drive vehicles are described and performance metrics are provided. Additionally, advanced cooling technologies developed at NREL are presented. Finally, an overview is provided for electric machine cooling, integrated drives, and thermomechanical research.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

NASA NTRSDate not supplied

Helmholtz Motor: A Novel Electric Machine That Enables High Temperature Superconducting Armatures

Electrified aircraft are being developed to increase the efficiency and reduce the cost of operating subsonic transport aircraft. Achieving a substantial impact necessitates focusing on single- and twin-aisle aircraft which use propulsion systems with >20 MW ratings. For these aircraft, multi-MW superconducting electric machines are being developed due to their high specific power and high efficiency. Cryogenic electric machines are a promising technology for multi megawatt electric aircraft drivetrains. Second generation high temperature superconductors (HTS) are the ideal conductor for the field winding (typically the rotor) of superconducting machines, and they have attractive features for the armature winding (typically the stator) of these machines. However, their use in armature windings has been severely limited due to excessive AC losses in conventional electric machines. This presentation will present the working principle, design, and a performance trade study of a novel electric machine – termed a Helmholtz machine – that enables HTS armatures by significantly reducing AC losses. The working principle of the patent pending Helmholtz motor is to optimize the rotor-produced magnetic field (i.e., the field winding) so that it produces a magnetic field almost purely in the plane of the HTS. This is accomplished using 2 rotors that contain a set of matched Helmholtz coil pairs (or matched permanent magnet Halbach arrays). The armature (stator) HTS coils are positioned between the rotors and oriented to minimize the out of plane magnetic field. The armature HTS coils are also designed to minimize the out of plane component of their self field. The presentation will include the lessons learned in the sizing and design of this motor, including equations for how to match the magnet arrays. A performance trade study will be presented for a partially superconducting, radial flux version of the motor. The trade study involved an optimization of a motor design code based on analytical calculations (electromagnetic, AC loss, thermofluid, mechanical, and motor sizing) that determine the motor’s total efficiency and total specific power. The design code will be described in the presentation, with an emphasis on the calculation of magnetic fields, AC loss, and temperature distribution.

Superconducting electric machines↗

NASA NTRS2022

Specific Power and Efficiency Projections of Electric Machines and Circuit Protection Exploration for Aircraft Applications

The purpose of this paper is to generate specific power and efficiency projections through the year 2050 for electric machines for aircraft applications. A general literature review was performed to identify the types of electric machines that are commonly used and which types have the biggest potential for future aircraft applications due to their high specific power and efficiency. A database with historical data was built to include parameters such as weight [kg], rated power [kW], specific power [kW/kg], RPM, efficiency, year, motor cooling type, application type and motor type to allow for trend identification and accurate projections. Once the data was gathered, multiple curve fits on the historical data were generated and extrapolated to produce the projections for specific power according to conservative, nominal and aggressive projection scenarios. A different process was followed for the efficiency projections due to the scattered nature of the data. A state of the art (SoA) value for efficiency was identified through literature review and was used to create the conservative, nominal and aggressive projections for the time frames of 2030, 2040, and 2050. The efficiency and the specific power projections of EMs for 2050 are 0.989 and 50kW/kg respectively. This paper will also be examining circuit protection as it is an additional component of electric powertrains.

electric machines↗

NASA NTRS2019

Thermal Analysis of Potted Litz Wire for High-Power-Density Aerospace Electric Machines

Increasing the power density and efficiency of electric machines (motors and generators) is integral to bringing Electrified Aircraft (EA) to commercial realization. To that end an effort to create a High Efficiency Megawatt Motor (HEMM) with a goal of exceeding 98% efficiency and 1.46 MW of power has been undertaken at the NASA Glenn Research Center. Of the motor components the resistive losses in the stator windings are by far the largest contributor (34%) to total motor loss. The challenge is the linear relationship between resistivity and temperature, making machine operation sensitive to temperature increases. In order to accurately predict the thermal behavior of the stator the thermal conductivity of the Litz wire-potting-electrical insulation system must be known. Unfortunately, this multi material system has a wide range of thermal conductivities (0.1 W/m-K â€“ 400 W/m-K) and a high anisotropy (axial vs transverse) making the prediction of the transverse thermal conductivity an in turn the hot spot temperatures in the windings is difficult. In order to do this a device that simulates the thermal environment found in the HEMM stator was designed. This device is not unlike the motorettes (little motors) that are described in IEEE standards for testing electrical insulation lifetimes or other electric motor testing. However, because the HEMM motor design includes significant rotor electrical and thermal considerations the term motorette was not deemed appropriate. Instead statorette (or little stator) was adopted as the term for this test device. This paper discussed the design, thermal heat conjugate analysis (thermal model), manufacturing and testing of HEMM's statorette. Analysis of the results is done by thermal resistance network model and micro thermal model and is compared to analytical predictions of thermal conductivity of the insulated and potted Litz wire system.

Motor↗

NASA NTRSDate not supplied

Concept Design of a 5 MW Axial Flux Partially Superconducting Electric Machine

Single aisle class and larger electric and hybrid electric airplanes require high performance electric machines with power levels greater than 1 MW. Partially superconducting machines with superconducting rotors cooled by cryocoolers and no-cryogenic stators are one possible solution for meeting the machine performance requirements at these power levels. In this paper, a conceptual design for a double-stator single-rotor axial-flux partially superconducting machine is presented. A design tool for the topology is presented and used to generate an initial concept design. High fidelity analysis of the concept design is used to access the feasibility of the concept design to meet its target performance metrics and find areas of refinement for the next iteration of the design tool and the design.

Thomas Tallerico↗