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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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All sources NASA NTRS DOE OSTI

DOE OSTI2022

Designing an Intrusion Proof Adjustable Speed Drive System Controlling a Critical Process

In this paper, an intrusion proof adjustable speed drive system controlling a critical process in an industrial control system is detailed. In such a system, should the motor speed sensor signal data be compromised and/or altered via a cyber-attack, the system can potentially be unregulated, over speed and/or malfunction thereby disrupting the critical process. The proposed active detection scheme detailed in this paper introduces a private (secret) random signal termed as "watermark" into the inverter control signal that determines the PWM gating signals of the DC-AC inverter powering the motor. The watermarking signal introduced into the PWM modulation for the DC-AC inverter is shown to propagates its unique signature, which appears in all sensors signals at the inverter output such as voltage/current/speed used to control the motor. Now employing the measured data (from sensors), two statistical variance tests are conducted to identify anomalies if any in the presence of the watermarking signal. It is shown when an intrusion occurs to manipulate the sensor data to disturb and/or destabilize the process, the proposed tests immediately display a high value indicating a compromise in sensor data. It is shown that the proposed system is capable of immediate detection of a sophisticated attacks such as record/reply attack in which the actual speed sensor is disconnected and a prerecorded speed signal from the past of the same magnitude is played back to the controller. Several types of cyber-attacks such as speed reduction/increase including vibration have been tested. Extensive simulation results verify the proposed concepts. Experimental results will be discussed in the conference presentation.

Alotaibi, Faris↗

NASA NTRS1995

PV Array Driven Adjustable Speed Drive for a Lunar Base Heat Pump

A study of various aspects of Adjustable Speed Drives (ASD) is presented. A summary of the relative merits of different ASD systems presently in vogue is discussed. The advantages of using microcomputer based ASDs is now widely understood and accepted. Of the three most popular drive systems, namely the Induction Motor Drive, Switched Reluctance Motor Drive and Brushless DC Motor Drive, any one may be chosen. The choice would depend on the nature of the application and its requirements. The suitability of the above mentioned drive systems for a photovoltaic array driven ASD for an aerospace application are discussed. The discussion is based on the experience of the authors, various researchers and industry. In chapter 2 a PV array power supply scheme has been proposed, this scheme will have an enhanced reliability in addition to the other known advantages of the case where a stand alone PV array is feeding the heat pump. In chapter 3 the results of computer simulation of PV array driven induction motor drive system have been included. A discussion on these preliminary simulation results have also been included in this chapter. Chapter 4 includes a brief discussion on various control techniques for three phase induction motors. A discussion on different power devices and their various performance characteristics is given in Chapter 5.

Domijan, Alexander, Jr.↗

DOE OSTI2021

Industrial Conveyor Motor Performance Evaluation

The purpose of this project is to estimate the energy savings potential from a switched-reluctance motor (SRM) compared to an induction motor equipped with variable frequency drive (VFD) in a straight belt conveyor application. To experimentally evaluate savings in a realistic scenario, a baseline motor and VFD were selected from one of ComEd’s manufacturing customers’ conveyor systems. It was desired to not only estimate savings in the selected conveyor system, but to evaluate potential savings from using the SRM in any straight belt conveyor. Therefore, NREL developed a conveyor system energy calculation tool to supplement the experimental results of this assessment.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

NASA NTRS1981

A Solution in Search of Problems

Ferrofluids offered vast-problem solving potential. Under license for the NASA technology, Dr. Ronald Moskowitz and Dr. Ronald Rosensweig formed Ferrofluids Corporation. First problem they found a solution for was related to the manufacture of semiconductor "chips" for use in electronic systems. They developed a magnetic seal composed of ferrofluid and a magnetic circuit. Magnetic field confines the ferrofluid in the regions between the stationary elements and the rotary shaft of the seal. Result is a series of liquid barriers that totally bar passage of contaminants. Seal is virtually wear-proof and has a lifetime measured in billions of shaft revolutions. It has reduced maintenance, minimizes "downtime" of production equipment, and reduces the cost of expensive materials that had previously been lost through seal failures. Products based on ferrofluid are exclusion seals for computer disc drives and inertia dampers for stepper motors. Uses are performance-improving, failure-reducing coolants for hi-fi loudspeakers. Other applications include analytical instrumentation, medical equipment, industrial processes, silicon crystal growing furnaces, plasma processes, fusion research, visual displays, and automated machine tools.

Source record↗

NASA NTRS2014

A Recommended New Approach on Motorization Ratio Calculations of Stepper Motors

Stepper motors are widely used on most spacecraft mechanisms requiring repeatable and reliable performance. The unique detent torque characteristics of these type of motors makes them behave differently when subjected to low duty cycle excitations where the applied driving pulses are only energized for a fraction of the pulse duration. This phenomenon is even more pronounced in discrete permanent magnet stepper motors used in the space industry. While the inherent high detent properties of discrete permanent magnets provide desirable unpowered holding performance characteristics, it results in unique behavior especially in low duty cycles. Notably, the running torque reduces quickly to the unpowered holding torque when the duty cycle is reduced. The space industry's accepted methodology of calculating the Motorization Ratio (or Torque Margin) is more applicable to systems where the power is continuously applied to the motor coils like brushless DC motors where the cogging torques are low enough not to affect the linear performance of the motors as a function of applied current. This paper summarizes the theoretical and experimental studies performed on a number of space qualified motors under different pulse rates and duty cycles. It is the intention of this paper to introduce a new approach to calculate the Motorization Ratios for discrete permanent magnet steppers under all full and partial duty cycle regimes. The recommended approach defines two distinct relationships to calculate the Motorization Ratio for 100 percent duty cycle and partial duty cycle, when the motor detent (unpowered holding torque) is the main contributor to holding position. These two computations reflect accurately the stepper motor physical behavior as a function of the command phase (ON versus OFF times of the pulses), pointing out how the torque contributors combine. Important points highlighted under this study are the torque margin computations, in particular for well characterized mechanisms. The rationale at CDR level versus TRR/TRB level will be discussed, aiming at avoiding too much conservatism for units that have extensive test and in flight heritage. A critical topic is related to the magnetic losses and how to sort out such phenomena as a function of the motor type being used. For instance, detent torque is a major contributor that has no reason to evolve during life and is not an uncontrolled torque loss.

Nalbandian, Ruben↗

NASA NTRS1986

Controlling a Four-Quadrant Brushless Three-Phase dc Motor

Control circuit commutates windings of brushless, three-phase, permanent-magnet motor operating from power supply. With single analog command voltage, controller makes motor accelerate, drive steadily, or brake regeneratively, in clockwise or counterclockwise direction. Controller well suited for use with energy-storage flywheels, actuators for aircraft-control surfaces, cranes, industrial robots, and other electromechanical systems requiring bidirectional control or sudden stopping and reversal.

Nola, F. J.↗

NASA NTRS2013

US Rocket Propulsion Industrial Base Health Metrics

The number of active liquid rocket engine and solid rocket motor development programs has severely declined since the "space race" of the 1950s and 1960s center dot This downward trend has been exacerbated by the retirement of the Space Shuttle, transition from the Constellation Program to the Space launch System (SLS) and similar activity in DoD programs center dot In addition with consolidation in the industry, the rocket propulsion industrial base is under stress. To Improve the "health" of the RPIB, we need to understand - The current condition of the RPIB - How this compares to past history - The trend of RPIB health center dot This drives the need for a concise set of "metrics" - Analogous to the basic data a physician uses to determine the state of health of his patients - Easy to measure and collect - The trend is often more useful than the actual data point - Can be used to focus on problem areas and develop preventative measures The nation's capability to conceive, design, develop, manufacture, test, and support missions using liquid rocket engines and solid rocket motors that are critical to its national security, economic health and growth, and future scientific needs. center dot The RPIB encompasses US government, academic, and commercial (including industry primes and their supplier base) research, development, test, evaluation, and manufacturing capabilities and facilities. center dot The RPIB includes the skilled workforce, related intellectual property, engineering and support services, and supply chain operations and management. This definition touches the five main segments of the U.S. RPIB as categorized by the USG: defense, intelligence community, civil government, academia, and commercial sector. The nation's capability to conceive, design, develop, manufacture, test, and support missions using liquid rocket engines and solid rocket motors that are critical to its national security, economic health and growth, and future scientific needs. center dot The RPIB encompasses US government, academic, and commercial (including industry primes and their supplier base) research, development, test, evaluation, and manufacturing capabilities and facilities. center dot The RPIB includes the skilled workforce, related intellectual property, engineering and support services, and supply chain operations and management. This definition touches the five main segments of the U.S. RPIB as categorized by the USG: defense, intelligence community, civil government, academia, and commercial sector.

Doreswamy, Rajiv↗

NASA NTRS2010

Granular Flow and Dynamics of Lunar Simulants in Excavating Implements

The exploration of the lunar surface will rely on properly designed excavation equipment for surface preparations and for collection of lunar regolith in In-Situ Resource Utilization (ISRU) processes. Performance efficiency, i.e minimizing loading forces while maximizing material collection, and mass and volume reductions are major design goals. The NASA Glenn Research Center has embarked on an experimental program to determine the flow characteristics and dynamic forces produced by excavation operations using various excavator bucket designs. A new large scale soil bin facility, 2.27 m x 5.94 m x 0.76 m (nominally 8 ft. x 20 ft. x 27 in.) in size, capable of accommodating moderately large test implements was used for the simulations of lunar operations. The soil bin is filled with GRC-3simulant (a mixture of industrial sands and silt with a particle size distribution and the bulk mechanical (shear) strength representative of an average of lunar regolith from different regions) and uses motorized horizontal rails and a vertical actuator to drive the implement through the lunar simulant soil. A six-axis load cell and encoders provide well resolved measurements of the three dimensional forces and torques and motion of the bucket. In addition, simultaneous video allows for the analysis of the flow behavior and structure formation of the regolith during excavation. The data may be useful in anchoring soil mechanic models and to provide engineering data for design consideration.

Agui, Juan H.↗

NASA NTRS2001

Cybersonics: Tapping into Technology

With the assistance of Small Business Innovation Research (SBIR) funding from NASA's Jet Propulsion Laboratory, Cybersonics, Inc., developed an ultrasonic drill with applications ranging from the medical industry to space exploration. The drill, which has the ability to take a core sample of the hardest granite or perform the most delicate diagnostic medical procedure, is a lightweight, ultrasonic device made to fit in the palm of the hand. Piezoelectric actuators, which have only two moving parts and no gears or motors, drive the components of the device, enabling it to operate in a wide range of temperatures. The most remarkable aspect of the drill is its ability to penetrate even the hardest rock with minimal force application. The ultrasonic device requires 20 to 30 times less force than standard rotating drills, allowing it to be safely guided by hand during operation. Also, the drill is operable at a level as low as three watts of power, where conventional drills require more than three times this level. Potential future applications for the ultrasonic drill include rock and soil sampling, medical procedures that involve core sampling or probing, landmine detection, building and construction, and space exploration. Cybersonics, Inc. developed an ultrasonic drill with applications ranging from the medical industry to space exploration.

Source record↗

DOE OSTI2025

Variable Frequency Drive (VFD): Emphasizing Energy Savings and Efficiency in Industrial Applications

This project explores the energy saving potential of using a VDA in an industrial pumping application. A 24-horsepower pump, 3-phase centrifugal pump powered by 480V AC supply analyzed under variable frequency control using an ABB ACS880-31-052A-5 VFD. by modulating the motor speed between 30Hz and 60Hz, the VFD enables precise control of power consumption based on system set speed. The article is intended for public cause of the poster session and presentation session. INL/Exp-25-86570

99 - GENERAL AND MISCELLANEOUS↗

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↗

NASA NTRS1982

Vehicle test report: Jet Industries Electra Van 600

The Electra Van 600, an electric vehicle, was tested. Tests were performed to characterize parameters of the Electra Van 600 and to provide baseline data to be used for comparison of improved batteries and to which will be incorporated into the vehicle. The vehicle tests concentrated on the electrical drive subsystem, the batteries, controller, and motor; coastdowns to characterize the road load and range evaluation for cyclic and constant speed conditions; and qualitative performance was evaluated. It is found that the Electra Van 600 range performance is approximately equal to the majority of the vehicles tested previously.

Price, T. W.↗

NASA NTRS1997

Hybrid Electric Transit Bus

A government, industry, and university cooperative is developing an advanced hybrid electric city transit bus. Goals of this effort include doubling the fuel economy compared to current buses and reducing emissions to one-tenth of current EPA standards. Unique aspects of the vehicle's power system include the use of ultra-capacitors as an energy storage system, and a planned natural gas fueled turbogenerator developed from a small jet engine. Power from both the generator and energy storage system is provided to a variable speed electric motor attached to the rear axle. At over 15000 kg gross weight, this is the largest vehicle of its kind ever built using ultra-capacitor energy storage. This paper describes the overall power system architecture, the evolution of the control strategy, and its performance over industry standard drive cycles.

Viterna, Larry A.↗

NASA NTRSDate not supplied

Subscale Hardware-In-The-Loop Results for Hybrid Electric Turbofan Controls Use Cases

NASA is investigating hybrid electric turbine engine systems for commercial transport aircraft due to the potentially significant improvements hybrid electric technology offers in performance, fuel consumption, and operational and design flexibility. Recently, the technology has been tested at full scale in partnership with industry and advanced to Technology Readiness Level 4. This presentation will focus on a recent subscale hardware-in-the-loop test of an open source turbofan engine model developed by NASA. The Advanced Geared Turbofan 30,000 lbf – electrified (AGTF30-e) engine is used as a reference model to demonstrate control system design and use cases for an example mild hybrid electric system with no large-scale energy storage. This model is run in real-time in NASA’s Hybrid Propulsion Emulation Rig (HyPER) and is used to drive an emulation of the turbomachinery system using subscale electric machines. This dynamic scaled shaft emulation interacts with a subscale (<100 kW) hybrid system consisting of electric machines, motor controllers, and a programmable electronic load. Specific use cases demonstrated include the use of Turbine Electrified Energy Management to improve operation during transients, megawatt-scale power extraction from the AGTF30-e, and power transfer between engine spools. Results related to the effectiveness of hybrid systems are qualitatively compared to results from industry testing.

Hybrid↗

DOE OSTI2023

NdFeB Permanent Magnet Uses, Projected Growth Rates and Nd Plus Dy Demands across End-Use Sectors through 2050: A Review

Rare earth element (REE) permanent magnets (NdFeB) are a critical element in a vast and growing number of industrial applications. In consumer electronics, a broad category encompassing computer, CD, and DVD hard drives, in addition to the ubiquitous cell phones, the nominal NdFeB magnet content may be small, but the global market share for this sector accounts for almost 30% of NdFeB demand, due to a large and continually increasing consumer base. It is estimated that wind turbines that primarily employ permanent magnets will add roughly 110 GW annually of on- and off-shore capability over the next few years. Electric vehicles (EVs) and E-bicycles (EBs) equipped with permanent magnet motors comprise the transportation contribution. Permanent magnet motors have garnered nearly 100% of the market share among EV manufacturers worldwide. Industrial, professional service, and personal robots, most using permanent magnets, are also included in the projected global need for rare earths, particularly Nd and Dy. The sector projects significant growth of approximately 10% across robotic categories. In this paper, we calculate the future demand for Nd and Dy through 2050 across these sectors using a compounded annual growth rate coupled with magnet weight and rare earth content. Uncertainties in the estimates, such as the true global production of Nd, a range of end-product scales and/or unit types in each sector, varied magnet compositions, and the variety of uses within a sector, are all considered.

Geochemistry & Geophysics↗

NASA NTRS1982

Losses in chopper-controlled DC series motors

Motors for electric vehicle (EV) applications must have different features than dc motors designed for industrial applications. The EV motor application is characterized by the following requirements: (1) the need for highest possible efficiency from light load to overload, for maximum EV range, (2) large short time overload capability (The ratio of peak to average power varies from 5/1 in heavy city traffic to 3/1 in suburban driving situations) and (3) operation from power supply voltage levels of 84 to 144 volts (probably 120 volts maximum). A test facility utilizing a dc generator as a substitute for a battery pack was designed and utilized. Criteria for the design of such a facility are presented. Two motors, differing in design detail, commercially available for EV use were tested. Losses measured are discussed, as are waves forms and their harmonic content, the measurements of resistance and inductance, EV motor/chopper application criteria, and motor design considerations.

Hamilton, H. B.↗

NASA NTRS1992

Precise positioning and compliance synthesis for automatic assembly using Lorentz levitation

Many manufacturing assembly tasks require fine compliant motion and fast, accurate positioning. Conventional robots perform poorly in these tasks because of their large mass, friction and backlash in gears, cogging in drive motors and other deleterious effects. Even robots equipped with special control systems enabling compliant operation offer only partial solutions. It is difficult or impossible to automate many product assemblies requiring fine, compliant motion. This problem can be greatly alleviated by dividing the manipulation system into coarse and fine domains. In this scenario, a standard industrial robot can serve as a coarse positioner which in turn carries a six degrees of freedom fine motion wrist. Thus the robot can access a workspace measured in meters at low bandwidth and low resolution while the wrist can move over millimeters at high bandwidth and high resolution during the final phase of the assembly operation. Work indicates that fine motion wrists using Lorentz levitation can greatly augment the accuracy and dexterity of robots because they are frictionless, have high bandwidths and have a single back drivable moving part. Also, since there is no contact between the moving and stationary parts, wear and contamination can be eliminated. The use of six Lorentz force actuators in combination with real time position and orientation sensing offers several important advantages over magnetic bearing approaches.

Hollis, R. L.↗

DOE OSTI2021

Electric Drive Technology Trends, Challenges, and Opportunities for Future Electric Vehicles

The transition to electric road transport technologies requires electric traction drive systems to offer improved performances and capabilities, such as fuel efficiency (in terms of MPGe, i.e., miles per gallon of gasoline-equivalent), extended range, and fast-charging options. The enhanced electrification and transformed mobility are translating to a demand for higher power and more efficient electric traction drive systems that lead to better fuel economy for a given battery charge. To accelerate the mass-market adoption of electrified transportation, the U.S. Department of Energy (DOE), in collaboration with the automotive industry, has announced the technical targets for light-duty electric vehicles (EVs) for 2025. This article discusses the electric drive technology trends for passenger electric and hybrid EVs with commercially available solutions in terms of materials, electric machine and inverter designs, maximum speed, component cooling, power density, and performance. Additionally, the emerging materials and technologies for power electronics and electric motors are presented, identifying the challenges and opportunities for even more aggressive designs to meet the need for next-generation EVs. Some innovative drive and motor designs with the potential to meet the DOE 2025 targets are also discussed.

33 ADVANCED PROPULSION SYSTEMS↗