Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “electric drive technologies”

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.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 37 records · Page 2
All sourcesNASA NTRSDOE OSTI
DOE OSTI2026

High-Torque Heavy-Rare-Earth-Free Electric Motor Thermal Management

This project is part of a multi-lab Next-Generation Reliable Electric Drive Systems for Medium and Heavy-Duty Vehicles (NEXT-DRIVE) project led by Oak Ridge National Laboratory (ORNL), and including NREL, Sandia National Laboratories (SNL), and Ames Laboratory that leverages research expertise and facilities of these national labs to develop tools and approaches for reducing the design and development time of new electric drive technologies for medium and heavy-duty vehicles (MHDVs) and their associated costs while increasing reliability and asset utilization. The Next-Drive project aligns with the DOE's goals by introducing high-fidelity multi-physics and AI/ML-based modeling to design low-cost, highly reliable, and longer-lifetime drivetrains, aiming to achieve 25 years of progress in 5 years. The efforts of this project will focus on NEXT-DRIVE Task 4 (led by ORNL, NREL, and AMES) - developing high-fidelity modeling framework and identifying technologies enabling heavy-rare-earth-free electric motors for medium- and heavy-duty vehicles to achieve 1 million miles of operation. Contrary to conventional approaches that optimize the motor for power density, the focus will be to identify motor designs that achieve the best trade-off between motor power density and durable operation. NREL tasks include development of high-fidelity motor thermal models incorporating rotor windage losses and identification, evaluation and measurement of motor interface materials in key thermal pathways. The poster summarizes NREL's accomplishments for the first half of FY 2025 and outlines future plans.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2020

Light-Duty Vehicle Choice Modeling and Benefits Analysis

The U.S. Department of Energy's Vehicle Technologies and Hydrogen and Fuel Cell Technologies Offices (VTO and HFTO) support research and development of efficient and sustainable transportation technologies that will improve energy efficiency, minimize emissions, and enable America to use less petroleum. This presentation steps through the approach, updates to the approach, and preliminary estimates of light-duty vehicle energy and emissions benefits from the continuation and success of VTO and HFTO programs. The programs include research on batteries, electric drive technologies (EDT), combustion, materials, fuel cells, and hydrogen storage. Preliminary results for battery and EDT program success show an annual 24% reduction in petroleum use and 13% reduction in carbon emissions.

47 OTHER INSTRUMENTATION↗
DOE OSTI2021

Light-Duty Vehicle Choice Modeling and Benefits Analysis (van018)

The U.S. Department of Energy’s Vehicle Technologies and Hydrogen and Fuel Cell Technologies Offices (VTO and HFTO) support research and development of efficient and sustainable transportation technologies that will improve energy efficiency, minimize emissions, and enable America to use less petroleum. The analysis in this poster is based on technical progress goals established in VTO and HFTO in the years immediately prior to and including 2020, and it summarizes the estimated energy and emissions benefits corresponding with achievement of those goals. The goals span research activities on batteries, electric drive technologies (EDT), combustion, lightweight materials, fuel cells, and hydrogen storage. The Automotive Deployment Options Projection Tool (ADOPT) is used to estimate the benefits for light-duty vehicles. ADOPT is a vehicle choice and stock model that estimates vehicle technology improvement impacts on sales, energy, and emissions. It includes all the existing vehicle options for realism, estimates their sales using extensively validated consumer preferences, creates new market-driven vehicle options through time, and rolls up sales to estimate energy and emissions. ADOPT takes in technology progress assumptions and applies these to the modeled vehicles through time. The assumptions are represented by a No Program scenario that reflects the technology improvements assumed to occur without further contributions from VTO or HFTO, and a Program Success scenario under which VTO and HFTO program goals are realized. The benefits are calculated by comparing ADOPT's estimated national-level energy and emissions resulting from the Program Success relative to the No Program scenario. By 2050, the Program Success scenario results in 11% less annual petroleum consumption and 10% less annual carbon emissions than the No Program scenario.

ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2021

Vehicle Technologies and Hydrogen and Fuel Cell Technologies Research and Development Programs Benefits Assessment Report for 2020

The U.S. Department of Energy’s Vehicle Technologies and Hydrogen and Fuel Cell Technologies Offices (VTO and HFTO) support research and development of efficient and sustainable transportation technologies that will improve energy efficiency, minimize emissions, and enable America to use less petroleum. VTO and HFTO regularly revisit and update relevant research and development goals and areas of emphasis in response to the latest technological advancements and in alignment with current national priorities. As such, analyses of expected benefits resulting from VTO and HFTO investments and anticipated goal achievements are updated periodically and will be again for 2021 in the context of the latest national-level transportation decarbonization goals. The analysis in the present report is based on technical progress goals established in VTO and HFTO in the years immediately prior to and including 2020, and it summarizes the estimated energy and emissions benefits corresponding to achievement of those goals. The goals span research activities on batteries, electric drive technologies (EDT), combustion, lightweight materials, fuel cells, and hydrogen storage. The evaluation includes detailed analyses into the benefits of technology improvements on the U.S. light-duty (LD) vehicle fleet and separately on the U.S. medium- and heavy-duty (MDHD) vehicle fleet. This report summarizes the outcomes from each of these analyses both independently and in combination.

08 HYDROGEN↗
DOE OSTI2024

Electric Motor Thermal Management

During FY 2022, NREL efforts focused on supporting collaborations with external research partners within the Electric Drive Technologies research consortium. The poster highlights collaborations with SNL, ORNL, and Georgia Tech. The collaboration with SNL utilized NREL's experimental capabilities to mechanically characterize SNL-provided material samples for motor applications. The collaboration with ORNL supported efforts to refine the design of a high-speed, non-heavy-rare-earth outer-rotor motor. The collaboration with Georgia Tech focused on a novel cooling technique for electric machines. NREL supported the effort by leading the thermal analysis and design of advanced machines.

ADVANCED PROPULSION SYSTEMS↗
NASA NTRS2016

Sizing Power Components of an Electrically Driven Tail Cone Thruster and a Range Extender

The aeronautics industry has been challenged on many fronts to increase efficiency, reduce emissions, and decrease dependency on carbon-based fuels. The NASA Aeronautics Research Mission Directorate has identified a suite of investments to meet long term research demands beyond the purview of commercial investment. Electrification of aviation propulsion through turboelectric or hybrid electric propulsion is one of many exciting research areas which has the potential to revolutionize the aviation industry. This paper will provide an overview of the turboelectric and hybrid electric technologies being developed under NASAs Advanced Air Transportation Technology (AATT) Project, and how these technologies can impact vehicle design. An overview will be presented of vehicle system studies and the electric drive system assumptions for successful turboelectric and hybrid electric propulsion in single aisle size commercial aircraft. Key performance parameters for electric drive system technologies will be reviewed, and the technical investment made in materials, electric machines, power electronics, and integrated power systems will be discussed. Finally, power components for a single aisle turboelectric aircraft with an electrically driven tail cone thruster and a hybrid electric nine passenger aircraft with a range extender will be parametrically sized.

turbogenerator↗
NASA NTRS2015

Key Performance Parameter Driven Technology Goals for Electric Machines and Power Systems

Transitioning aviation to low carbon propulsion is one of the crucial strategic research thrust and is a driver in the search for alternative propulsion system for advanced aircraft configurations. This work requires multidisciplinary skills coming from multiple entities. The feasibility of scaling up various electric drive system technologies to meet the requirements of a large commercial transport is discussed in terms of key parameters. Functional requirements are identified that impact the power system design. A breakeven analysis is presented to find the minimum allowable electric drive specific power and efficiency that can preserve the range, initial weight, operating empty weight, and payload weight of the base aircraft.

Electric Machines↗
DOE OSTI2020

Dual Phase Soft Magnetic Laminates for Low-cost, Non/Reduced-Rare-Earth Containing Electrical Machines

To accelerate the mass market adoption of electric drive vehicles, the key technology barriers in electric motors are (1) magnet cost and rare-earth element price volatility; (2) non-rare-earth electric motor performance; and (3) materials property optimization. The goal of this project was to address these barriers by advancing a unique and innovative dual phase soft magnetic material technology and demonstrating the material in a 30-kW synchronous reluctance motor without using any permanent magnet for electric vehicles. Dual phase magnetic materials offer the electric motor designer the ability to locally control the magnetic saturation level in a motor laminate, while at the same time enhancing the mechanical strength of the laminate material, resulting in an enhancement in motor performance and efficiency. Scalable dual phase soft magnetic laminates manufacturing technologies were developed in collaboration with multiple US manufacturers. 1000 lbs of alloy sheet with a thickness of 0.25mm and width of 280 mm was manufactured within the specifications. Batch sizes of up to 240 laminates per run were produced from the alloy sheet. Two prototype motors with dual phase soft magnetic laminates were designed, built, and tested. The major goal of building the subscale prototype as a pathway to develop scalable manufacturing technologies for the dual phase soft magnetic laminates was met. The additional goal of building and testing the subscale prototype in order to validate the calculated performance with the tested motor performance was also met. For the full-scale 30kW continuous power synchronous reluctance motor prototype, the tested performance met the targets in terms of continuous power at the operating speeds up to 8000 rpm. Post-test studies were conducted and the root causes for the discrepancy between the predicted and tested peak power, continuous power at high speed range, and efficiency were identified. Further modeling study showed that the dual phase rotor machine has a 27% higher torque to active weight ratio than an equivalent performance silicon steel rotor machine. Application space and multiple discussions with traction motor and electric vehicle manufacturers for commercialization of the dual phase soft magnetic material technology were identified and conducted. An initial cost model was established based on the developed manufacturing technologies with the US manufacturers. Future paths for further cost reduction were identified, including increasing the market volume by broadening the applications of the dual phase soft magnetic laminate technology for electric machines in other energy sections such as oil & gas, heating, ventilation, and air conditioning (HVAC), and power generation.

33 ADVANCED PROPULSION SYSTEMS↗
NASA NTRS2016

Visions of the Future: Hybrid Electric Aircraft Propulsion

The National Aeronautics and Space Administration (NASA) is investing continually in improving civil aviation. Hybridization of aircraft propulsion is one aspect of a technology suite which will transform future aircraft. In this context, hybrid propulsion is considered a combination of traditional gas turbine propulsion and electric drive enabled propulsion. This technology suite includes elements of propulsion and airframe integration, parallel hybrid shaft power, turbo-electric generation, electric drive systems, component development, materials development and system integration at multiple levels.

electric motor vehicles↗
DOE OSTI2023

Integrated Traction Drive Thermal Management: Keystone Project 3

The presentation represents a report of accomplishments during FY 2022 and is prepared for 2022 DOE VTO Annual Merit Review. The project goal is facilitation of achieving DOE 2025 target of 33 kW/L system power density for an electric traction drive through support of other EDT consortium members in design and development of thermal management systems for their respective integrated drive concepts. Namely, identifying pathways enabling high-performance, compact, and reliable integrated electric drives. Specific objectives are: 1) Research and evaluation of motor-integrated power electronics packaging technologies and thermal management approaches. 2) Development of thermal management system and its sub-components to enable integrated electric drive DOE power density targets in collaboration with project partners. 3) Supporting activities of DOE's Electric Drive Technologies (EDT) consortium members, Oak Ridge National Laboratory (ORNL) and University of Wisconsin research teams in thermal management component design and thermal modeling of their integrated traction drives. 4) Identifying candidate driveline fluids suitable for direct cooling of traction-drive components and high-voltage power electronics and evaluate their convective cooling performance.

ADVANCED PROPULSION SYSTEMS↗
NASA NTRS2001

A Survey of Power Electronics Applications in Aerospace Technologies

The insertion of power electronics in aerospace technologies is becoming widespread. The application of semiconductor devices and electronic converters, as summarized in this paper, includes the International Space Station, satellite power system, and motor drives in 'more electric' technology applied to aircraft, starter/generators and reusable launch vehicles. Flywheels, servo systems embodying electromechanical actuation, and spacecraft on-board electric propulsion are discussed. Continued inroad by power electronics depends on resolving incompatibility of using variable frequency for 400 Hz-operated aircraft equipment. Dual-use electronic modules should reduce system development cost.

Kankam, M. David↗
NASA NTRS2014

Miniaturized Power Processing Unit Study: A Cubesat Electric Propulsion Technology Enabler Project

This study evaluates High Voltage Power Processing Unit (PPU) technology and driving requirements necessary to enable the Microfluidic Electric Propulsion technology research and development by NASA and university partners. This study provides an overview of the state of the art PPU technology with recommendations for technology demonstration projects and missions for NASA to pursue.

High Voltage Power Processing Unit↗
DOE OSTI2026

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

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

Alam, Khorshed [General Motors LLC, Detroit, MI (U↗
NASA NTRS1978

System design of an ion drive spacecraft

As electric propulsion technology has improved and mission requirements have changed, a series of Ion Propulsion Module (IPM) design concepts have evolved. The most recent iteration occurred in the NASA-sponsored Halley Comet Rendezvous Mission (HCRM) study of ion drive. Spacecraft system design considerations introduced by the integration of such an IPM as the primary propulsion source are described with reference to the synthesis of the HCRM spacecraft and spacecraft design considerations for other interplanetary applications. IPM interactions with the system (especially telecommunications and science) are found to be manageable. The spacecraft design developed for the HCRM indicates the interface simplicity between the IPM and the spacecraft. Methods are shown for readily applying this IPM to a variety of planetary missions. Methods are also described for the IPM to provide up to 5 kW to the spacecraft for increasing the mission science return

Stuart, J.↗
DOE OSTI2025

Low Cost High-Performance HRE-Free 3-in-1 Electric Drive Unit

The project team completed work to expand upon American Axle & Manufacturing’s (AAM) baseline technology and develop a high-speed, AC induction electric drive unit (EDU) with total direct-oil-cooling and integrated power electronics. The project accelerated advancements in EDU technology by allowing AAM to build upon the progress made in developing the underlying baseline technologies. The following seven improvements to AAM’s baseline technology were implemented in this research and development program: 1) Increased speed (30k RPM) AC induction motor, 2) Silver-sintering of discrete silicon carbide (SiC) metal-oxide-semiconductor field-effect transistors (MOSFET) to heat sinks, 3) Electrically insulated rotor bars, 4) Optimized lamination steel, 5) EDU-integrated 650VDC inverter package, 6) Over-molded stator with molded liners, and 7) 650VDC power-dense stator design. The successful development of the technology resulted in a meaningful cost reduction for EDU systems in the market. Coupled with falling battery system costs, lower EDU costs will likely accelerate the market acceptance and related production scaling of battery electric vehicles. The objective of this project was to research, develop, and test a Heavy Rare Earth (HRE)-free 3-In-1 electric drive unit (EDU) that has class leading power density and cost. The key technologies to be developed were anticipated to meet or exceed the Department of Energy (DOE) targets of a cost ≤ $\$$7/kilowatt (kW), power density ≥ 12 kW/liter, and operating voltage ≥ 600 VDC.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2024

Heterogeneous Integration Technologies for High-temperature, High-density, Low-profile Power Modules of Wide Bandgap Devices in Electric Drive Applications (Final Technical Report)

The goal of this project is to develop packaging technologies for making high-temperature, high-density, and low-profile wide-bandgap (WBG) power electronics modules for electric drives. These modules are aimed at enabling the DOE’s University Consortium to reach its 2025 inverter targets of ≥ 100 kW/L and ≤ 2.7 $/kW. The specific objectives are to: design and fabricate SiC half-bridge power modules with double-sided cooling and parasitic inductances < 5 nH, heat flux density > 400 W/cm 2 , and working junction temperature of 200 o C; design, fabricate, and deliver a gate driver with double-sided cooled modules for the construction of a 100 kW/L inverter at Oak Ridge National Lab; and design and prototype intelligent gate drivers with integrated current sensor and a low-profile DC-DC power supply with air-core transformer for testing power modules at 200 o C junction temperature. We followed an iterative technical approach of design, simulation, fabrication, and testing of various versions of modules, current sensors, and power supply. The state-of-the-art silicon carbide devices rated at 1.2 kV and 149 A were packaged by sintered-silver bonding on an aluminum nitride direct-bond-copper substrate for high thermal conductivity, high working temperature, and high joint reliability. Porous silver posts were used to interconnect the device’s source pads to the other direct-bond-copper substrate for low mechanical stresses, ease of manufacturing, and double-sided cooling. A current sensor based on package parasitic inductance was developed to measure switching current. A dynamic feedback scheme was developed to compensate the effect of parasitic resistance and temperature variation. A constant-current class-E dc-dc converter with air-core transformer was developed. Air-core transformer was used due to the unavailability of magnetic core at high temperatures. Gate driver and power supply were integrated with the double-side cooled, high temperature SiC power modules for testing the modules at 200 o C junction temperature. Double-pulse and continuous testing of the integrated technologies validated the design and fabrication of the three component technologies. Throughout the project, we overcame the challenge for design verification caused by low prototyping yield, which then helped train the graduate students, the future workforce, to learn the engineering know-how for low-cost manufacturing of reliable products. Below is a summary of the major accomplishments of this project: development of a prototyping process for fabricating double-side cooled (1200 V, 149 A) SiC phase-leg modules capable of working to 200 o C Tj; simulation and experimental verification of the improvement of thermo-mechanical reliability of the double-side cooled SiC phase-leg module by using rigid encapsulant; design and experimental validation of a current sensor based on package parasitic inductance and a compensation solution for eliminating the effect of parasitic resistance; design and experimental validation of a low-profile power supply with six-output air-core transformer for gate driver; functional demonstration of a SiC phase-leg module integrated with its gate driver, current sensor, and an air-core power supply at 200 o C Tj in a double-pulse switching test setup and Buck converter continuous test setup; successful completion of six PhD and two MS students who are or will work at Apple Inc., Tesla Inc., Wolfspeed Inc., Microchip Inc., Monolithic Power Systems Inc., and LG Magna Inc.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
NASA NTRSDate not supplied

Design Study of a Coupled Inner-Stator Magnetically Geared Motor for Electric Aircraft Applications

Electric aircraft require high performance and high reliability electric motor drivetrains. A geared electric motor drivetrain will outperform a direct drive motor drivetrain in most applications. Traditional mechanical gearing, however, has mechanical contact-based wear and failure modes that result in added maintenance costs and require an oil lubrication system. Magnetically geared motor drives are a potential technology for electric aircraft applications capable of enabling the benefits of a geared drive without the maintenance, reliability, and lubrication system cost of mechanical gears. In this paper, a topology of magnetically geared motor, an inner stator magnetically geared motor, is explored to estimate its achievable performance for electric aircraft applications. Optimization results on the topology show that it can achieve greater than 15 Nm/kg and 96% efficiency at 100 kW of power.

Thomas Tallerico↗