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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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The poster showcases NREL team's accomplishments in supporting Electric Drive Technologies (EDT) consortium members in a fifth year of a six-year project funded by DOE Vehicle Technologies Office.
A design of a propeller pitch control mechanism is described that meets the demanding requirements of a high-power, advanced turboprop. In this application, blade twisting moment torque can be comparable to that of the main reduction gearbox output: precise pitch control, reliability and compactness are all at a premium. A key element in the design is a compact, high-ratio hybrid traction drive which offers low torque ripple and high torsional stiffness. The traction drive couples a high speed electric motor/alternator unit to a ball screw that actuates the blade control links. The technical merits of this arrangement and the performance characteristics of the traction drive are discussed. Comparisons are made to the more conventional pitch control mechanisms.
A design of a propeller pitch control mechanism is described that meets the demanding requirements of a high-power, advanced turboprop. In this application, blade twisting moment torque can be comparable to that of the main reduction gearbox output: precise pitch control, reliability and compactness are all at a premium. A key element in the design is a compact, high-ratio hybrid traction drive which offers low torque ripple and high torsional stiffness. The traction drive couples a high speed electric motor/alternator unit to a ball screw that actuates the blade control links. The technical merits of this arrangement and the performance characteristics of the traction drive are discussed.
The ever-increasing demand for compact, efficient, and high-performance traction drive systems for transportation applications has accelerated the development of integrated electric drives. In these systems, the electric machine and inverter are integrated within a single housing, offering significant advantages in electrical performance, volume, weight, cost, and overall system efficiency. Despite these benefits, such high levels of integration introduce a new set of challenges, particularly in power electronic design and component selection. This article presents an in-depth investigation of a highly integrated electric drive architecture with an internal stator-mounted inverter, highlighting key design considerations and trade-offs aimed exclusively at maximizing system power density.Based on a comprehensive review of the literature, the power density of a voltage-source-inverter-driven electric drive is primarily governed by the volumetric contributions of the power modules, heat sinks, and DC-link capacitors. Accordingly, this work focuses on the optimization of these three critical components to enhance the inverter's overall power density. The proposed design achieves a power density of 100 kW/L, demonstrating the effectiveness of the presented approach for next-generation integrated electric drive systems.
The continued expansion of the global electric vehicle fleet is accompanied by an unprecedented demand for high power density electric traction motors. With the ambitious U.S. DRIVE 2025 target of 50 kW/L power density and an equally aggressive cost reduction goal, innovative approaches have to be utilized in terms of both the design and manufacturing of electric traction motors. In this paper, six motor options are compared and the best design is picked for each option to investigate the drive and excitation requirements and the weighted power efficiency over multiple load points, with necessary mechanical stress and demagnetization checks. State-of-the-art winding technologies, including high slot fill die compressed windings and hairpin windings, and rotors both with permanent magnet (PM) and PM-free are incorporated. The design of high flux density and low harmonic content magnetic field is also demonstrated.
Performance test results are presented for a four-passenger Austin A40 sedan that was converted to a heat-engine-alternator-and battery-powered hybrid. It is propelled by a conventional, gasoline-fueled, heat-engine-driven alternator and a traction pack powering a series-wound, 10 hp direct-current electric drive motor. The 16 hp gasoline engine drives the 7 kilowatt alternator, which provides electrical power to the drive motor or to the 96 volt traction battery through a rectifier. The propulsion battery consists of eight 12 volt batteries connected in series. The electric motor is coupled to a four-speed standard transmission, which drives the rear wheels. Power to the motor is controlled by a three-step foot throttle, which actuates relays that control armature current and field excitation. Conventional hydraulic brakes are used.
The development, evaluation, and optimization of a preliminary design concept for a continuously variable transmission (CVT) to couple the high-speed output shaft of an energy storage flywheel to the drive train of an electric vehicle is discussed. An existing computer simulation program was modified and used to compare the performance of five CVT design configurations. Based on this analysis, a dual-cavity full-toroidal drive with regenerative gearing is selected for the CVT design configuration. Three areas are identified that will require some technological development: the ratio control system, the traction fluid properities, and evaluation of the traction contact performance. Finally, the suitability of the selected CVT design concept for alternate electric and hybrid vehicle applications and alternate vehicle sizes and maximum output torques is determined. In all cases the toroidal traction drive design concept is applicable to the vehicle system. The regenerative gearing could be eliminated in the electric powered vehicle because of the reduced ratio range requirements. In other cases the CVT with regenerative gearing would meet the design requirements after appropriate adjustments in size and reduction gearing ratio.
High power density is one of the requirements for traction drive inverters for meeting increasing demand for higher power and performance electrical vehicles (EV). This paper presents design and preliminary experimental results for a 100 kW high-power density inverter for EV traction drive applications. The inverter design was based on the segmented inverter topology that can significantly reduce the inverter DC filter capacitor and employs low-profile planar double-sided cooled SiC MOSFET-based power modules, compact mini-channel heat sinks with fin-profile optimized using genetic-algorithms, and high-ripple current capacitors. The design produced a compact inverter package with a total volume less than 1 litter, exceeding the power density goal of 100 kW/L. Experimental results are included to demonstrate the cooling and electrical performance.
To meet performance and reliability requirements necessary for broader adoption of electric drive vehicles, the Electrical and Electronics Technical Team of the U.S. Drive partnership has established aggressive design goals for next-generation electric vehicle drivetrains. Specifically, the 2025 roadmap stipulates a 100 kW/L power density target and a $\$$2.7/kW cost target for power electronics, in addition to high-voltage operation (i.e., greater than 800 VDC). The additional targets for traction motor and the overall system performance impose further challenges on the power electronics design. For example, many high specific power machines have reduced iron content, and therefore reduced intrinsic filtering, thus requiring the inverter to supply a low-distortion drive current. These machines also typically have a high pole count, thus requiring drive current at a higher electrical frequency. Other motors, such as brush-less dc and switch reluctance machines, require a carefully-shaped, non-sinusoidal drive current (Yang, Shang, Brown, & Krishnamurthy, 2015), (Zhang, Bowman, O'Connel, & Haran, 2018), (Anderson, et al., 2018). Two- and three-level inverter topologies are the conventional framework for the power electronics design of the drivetrain, and some demonstrations have shown recent progress towards addressing cost, power density and efficiency goals (Gurpinar & Ozpineci, 2018), (Zhu, Kim, Chen, Erickson, & Maksimović, 2018), (Deshpande, Chen, Narayanasamy, Sathyanarayanan, & Luo, 2018), (Alizadeh, et al., 2019). However, an unconventional approach may be necessary to take the dramatic leap in power density necessitated by the roadmap—while simultaneously addressing the other system needs. Therefore, this project leverages the flying capacitor multilevel (FCML) topology, together with a scalable, modular approach, to address these needs. This type of hybrid converter has several advantages: lower voltage (i.e., less than 300 V) transistors can be used, energy-dense capacitors process most of the power, and the output current waveform is multilevel and exhibits a frequency multiplying effect—in other words, the output has reduced dv/dt and filtering requirements for the same high voltage dc bus. For example, in an electric vehicle with an 800 V bus, a 10-level FCML could leverage 100 V, commercially available GaN devices switching at 115 kHz to produce a ~1 MHz switching waveform (modulated according to the motor drive requirements) with one ninth of the dv/dt of a two-level converter. Prior work has already demonstrated promising performance and gravimetric power density figures for more electric aircraft applications (Pallo, Foulkes, Modeer, Coday, & Pilawa-Podgurski, 2018). This project leverages lessons learned to achieve the volumetric power density of 100 kW/L by employing advanced liquid cooling, address the 300,000 mile reliability challenge with redundant design, topology failure studies and online health monitoring, and reduce costs to $\$$2.7/kW through the use of low-cost GaN devices, modular converter assemblies, and modest modifications to traditional manufacturing methods. The project involved several hardware designs, each achieving increasing performance. At the conclusion of the project, a volumetric power density of 380 kW/L was achieved, in a 800V dc-ac converter, greatly surpassing even the aggressive target goal.
This project is intended to support the development of new traction drive systems that meet the targets of 100 kW/L for power electronics and 50 kW/L for electric machines with reliable operation to 300,000 miles. To meet these goals, new designs must be identified that make use of state-of-the-art and next-generation electronic materials and design methods. Designs must exploit synergies between components, for example converters designed for high-frequency switching using wide band gap (WBG) devices and ceramic capacitors. This project included: (1) a survey of available technologies; (2) investigating new technologies, that for example, reduce volume of thermal management or magnetic components; (3) the development of computer aided design tools that consider the converter volume, reliability, and electrical performance; (4) exercising the design software to evaluate performance gaps and predict the impact of certain technologies and design approaches, i.e. GaN semiconductors, ceramic capacitors, ceramic thermal management components, and select topologies; (5) building and testing hardware prototypes to validate models and concepts. The design tools enable co-optimization of the power module and passive elements and provide some design guidance. At the end of the project, new advanced computing methods, such as machine learning approaches, were considered.
The overall objective of the electric motor portion of the Electric Drives Technology consortium is to research, develop, and test electric motors for use in electric vehicle applications capable of a peak power greater than 100 kW, power density greater than or equal to 50 kW/l, and a cost less than 3.3 $/kW. To meet the electric traction motor power density and cost targets a number of approaches were pursued simultaneously throughout the course of this project which address all of the major volumetric power density variables. The specific research thrusts at the Illinois Institute of Technology (IIT) are the following: multiphysics design for increased power density through maximum utilization of active materials, synthesis of electric machine windings and PM flux barriers with controlled space harmonics, high slot fill windings for increased current loadings or efficiency, aggressive cooling strategies, and design studies and prototype construction of candidate electric machines.
Five electric vehicles were tested at vehicle test tracks using the SAE. The tests provide range data at steady speeds and for several driving cycles. Most tests were conducted with lead-acid traction batteries. The Otis Van and the Copper Electric Town Car were also tested with lead-acid and nickel-zinc batteries. The tests showed a range increase of from 82 to 101 percent depending on vehicle, speed, and test cycle.
The report “America’s Strategy to Secure the Supply Chain for a Robust Clean Energy Transition” lays out the challenges and opportunities faced by the United States in the energy supply chain as well as the federal government plans to address these challenges and opportunities. It is accompanied by several issue-specific deep dive assessments, including this one, in response to Executive Order 14017 “America’s Supply Chains,” which directs the Secretary of Energy to submit a report on supply chains for the energy sector industrial base. The Executive Order is helping the federal government to build more secure and diverse U.S. supply chains, including energy supply chains. This report focuses on the supply chain for rare earth permanent magnets, specifically sintered neodymiumiron-boron (NdFeB) magnets, used in clean energy technologies. Sintered NdFeB magnets are the strongest magnets commercially available and provide a host of benefits to wide-ranging applications in consumer and industrial electronics, especially in advanced motor and drive systems. Within the Energy Sector Industrial Base, and clean energy in particular, NdFeB magnets are key intermediate components of permanent magnet synchronous (direct drive) generators in wind turbines (especially for offshore turbines) and electric synchronous traction motors for propulsion systems in battery and hybrid electric vehicles.
The development of Mn-Al-C permanent magnets is reviewed. The general properties of the material are discussed and put into perspective relative to alnicos and ferrites. The traction motor designer's demands of a permanent magnet for potential use in electric vehicle drives are reviewed. Tests determined magnetic design data and mechanical strength properties. Easy axis hysteresis and demagnetization curves, recoil loops and other minor loop fields were measured over a temperature range from -50 to 150 C. Hysteresis loops were also measured for three orthogonal directions (the one easy and two hard axes of magnetization). Extruded rods of three different diameters were tested. The nonuniformity of properties over the cross section of the 31 mm diameter rod was studied. Mechanical compressive and bending strength at room temperature was determined on individual samples from the 31 mm rod.
The development of Mn-Al-C permanent magnets is reviewed. The general properties of the material are discussed and put into perspective relative to alnicos and ferrites. The commercial material now available is described by the manufacturer's data. The traction motor designer's demands of a permanent magnet for potential use in electric vehicle drives are reviewed. From this, a list of the needed specific information is extracted. A plan for experimental work is made which would generate this information, or verify data supplied by the producer. The results of these measurements are presented in the form of tables and graphs. The tests determined magnetic design data and some mechanical strength properties. Easy axis hysteresis and demagnetization curves, recoil loops and other minor loop fields were measured over a temperature range from -50 C to +150 C. Hysteresis loops were also measured for three orthogonal directions (the easy and 2 hard axes of magnetization).
This project is intended to support the development of new traction drive systems that meet the targets of 100 kW/L for power electronics and 50 kW/L for electric machines with reliable operation to 300,000 miles. To meet these goals, new designs must be identified that make use of state-of-the-art and next-generation electronic materials and design methods. Designs must exploit synergies between components, for example converters designed for high-frequency switching using wide band gap devices and ceramic capacitors. This project includes: (1) a survey of available technologies; (2) the development of design tools that consider the converter volume and performance; (3) exercising the design software to evaluate performance gaps and predict the impact of certain technologies and design approaches, i.e. GaN semiconductors, ceramic capacitors, and select topologies; and (4) building and testing hardware prototypes to validate models and concepts. Early instantiations of the design tools enable co-optimization of the power module and passive elements and provide some design guidance; later instantiations will enable the co-optimization of inverter and machine. Prototype testing begins with evaluation of simpler conversion topologies (i.e. the half-bridge boost converter) and progresses with fabrication of prototype inverter drives.
Electrifying Class-8 heavy-duty trucks presents a promising opportunity to enhance energy efficiency and reduce freight transport costs. Battery electric trucks (BETs), once considered niche, are gaining traction due to advancements in battery technology and cost reductions. However, accurately predicting battery lifespan under realistic usage conditions remains a key challenge. Understanding battery failure mechanisms and their links to design, operation, and management is essential for developers and fleet operators. This study introduces a method to develop simplified, lab-testable dynamic stress test (DST) cycles for regional and long-haul Class-8 BETs, derived from real-world diesel truck usage. These DSTs enable benchmarking of battery technologies, identification of aging stressors, and optimization of battery design, life, and cost. The approach supports evaluation of key metrics such as levelized cost of driving and total cost of ownership, aiding fair comparisons and adoption decisions. We also propose feasible battery pack sizes that meet current driving demands with strategic charging, and a method to scale pack-level DSTs to cell-level cycles for lab-based testing. These tools facilitate tradeoff analysis across battery chemistries, pack sizing, and charging strategies, while offering means to get insights into battery aging under realistic conditions-ultimately supporting informed BET deployment decisions.
Axial flux permanent magnet machines (AFPM) are popular for applications that benefit from high torque density and an axially compact form factor, such as in-wheel traction drives. Although the radial flux permanent magnet machine (RFPM) and the AFPM work based on the same underlying principle, the differences in their geometry introduce complexities in analysis of the AFPM. In this paper, the different AFPM design variants, their sizing approaches, computationally efficient design optimization techniques, and manufacturing techniques reported in literature are reviewed. In addition to classical AFPM machines, emerging variants and research opportunities with potential to push the boundaries of electric machine technology are reviewed. These include bearingless AFPMs, magnetically geared AFPMs, and combined radial-axial flux machines.