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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 37 records · Page 2
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Acceleration of uranium beam to record power of 10.4 kW and observation of new isotopes at Facility for Rare Isotope Beams

The Facility for Rare Isotope Beams (FRIB) is a major nuclear physics facility for research with fast, stopped, and reaccelerated beams that was successfully commissioned in May 2022. A key capability of FRIB is the production of an acceleration of the uranium beam, but this capability requires the facility to work at the design limits of the lowest charge-to-mass ratio and the highest power density on the beam intercepting devices. This paper presents techniques for overcoming the significant challenges in accelerating the uranium beam, culminating in the demonstration of 10.4 kW on target, and the discovery of three new isotopes. The high-power uranium beam enabled us to produce and identify G 88 a , A 93 s , and S 96 e , within the first 24 h of operation. The successful uranium operation at FRIB sets a new record for accelerated uranium beam power above 10 kW and opens a new avenue of research with rare isotopes. Published by the American Physical Society 2024

43 PARTICLE ACCELERATORS↗
DOE OSTI2022

Design and Analysis of a 200 kW Dynamic Wireless Charging System for Electric Vehicles

Dynamic wireless charging of electric vehicles can significantly alleviate or eliminate range anxiety while reducing the required on-board battery capacity. To achieve an electric vehicle charging balance with minimal infrastructure costs, power transfer levels around 200 kW are required. In this paper, a system architecture with a modularized power electronics and optimized power transfer couplers was adopted to enable efficient power transfer. A DC/DC converter was used for secondary-side charging control of the battery. The system performance was validated in an experimental setup at 120 kW with 91.31% efficiency from the DC input on the primary side to the vehicle battery.

Xue, Lincoln↗
DOE OSTI2021

Modular Design of Receiver Side Power Electronics for 200 kW High Power Dynamic Wireless Charging System

Dynamic wireless power transfer (DWPT) can provide energy to EVs in motion and extend the drive range. By upscaling the charging power to 200 kW (High Power DWPT), the percentage of electrified roadway reduces and the solution becomes cost-effective. However, coil coupling-coefficient variation during vehicle movement fluctuates the transferred power which is unfavorable for vehicle battery. Secondary regulation design can smooth the power but the converter design becomes very challenging due to requirement in high power, high efficiency, fast control, as well as high power density since the unit will be onboard. This paper provides the modular design approach of a 200 kW secondary side unit to achieve high performance and scalability. The DC/DC converter using SiC devices demonstrated 98.3% efficiency.

Xue, Lincoln↗
DOE OSTI2022

A 100-kW Wireless Power Transfer System Development Using Polyphase Electromagnetic Couplers

Wireless power transfer (WPT) is an essential technology enabling automated charging of electric vehicles with safety, convenience, and flexibility while having high efficiencies. High-power wireless charging systems will be one of the dominating charging technologies for electric vehicles (EVs) in an effort to eliminate range anxiety and reduce charging times similar to that of gas station refueling practice. Polyphase electromagnetic coupler with rotating fields is a new bipolar wireless charging pad technology that can significantly increase the surface power density (kW/m2) of wireless charging coils. This study proposes a 100-kW wireless power transfer system with a compact vehicle-side (receiver) coupler that reaches to about 0.905 MW/m2 surface power density with a transmitter rated for up to 300 kW with 0.68 MW/m2. High-frequency power electronics including the inverter and rectifier designs are included in this digest along with the hardware prototype developments and preliminary experimental results.

Onar, Omer↗
DOE OSTI2021

Bidirectional LCC-LCC -Compensated 20 kW Wireless Power Transfer System for Medium-Duty Vehicle Charging

This paper presents the design and demonstration of a bidirectional 20 kW wireless charging system (WCS) with a significantly large airgap (11 inches) and asymmetrical input-output voltage levels. Analytical and experimental sensitivity analyses of the WCS resonant tank were conducted to verify the optimal operating region under the load and frequency variation. The inverter and rectifier were designed with switching components, the charging pads were designed with double-D (DD) coils, and the tuning networks were designed with an LCC-LCC tuning circuit. The grid and vehicle side tuning circuits were designed separately to achieve a ~1:2 gain for the asymmetrical input (800 V dc ) and output (350 V dc ) voltage. The proposed WCS was designed, simulated, and tested to verify the efficiency, power transfer capacity, and sensitivity under load variation. The experimental results show that, at 20-kW output power, the achieved grid to vehicle dc-dc efficiency was 96.1%, and vehicle to grid dc-dc efficiency was 96.2%. The proposed system is the largest-airgap bidirectional WCS with the highest efficiency and power density.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2022

Improvements to the Recycler/Main Injector to Deliver 850 kW+

The Main Injector is used to deliver a 120 GeV high power proton beam for Neutrino experiments. The design power of 700 kW was reached in early 2017 but further improvements have seen a new sustained peak power of 893 kW. Two of the main improvements include the shortening of the Main Injector ramp length as well optimizing the slip-stacking procedure performed in the Recycler to reduce the amount of uncaptured beam making its way into the Main Injector. These improvements will be discussed in this paper as well future upgrades to reach higher beam powers.

43 PARTICLE ACCELERATORS↗
DOE OSTI2021

Development of Gyrosole™ and Solar Thermal HVAC Technology for 20-60kW Applications, Final Report, CRADA No. TC02164.0

This was a collaborative effort between Lawrence Livermore National Security, LLC as manager and operator of Lawrence Livermore National Laboratory (LLNL) and Sol Xorce LLC to develop LLNL’s Gyrosole™ solar thermal energy system. The original scope of the CRADA project was to develop LLNL’s Gyrosole™thermal-powered motor technology for solar thermal energy system use, and was originally entitled, "Development of Gyrosole™ Solar Thermal Technology for 20-60 kW Applications". The scope and title of the project were later modified under Amendment One to the CRADA. The technical objective of this CRADA project was to develop Gyrosole™ motor technology so that it is marketplace-ready, and to produce a motor prototype that: Produces 50kW power at >22% efficiency; Operates oil-free; Has sufficient reliability and lifetime to be suitable for both commercial and residential applications; Costs less than $100 per kW installed to produce at scale; and, Can be combined cost-effectively to produce 200kW. The motor prototype would be integrated into model systems that provide electricity generation in combination with air/water heating, heat-pump driven cooling, desiccant dehumidification, and light industrial heat supply.

14 SOLAR ENERGY↗
DOE OSTI2024

Enabling Ultra-Compact, Lightweight, Efficient, and Reliable 6.6 kW On-Board Bi-Directional Electric Vehicle Charger with Advanced Topology and Control

The research explored new topologies, control methods, mechanical integration, and thermal management methods for electric vehicle (EV) on-board chargers. The team investigated capacitor-based power conversion, leveraging the high energy densities inherent to capacitive energy storage compared to inductive methods. The proposed topologies simultaneously enabled high power density and high efficiency of the design. The proposed architecture was demonstrated in a 6.6 kW bi-directional charger prototype. The research pursued several directions to improve system performance. Innovative topologies were studied for both the main power conversion stage as well as the single-phase twice-line-frequency energy buffer. To ensure robust and efficient operation, new control methods were developed to integrate these two subsystems. To achieve high power density in the full system solution, the mechanical structure of the charger is highly optimized to maximally fill the converter box volume. In parallel with the mechanical design effort, the converter was packaged with high-performance cooling methods which removed heat from key areas of power dissipation in the converter. The thermal management system was optimized to minimize its weight and volume, ultimately motivating the design of a custom additively manufactured cold-plate. The full system achieves a peak power of 7 kW with less than 0.3% total harmonic distortion (THD) and greater than 0.994 power factor in power factor correction (PFC) operation, corresponding to a total box-volume power density of 47.9 kW/L and gravimetric power density of 24.6 W/g. The system achieves a peak efficiency of 98.9%, with 97.9% efficiency at maximum power.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2025

Multi-Objective Design Optimization of 100 kW Non-Rare-Earth or Reduced-Rare-Earth Machines

The goal of this project is to reduce the size, weight, cost, and losses associated with rotating electric machinery and its associated power electronics for electric and hybrid vehicle applications. In particular, this effort strives to facilitate electric machinery that will meet the requirements set forth in the USDRIVE Electrical and Electronics Technical Team Roadmap of October 2017. This roadmap calls for an electric machine with a peak power of 100 kW, a continuous rated power of 55 kW, a peak speed of less than 20,000 rpm, a volume of no more than 2 liters, a mass of less than 20 kg, and a useful life of 15 years or 300,000 miles of vehicle service. This will be achieved through a combination of (i) new materials, (ii) new electric machine topologies, (iii) advances in power electronics, and (iv) superior design through the use of formal and rigorous multi-objective optimization-based design founded on advanced analysis techniques.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2024

Double-Side Cooled 1.2kV, 300A SiC MOSFET Phase-leg Modules for 200 kW, > 100 kW/L Traction Inverters

The packaging of a double-side cooled 1.2 kV, 149 A SiC phase-leg modules has been reported in recent years for making 100 kW, 100 kW/L traction inverters. Each phase-leg module consists of two SiC MOSFETs, one per switch position. Six of the phase-leg modules are assembled into a segmented inverter configuration to meet the power and power density requirement. In this work, the layout of the phase-leg module was redesigned to include four of the SiC MOSFETs, two per switch position, with the aim of doubling the power to 200 kW and increasing the power density beyond 100 kW/L, but with only a 10.25% footprint increase. Key features of the packaging technology developed in the previous work were implemented in the current work, which include silver sintering for chip bonding and porous silver inter-posts for bonding device source pads to substrate. Parasitic extraction simulation showed that the four-chip module has a low parasitic inductance of 4.7 nH, like the two-chip module. Static characterization of the four-chip prototypes showed a low average on-resistance of 9 mΩ and a low average leakage current of 5 nA at Vds of 1.2 kV.

Zhang, Zichen↗
DOE OSTI2020

Coal direct chemical looping process: 250 kW pilot-scale testing for power generation and carbon capture

Chemical looping combustion (CLC) is an energy conversion technology that can produce concentrated CO 2 stream without the need for a gas separation step, and thus, has the potential to drastically reduce the energy consumption and cost associated with CO 2 capture in power generation. The coal-direct chemical looping (CDCL) process is a CLC technology that uses a moving bed reducer configuration that can directly consume coal as a feedstock without requiring an upstream gasification step. An integrated 250 kW th CDCL pilot unit using iron-based oxygen carriers was constructed and demonstrated for over 1000 h of testing. The principles for the CDCL pilot unit design and operation are summarized in this article. During the 288-hour continuous operation testing, the CDCL pilot unit achieved >96% coal conversion with a CO 2 purity of >97%. Low carbon carryover into the combustor, i.e. <2%, was also confirmed during the test, which shows the capability of the moving bed reactor to retain and convert coal using the oxygen available on the iron-based oxygen carrier. The results from the pilot unit testing confirms the CDCL concept as a promising coal combustion technology for heat and power generation with CO 2 capture.

10 SYNTHETIC FUELS↗
DOE OSTI2022

Dynamic characterization and performance evaluation of a 10-kW power take-off with mechanical motion rectifier for wave energy conversion

The power take-off (PTO) is a key component for wave energy converters. In this paper, a compact PTO with mechanical motion rectification rated at 10 kW is designed and prototyped, and characterized. A piecewise nonlinear dynamic model is established to describe its unique dynamic property. A linear hydraulic actuator is adopted in lab testing to drive the prototype and the unknown parameters of the dynamic model are identified. Further verification shows that the model can predict the dynamic performance of the PTO well. The test results show that the mechanical motion rectifier-based PTO can achieve overall energy transfer efficiency as high as 65% in regular waves even when the generator is working below the rated electric load and speed. In the irregular wave test, the PTO achieved the overall energy transfer efficiency of 54%, and the peak-to-average ratio acquired during the test is 12.5.

16 TIDAL AND WAVE POWER↗
DOE OSTI2023

Design and Demonstration of an 850 V dc to 13.8 kV ac 100 kW Three-phase Four-wire Power Conditioning System Converter Using 10 kV SiC MOSFETs

In this paper, an 850 V dc to 13.8 kV ac 100 kW modular multilevel three-phase four-wire dc/ac converter based on 10 kV SiC MOSFETs is designed and demonstrated. The design considerations of key components, including the dc-link, device cooling, gate driver, isolated gate driver power supply (GDPS), medium voltage (MV) ac filter inductor, MV and medium frequency transformer, and the mechanical design are discussed. Two converters are designed, and two prototypes are developed, to study the converter paralleling operation and scalability. Both converters are fully tested up to their voltage and power ratings. However, the two converters are not identical. Based on the design and test results of the first converter, the MV power stage, transformer design, GDPS, as well as the low voltage power stage in the second converter are improved for smaller size and/or higher efficiency. Compared to the version 1 converter, the version 2 converter achieves 49% volume reduction and 2 percentage point efficiency improvement, with a peak efficiency of 98.4% at the rated power.

Li, Haiguo↗
DOE OSTI2022

A 50-kW Bidirectional Step-up / Step-down DC/DC Oak Ridge Converter for Wireless Charger Applications

This study presents a novel bidirectional concept by using Oak Ridge Converter (ORC) for wireless energy conversion (WEC) technologies such as wireless electric vehicle (EV) chargers, wireless mobile or energy storage systems (MESS / ESS), etc. The presented system can be deployed in a bidirectional wireless power transfer (WPT) structure for different input voltages by using two different operating frequencies. The proposed concept here achieves zero voltage switching (ZVS) in during step-up and step-down configurations. The system overall theoretical design and experimental test results are presented for 50 kW power transfer in both bidirectional operations modes. The laboratory demonstration of the system is presented for the three-phase bidirectional system with 6 inches of airgap between the coils and output of 560 VDC with 95.4% dc-to-dc efficiency.

Asa, Erdem↗
DOE OSTI2022

A 20-kW DC Oak Ridge Converter with Integrated AC & DC Sources for Grid Services and Energy Storage Systems

This paper proposes a wireless power transfer (WPT) platform with integrated energy conversion that has the capability for 1) recharging the energy storage systems (ESSs) from the grid systems, including renewable energy sources such as wind, solar, etc., 2) off grid systems recharging the ESSs from dc grid systems, 3) grid recharging of electric vehicles (EVs), and 4) off grid recharging of EVs from ESSs. The unique aspect of the method is the use of multi-interface power electronic converter for the grid and ESSs and EVs that can support a range of applications with ac / dc and dc / dc energy conversion ability in a single converter system. The key enabling technology to achieve these functionalities is Oak Ridge Converter (ORC) with polyphase coupler coil system both developed at ORNL. This new technology enables higher power density WPT systems while allowing the coils to interface from ac grid at 60 Hz frequency or dc source directly merging with 85 kHz operating frequency of switching component. The experimental results of the proposed system are presented for 20 kW output power with the system overall efficiency around 95.4% from dc source and 93% overall efficiency from ac grid achieving 9-10% current total harmonic distortion (THD) and 0.98-0.99 power factor (PF).

Asa, Erdem↗
DOE OSTI2024

Thermal Analysis of a 100 kW Polyphase Wireless Power Transfer System

Charging Electric Vehicles (EVs) fast and safely has a crucial role in the future of the EV technology. High-power Wireless Power Transfer (WPT) helps to significantly decrease the charging time. However, when the power transfer levels increase, thermal management becomes a significant challenge. The thermal design of the WPT systems needs more consideration in the design and implementation steps. This paper presents a thermal analysis of a 100 kW high-power WPT system. The thermal performance of the proposed design was evaluated at different power levels by considering the magnetic design and loss analysis. Finite Element Analysis (FEA) of the proposed design was performed and the thermal images of the implemented system were taken to prove the simulation results. The results show that, a liquid cooling design is needed for a high-power WPT systems for the long-time continuous operations of the charging pads.

Aydin, Emrullah↗
DOE OSTI2025

Circuit Modeling, Simulation, and Experimental Validation of a 100-kW Polyphase Wireless Power Transfer System for EV Applications

Polyphase wireless power transfer (WPT) systems can achieve much higher surface power densities (kW/m2) and specific power levels (kW/kg) compared to the conventional circular single phase WPT systems. Therefore, polyphase WPT systems can reduce the size, weight, volume, and cost of the WPT systems and can simplify the electric vehicle integration with less demand for space. This study presents the high-performance and compact 100-kW WPT development using polyphase electromagnetic coupling coils with rotating magnetic fields.

Onar, Omer [ORNL] (ORCID:0000000292028857)↗
DOE OSTI2020

Shield Design for 50 kW Three-Phase Wireless Charging System

In this paper, magnetic field emissions (MFE) from a 50 kW bipolar coil-based three-phase wireless charging system (WCS) is investigated. Then, a shield design is proposed to suppress the MFE below the safety limit identified by the International Commission of Non-Ionized Radiation Protection (ICNIRP) guidelines. Bipolar coil-based three-phase (3φ) WCSs provide extremely high power-density; therefore, the 3φ WCSs are highly promising for high-power fast-wireless-charging of the electric vehicles. For the high-power EV application, it is a critical challenge to design a shield to suppress the MFE below the safety limit. The traditional aluminum shield is found ineffective for the bipolar 3φ-WCS. The proposed shield is designed with high-permeability magnetic material, i.e. ferrite, nanocrystalline material, etc. The proposed shield is simulated in finite element analysis (FEA) and the FEA results show that the proposed magnetic shield effectively suppresses the magnetic field emission below the ICNIRP limit. The generalized design of the proposed shield can be used for even higher power bipolar coil based WCSs.

Mohammad, Mostak↗