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NASA NTRS1989

Magnification of starting torques of dc motors by maximum power point trackers in photovoltaic systems

Direct current (dc) motors are used in terrestrial photovoltaic (PV) systems such as in water-pumping systems for irrigation and water supply. Direct current motors may also be used for space applications. Simple and low weight systems including dc motors may be of special interest in space where the motors are directly coupled to the solar cell array (with no storage). The system will operate only during times when sufficient insolation is available. An important performance characteristic of electric motors is the starting to rated torque ratio. Different types of dc motors have different starting torque ratios. These ratios are dictated by the size of solar cell array, and the developed motor torque may not be sufficient to overcome the load starting torque. By including a maximum power point tracker (MPPT) in the PV system, the starting to rated torque ratio will increase, the amount of which depends on the motor type. The starting torque ratio is calculated for the permanent magnet, series and shunt excited dc motors when powered by solar cell arrays for two cases: with and without MPPT's. Defining a motor torque magnification by the ratio of the motor torque with an MPPT to the motor torque without an MPPT, a magnification of 3 was obtained for the permanent magnet motor and a magnification of 7 for both the series and shunt motors. The effect of the variation of solar insolation on the motor starting torque was covered. All motor types are less sensitive to insolation variation in systems including MPPT's as compared to systems with MPPT's. The analysis of this paper will assist the PV system designed to determine whether or not to include an MPPT in the system for a specific motor type.

Appelbaum, Joseph↗

NASA NTRS1994

Pressurized fluid torque driver control and method

Methods and apparatus are provided for a torque driver including a displaceable gear to limit torque transfer to a fastener at a precisely controlled torque limit. A biasing assembly biases a first gear into engagement with a second gear for torque transfer between the first and second gear. The biasing assembly includes a pressurized cylinder controlled at a constant pressure that corresponds to a torque limit. A calibrated gage and valve is used to set the desired torque limit. One or more coiled output linkages connect the first gear with the fastener adaptor which may be a socket for a nut. A gear tooth profile provides a separation force that overcomes the bias to limit torque at the desired torque limit. Multiple fasteners may be rotated simultaneously to a desired torque limit if additional output spur gears are provided. The torque limit is adjustable and may be different for fasteners within the same fastener configuration.

Cook, Joseph S., Jr.↗

NASA NTRS1997

Displaceable Gear Torque Controlled Driver

Cook, Joseph S., Jr.↗

NASA NTRS2002

Torque Splitting by a Concentric Face Gear Transmission

Tests of a 167 Kilowatt (224 Horsepower) split torque face gearbox were performed by the Boeing Company in Mesa, Arizona, while working under a Defense Advanced Research Projects Agency (DARPA) Technology Reinvestment Program (TRP). This paper provides a summary of these cooperative tests, which were jointly funded by Boeing and DARPA. Design, manufacture and testing of the scaled-power TRP proof-of-concept (POC) split torque gearbox followed preliminary evaluations of the concept performed early in the program. The split torque tests were run using 200 N-m (1767 in-lbs) torque input to each side of the transmission. During tests, two input pinions were slow rolled while in mesh with the two face gears. Two idler gears were also used in the configuration to recombine torque near the output. Resistance was applied at the output face gear to create the required loading conditions in the gear teeth. A system of weights, pulleys and cables were used in the test rig to provide both the input and output loading. Strain gages applied in the tooth root fillets provided strain indication used to determine torque splitting conditions at the input pinions. The final two pinion-two idler tests indicated 52% to 48% average torque split capabilities for the two pinions. During the same tests, a 57% to 43% average distribution of the torque being recombined to the upper face gear from the lower face gear was measured between the two idlers. The POC split torque tests demonstrated that face gears can be applied effectively in split torque rotorcraft transmissions, yielding good potential for significant weight, cost and reliability improvements over existing equipment using spiral bevel gearing.

Filler, Robert R.↗

NASA NTRS2011

Methodology for Determining Limit Torques for Threaded Fasteners

In aerospace design, where minimizing weight is always a priority, achieving the full capacity from fasteners is essential. To do so, the initial bolt preload must be maximized. The benefits of high preload are well documented and include improved fatigue resistance, a stiffer joint, and resistance to loosening. But many factors like elastic interactions and embedment tend to lower the initial preload placed on the bolt. These factors provide additional motivation to maximize the initial preload. But, to maximize bolt preload, you must determine what torque to apply. Determining this torque is greatly complicated by the large preload scatter generally seen with torque control. This paper presents a detailed methodology for generating limit torques for threaded fasteners. This methodology accounts for the large scatter in preload found with torque control, and therefore, addresses the statistical nature of the problem. It also addresses prevailing torque, a feature common in aerospace fasteners. Although prevailing torque provides a desired locking feature, it can also increase preload scatter. In addition, it can limit the amount of preload that can be generated due to the torsion it creates in the bolt. This paper discusses the complications of prevailing torque and how best to handle it. A wide range of torque-tension bolt testing was conducted in support of this research. The results from this research will benefit the design engineer as well as analyst involved in the design of bolted joints, leading to better, more optimized structural designs.

Hissam, Andy↗

DOE OSTI2025

Field validation of dynamic mechanical torque measurements using fiber-optic strain sensors for geared wind turbines

Abstract Accurate knowledge of the mechanical loads of wind turbine gearboxes has become essential in modern, highly loaded gearbox designs, as maintaining or even improving gearbox reliability with increasing torque density demands is proving to be challenging. Unfortunately, the traditional method of measuring dynamic mechanical torque using strain gauges placed on the outer surface of a rotating shaft and transmitting the resulting signal is unsuitable for serial deployment due to technical and economic constraints. An alternative method based on fiber-optic strain sensors placed on the stationary outer surface of the gearbox ring gear has been proposed. Like shaft torsion, the radial deformation of the ring gear is proportionate to the rotor torque. Placing the sensors on a stationary component is a cost-effective alternative for serial implementation because the need for complex and expensive data transfer via wireless transmission or a slip ring is eliminated. In this paper, we present the results of an extensive field experiment conducted to evaluate the torque measurement accuracy of this novel sensing solution installed on the gearbox of a Gamesa G97 2-MW wind turbine at the National Renewable Energy Laboratory’s Flatirons Campus. Torque measurements derived from fiber-optic strain sensors placed on the ring gear of the planetary stage are compared to conventional torque measurements from strain gauges placed on the main shaft. Two different torque estimation data processing methods were evaluated, with the method based on operational deflection shapes providing the most accurate results with an average normalized root mean square error below 0.7% for a load revolution distribution analysis. The effect of operating conditions on the torque estimate was also investigated, and the third planet-passing operational deflection shape was found to be the least sensitive to nontorque load-related effects. The fiber-optic strain sensors’ successful operation during the complete test campaign has demonstrated a robust and accurate solution for fleet-wide enhanced gearbox remaining useful life estimation.

17 WIND ENERGY↗

DOE OSTI2020

Interfacial spin–orbit torques

Spin–orbit torques offer a promising mechanism for electrically controlling magnetization dynamics in nanoscale heterostructures. While spin–orbit torques occur predominately at interfaces, the physical mechanisms underlying these torques can originate in both the bulk layers and at interfaces. Classifying spin–orbit torques based on the region that they originate in provides clues as to how to optimize the effect. While most bulk spin–orbit torque contributions are well studied, many of the interfacial contributions allowed by symmetry have yet to be fully explored theoretically and experimentally. To facilitate progress, we review interfacial spin–orbit torques from a semiclassical viewpoint and relate these contributions to recent experimental results. In this study, we show the relationship between different interface transport parameters within the same model. For charges and spins flowing perpendicular to the interface, interfacial spin–orbit coupling both modifies the mixing conductance of the magnetoelectronic circuit theory and gives rise to spin memory loss. For in-plane electric fields, interfacial spin–orbit coupling gives rise to torques described by spin–orbit filtering, spin swapping, and precession. In addition, these same interfacial processes generate spin currents that flow into the non-magnetic layer. For in-plane electric fields in trilayer structures, the spin currents generated at the interface between one ferromagnetic layer and the non-magnetic spacer layer can propagate through the non-magnetic layer to produce novel torques on the other ferromagnetic layer.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

DOE OSTI2024

Unconventional fieldlike spin torques in CrPt 3

The topological semimetal CrPt 3 has potential for generating unconventional spin torques due to its ferrimagnetic ordering, topological band structure, and high anomalous Hall effect. CrPt 3 exhibits ferrimagnetic behavior only in its chemically ordered phase and is paramagnetic in its chemically disordered phase. By controlling the growth and annealing temperatures, we prepare epitaxial films of both chemically ordered and chemically disordered phases of CrPt 3 , allowing us to investigate the effect of magnetic ordering on unconventional-torque generation. We use angle-dependent spin-torque-ferromagnetic-resonance and second-harmonic Hall measurements to probe the spin torques generated from epitaxial CrPt 3 in CrPt 3 /Cu/Ni 81 ⁢Fe 19 heterostructures. With current applied along specific directions with respect to the crystal order, we reveal unconventional spin torques in both ordered and disordered films. When current flows parallel to the [$1\bar{1}1$] and [ $\bar{1}11$] directions, we observe an unconventional fieldlike torque that is opposite in sign for the two directions. Finally, our calculations reveal that this unconventional torque originates from an indirect nonlocal spin-orbit torque due to spin scattering at the CrPt 3 /Cu interface, in addition to symmetry breaking at this interface.

ferromagnetic resonance↗

DOE OSTI2025

Field Validation of Dynamic Mechanical Torque Measurements for Geared Wind Turbines

Accurate knowledge of the mechanical loads of wind turbine gearboxes has become essential in modern, highly loaded gearbox designs, as maintaining or even improving gearbox reliability with increasing torque density demands is proving to be challenging. Unfortunately, the traditional method of measuring dynamic mechanical torque using strain gauges placed on the outer surface of a rotating shaft and transmitting the resulting signal is unsuitable for serial deployment due to technical and economic constraints. An alternative method based on fiber-optic strain sensors placed on the stationary outer surface of the gearbox ring gear has been proposed. Like shaft torsion, the radial deformation of the ring gear is proportionate to the rotor torque. Placing the sensors on a stationary component is a cost-effective alternative for serial implementation because the need for complex and expensive data transfer via wireless transmission or a slip ring is eliminated. In this paper, we present the results of an extensive field experiment conducted to evaluate the torque measurement accuracy of this novel sensing solution installed on the gearbox of a Gamesa G97 2-MW wind turbine at the National Renewable Energy Laboratory's Flatirons Campus. Torque measurements derived from fiber-optic strain sensors placed on the ring gear of the planetary stage are compared to conventional torque measurements from strain gauges placed on the main shaft. Two different torque estimation data processing methods were evaluated, with the method based on operational deflection shapes providing the most accurate results with an average normalized root mean square error below 0.7% for a load revolution distribution analysis. The effect of operating conditions on the torque estimate was also investigated, and the third planet-passing operational deflection shape was found to be the least sensitive to nontorque load-related effects. The fiber-optic strain sensors' successful operation during the complete test campaign has demonstrated a robust and accurate solution for fleet-wide enhanced gearbox remaining useful life estimation.

17 WIND ENERGY↗

DOE OSTI2021

Systematics and Consequences of Comet Nucleus Outgassing Torques

Anisotropic outgassing from comets exerts a torque sufficient to rapidly change the angular momentum of the nucleus, potentially leading to rotational instability. Here, we use empirical measures of spin changes in a sample of comets to characterize the torques, and to compare them with expectations from a simple model. Both the data and the model show that the characteristic spin-up timescale, τ {sub s}, is a strong function of nucleus radius, r {sub n}. Empirically, we find that the timescale for comets (most with perihelion 1–2 au and eccentricity ∼0.5) varies as τ{sub s}∼100r{sub n}{sup 2}, where r {sub n} is expressed in kilometers, and τ {sub s} is in years. The fraction of the nucleus surface that is active varies as f{sub A}∼0.1r{sub n}{sup −2}. We find that the median value of the dimensionless moment arm of the torque is k {sub T} = 0.007 (i.e., ∼0.7% of the escaping momentum torques the nucleus), with weak (<3σ) evidence for a size dependence k{sub T}∼10{sup −3}r{sub n}{sup 2}. Sub-kilometer nuclei have spin-up timescales comparable to their orbital periods, confirming that outgassing torques are quickly capable of driving small nuclei toward rotational disruption. Torque-induced rotational instability likely accounts for the paucity of sub-kilometer short-period cometary nuclei, and for the pre-perihelion destruction of sungrazing comets. Torques from sustained outgassing on small active asteroids can rival YORP torques, even for very small (≲1 g s{sup −1}) mass-loss rates. Finally, we highlight the important role played by observational biases in the measured distributions of τ {sub s}, f {sub A}, and k {sub T}.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

NASA NTRS2017

Installation Torque Tables for Noncritical Applications

The objective of this project is to define torque values for bolts and screws when loading is not a concern. Fasteners require a certain torque to fulfill its function and prevent failure. NASA Glenn Research Center did not have a set of fastener torque tables for non-critical applications without loads, usually referring to hand-tight or wrench-tight torqueing. The project is based on two formulas, torque and pullout load. Torque values are calculated giving way to preliminary data tables. Testing is done to various bolts and metal plates, torqueing them until the point of failure. Around 640 torque tables were developed for UNC, UNF, and M fasteners. Different lengths of thread engagement were analyzed for the 5 most common materials used at GRC. The tables were put together in an Excel spreadsheet and then formatted into a Word document. The plan is to later convert this to an official technical publication or memorandum.

installation↗

NASA NTRS1981

Torque characteristics of a 122-centimeter butterfly valve with a hydro/pneumatic actuator

Actuating torque data from field testing of a 122-centimeter (48 in.) butterfly valve with a hydro/pneumatic actuator is presented. The hydraulic cylinder functions as either a forward or a reverse brake. Its resistance torque increases when the valve speeds up and decreases when the valve slows down. A reduction of flow resistance in the hydraulic flow path from one end of the hydraulic cylinder to the other will effectively reduce the hydraulic resistance torque and hence increase the actuating torque. The sum of hydrodynamic and friction torques (combined resistance torque) of a butterfly valve is a function of valve opening time. An increase in the pneumatic actuating pressure will result in a decrease in both the combined resistance torque and the actuator opening torque; however, it does shorten the valve opening time. As the pneumatic pressure increases, the valve opening time for a given configuration approaches an asymptotical value.

Lin, F. N.↗

NASA NTRS1986

A torque, tension and stress corrosion evaluation of high strength A286 bolts

The problems associated with overtorque applied to the Booster Separation Motor (BSM) Igniter Adapter high strength 200 KSI (1379 Mpa) A286 CRES bolts and the threaded holes of the 7075-T73 aluminum alloy BSM cases are addressed. The evaluation included torque, tensile, and stress corrosion tests incorporating the A286 CRES bolts and the 7075-T73 aluminum alloy BSM cases. The tensile test data includes ultimate tensile load (UTL), Johnson's 2/3 yield load (J2/3YL), proportional limit load (PLL), and total bolt stretch. Torque tension data includes torque, torque induced load, and positive and negative break-away torque. Stress corrosion test data reflect the overtorque and the resulting torque induced loads sustained by the A286 CRES bolts torqued into a 7075-T73 aluminum alloy forged dome with threaded holes. After 60 days of salt fog exposure, the positive and the negative break-away torques, the subsequent mechanical property tensile test results, and the BSM dome threaded hole axial tensile pullout loads are reported.

Montano, J. W.↗

NASA NTRS2004

Heat Control via Torque Control in Friction Stir Welding

In a proposed advance in friction stir welding, the torque exerted on the workpiece by the friction stir pin would be measured and controlled in an effort to measure and control the total heat input to the workpiece. The total heat input to the workpiece is an important parameter of any welding process (fusion or friction stir welding). In fusion welding, measurement and control of heat input is a difficult problem. However, in friction stir welding, the basic principle of operation affords the potential of a straightforward solution: Neglecting thermal losses through the pin and the spindle that supports it, the rate of heat input to the workpiece is the product of the torque and the speed of rotation of the friction stir weld pin and, hence, of the spindle. Therefore, if one acquires and suitably processes data on torque and rotation and controls the torque, the rotation, or both, one should be able to control the heat input into the workpiece. In conventional practice in friction stir welding, one uses feedback control of the spindle motor to maintain a constant speed of rotation. According to the proposal, one would not maintain a constant speed of rotation: Instead, one would use feedback control to maintain a constant torque and would measure the speed of rotation while allowing it to vary. The torque exerted on the workpiece would be estimated as the product of (1) the torque-multiplication ratio of the spindle belt and/or gear drive, (2) the force measured by a load cell mechanically coupled to the spindle motor, and (3) the moment arm of the load cell. Hence, the output of the load cell would be used as a feedback signal for controlling the torque (see figure).

Venable, Richard↗

DOE OSTI2022

System and method for torque split arbitration

A method for torque split arbitration in a vehicle includes identifying at least one route characteristic of a portion of a route being traversed by the vehicle. The method further includes determining a target torque split based on the at least one route characteristics. The method further includes generating a first output torque demand that corresponds to a product of a first portion of a target torque demand to be provided by a first propulsion unit and a ratio of a total propulsion system torque demand and the target torque demand. The method further includes generating a second output torque demand based on the first output torque demand.

Aggoune, Karim↗

DOE OSTI2023

Evaluation of Torque-Dense Electric Machine Technology for Off-Highway Vehicle Electrification

Electrification of off-highway vehicles offers the benefits of improved energy efficiency, enhanced control, and reduction in greenhouse gas emissions. However, progress towards electrification has been limited by the low torque density (30 kNm/m 3 ) of conventional electric machines compared to mobile hydraulic machines (up to approximately 1000 kNm/m 3 ). This paper reviews emerging variants of electric machines that offer a step improvement in torque density and potential pathway to enable electrified off-highway vehicles. First, sizing approaches for electric and hydraulic machines are developed, and torque-dense electric machines reviewed in literature are compared to commercial hydraulic machines to identify design trends in terms of speed, torque density, and power density. Next, key metrics are identified for the electric machine, based on which the following four emerging electric machine variants that promise to improve torque density are reviewed: i) multi-harmonic machines injection, ii) combined radial-axial flux machines, iii) magnetic gears, and iv) magnetically-geared machines. Here, the findings from this review show that these new electric machines can achieve upwards of 300% improvement in electric machine torque density, with several designs exceeding 100 kNm/m 3 , making them worthy candidates for further research to bridge the torque density gap with hydraulic machines.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2024

Unconventional Spin-Orbit Torques Due to Reduced Crystal Symmetries

Spin-orbit torques have emerged as a powerful mechanism for manipulating magnetic moments in spintronic devices, offering a pathway to more efficient and scalable memory and logic technologies. While conventional spin-orbit torques generated in heavy metals and topological insulators have been extensively studied, recent advancements in unconventional spin-orbit torques demonstrated out-of-plane spin polarizations that could effectively switch perpendicular magnetizations without the need for additional external in-plane magnetic fields, promising significant implications for the development of energy-efficient and compact spintronic devices. Unconventional spin-orbit torques are usually found in materials with low symmetries, such as transition metal dichalcogenides, topological insulators, and 2-D materials. Here, we provide a brief overview of unconventional spin-orbit torques and present two example material systems: CrPt 3 and MoTe 2 , both exhibiting strong spin-orbit coupling and phase-dependent spin-orbit torques, and focus on their unique origins and potential applications. We discuss the roles of magnetic and crystallographic orders in generating unconventional spin-orbit torques, highlighting how these factors contribute to the observed anisotropic and directional dependencies.

magnetic films↗

DOE OSTI2024

Postfault Operation of Three-Level Inverter Driven Six-Phase PMSM With Enhanced Torque–Speed Region

This article presents an open-switch postfault operational technique with enhanced torque–speed region for three-level (3L) active neutral point clamped (ANPC) inverter-driven symmetrical six-phase (SSP) permanent magnet synchronous machines (PMSMs). Maximum torque (MT), minimum loss (ML), and single three-phase (STP) operations are commonly used for the postfault operations of six-phase drives. The maximum possible torque and speed in these operations are generally limited by voltage, current ratings, and the neutral point configuration of the motor. To enhance the postfault torque and speed operating region, the torque and speed limits in different postfault operational techniques are determined based on the voltage, current constraints, and neutral point configuration of the SSP-PMSM. In this work, a unified postfault operation is proposed that increases the postfault operational limits by combining MT, ML, and STP operations and modifying the neutral point configuration of the SSP-PMSM. In addition, a technique is also presented that modifies the pulsewidth modulation technique to enable full torque operation below 0.5 p.u. speed. The proposed postfault operational technique enables full-speed (1 p.u.) operation by operating in STP mode and full torque operation (1 p.u.) below 0.5 p.u. speed. Furthermore, the postfault operational technique is experimentally validated using a Gallium Nitride (GaN) device-based3L-ANPC inverter-driven SSP-PMSM.

42 ENGINEERING↗