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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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This paper describes the new mission possibilities and technology requirements for a high power solar Electric Propulsion (SEP) system using a Taurus-class launch vehicle. A 10-kW Hall effect Thruster with Anode Layer (TAL) running direct-drive off a high voltage solar array could produce enough thrust to enable very rapid missions with a small sciencecraft to various destinations throughout the solar system.
Electric aircraft require advances in electric motor drivetrain efficiency, specific power, and reliability. In terms of mass and efficiency, mechanically geared electric motor drivetrains will significantly outperform direct drive electric motor drive trains in most applications. Mechanical gears however have numerous wear and failure modes that can result in increased maintenance and reliability penalties for an aircraft. Magnetic gears are being explored by NASA as a potential alternative to mechanical gears for electric aircraft applications. Magnetic gears have none of the surface contact related wear and failure modes of mechanical gears. Therefore, they potentially pose a high reliability alternative to mechanical gears. Magnetic gears can also share magnetic components with an electric motor in a magnetically geared drivetrain to achieve significant weight savings. In this paper, one possible topology of magnetically geared motor, the double-sided axial flux magnetically geared motor, is studied to quantify its achievable performance. Design study results suggest that the topology can achieve greater than 20 Nm/kg and 97% efficiency at a 100 kW output power.
Single aisle class electric aircraft require high power density and efficiency megawatt electric machines to be competitive with their tradition turbofan counterparts. Superconducting machines are seen as a key enabling technology for achieving the electric motor power density and efficiency needed by single aisle class electric aircraft. NASA’s High Efficiency Megawatt Motor (HEMM) is a partially superconducting machine being developed at NASA Glenn Research Center as a technology demonstration of a practical near-term superconducting machine. HEMM is being developed to meet the requirements of the generators on NASA’s STARC-ABL reference aircraft. HEMM is expected to achieve greater than 16 kW/kg electromagnetic specific power and greater than 98% efficiency at a nominal operating condition of 1.4 MW and 6800 RPM. In this paper, a design optimization algorithm for partially superconducting machines based on HEMM’s technologies is used to explore the possible performance of HEMM technology at other machine power levels and operating conditions. The design optimization algorithm is detailed in full and results for achievable geared and direct drive machine performance are presented.
Electric aircraft require advances in electric motor drivetrain efficiency, specific power, and reliability. In terms of mass and efficiency, mechanically geared electric motor drivetrains will significantly outperform direct drive electric motor drive trains in most applications. Mechanical gears however have numerous wear and failure modes that can result in increased maintenance and reliability penalties for an aircraft. Magnetic gears are being explored by NASA as a potential alternative to mechanical gears for electric aircraft applications. Magnetic gears have none of the surface contact related wear and failure modes of mechanical gears. Therefore, they potentially pose a high reliability alternative to mechanical gears. Magnetic gears can also share magnetic components with an electric motor in a magnetically geared drivetrain to achieve significant weight savings. In this paper, one possible topology of magnetically geared motor, the double-sided axial flux magnetically geared motor, is studied to quantify its achievable performance. Design study results suggest that the topology can achieve greater than 20 Nm/kg and 97% efficiency at a 100 kW output power.
To address problems experienced by current reaction wheels and control moment gyroscopebased attitude control systems (ACS), researchers at NASA’s Marshall Space Flight Center have begun developing a reaction sphere actuator based on correlated electromagnetic levitation that will be immune to destructive bearing friction, momentum saturation, and gimbal lock. The Correlated Electromagnetic Levitation Actuator (CELA) advances the state of the art of reaction sphere ACSs by employing the concept of correlated magnetics. It is a frictionless, direct-drive reaction sphere that harnesses a unique technology with an array of applications across multiple disciplines. Correlated electromagnets function in a manner that is analogous to a matched filter; the convolution of two signals is peaked at the index representing the greatest match. For CELA, the signals are the patterns of magnetic flux density as a function of position. The magnitude of the convolution equates to an attractive or repulsive force, and these forces can be azimuthal or radial. The development of CELA is based in four distinct disciplines: Advanced Manufacturing, Prototype Development, Electromagnetic Modeling, and Controls. We are developing novel manufacturing techniques required to build arrays of permanent and electromagnet dipoles on curved surfaces. To print the permanent magnetic array, we have developed a probe with pyramidal magnets that will reside on a robotic arm to induce localized magnetic fields on a surface. The probe also includes the ability to erase dipole patterns from a permanent magnet by heating the surface to its Curie temperature. A number of test articles and prototypes have been developed using additive manufacturing methods. These prototypes have included hemispherical motors to test the drive algorithm, and a levitation test bed that demonstrates a magnetic bearing method based on attractive magnetic forces and ratiometric Hall effect sensors. We developed an array of electromagnetic dipoles on a printed circuit board (PCB) with individual H-bridges controlling each coil. This device created various flux density patterns and we measured their magnetic fields using a custom Hall effect 3-D probe and a LabVIEW virtual instrument. These data will serve as a benchmark for characterizing the accuracy of future models. Current work is focused on modeling the magnetic fields of our prototype arrays using COMSOL Finite Element Analysis and verifying the model against our test data. Accurate modeling will allow us to quickly test new patterns of electromagnets and their macro behavior. Eventually, the magnetic field models will be implemented in our controls simulations to facilitate precise control of the reaction sphere. Initial model results agree with field measurements to within 1 G (5% of measured flux density). Currently, we are testing different material properties of the electromagnets and their magnetic fields and thermal effects. These results will be used to refine the design of the electromagnetic dipoles. Our control efforts have centered on developing commutation, levitation, and field pattern shaping hardware in the form of breadboards and PCBs with software running on a local microcontroller. In addition, our partners developed MATLAB Simulink models to demonstrate a PID controller thatmitigates disturbance forces resulting from the interaction of drive and levitation magnetics. Finally, we have designed a three-axis test stand that will be used in future work to demonstrate CELA’s orientation control capability.
To address problems experienced by current reaction wheels and control moment gyroscopebased attitude control systems (ACS), researchers at National Aeronautics and Space Administration’s (NASA’s) Marshall Space Flight Center (MSFC) have begun developing a reaction sphere actuator based on correlated electromagnetic levitation that will be immune to destructive bearing friction, momentum saturation, and gimbal lock. The Correlated Electromagnetic Levitation Actuator (CELA) advances the state of the art of reaction sphere ACSs by employing the concept of correlated magnetics. It is a frictionless, direct-drive reaction sphere that harnesses a unique technology with an array of applications across multiple disciplines. Correlated electromagnets function in a manner that is analogous to a matched filter; the convolution of two signals is peaked at the index representing the greatest match. For CELA, the signals are the patterns of magnetic flux density as a function of position. The magnitude of the convolution equates to an attractive or repulsive force, and these forces can be azimuthal or radial. The development of CELA is based in four distinct disciplines: Advanced Manufacturing, Prototype Development, Electromagnetic Modeling, and Controls. We are developing novel manufacturing techniques required to build arrays of permanent and electromagnet dipoles on curved surfaces. To print the permanent magnetic array, we have developed a probe with pyramidal magnets that will reside on a robotic arm to induce localized magnetic fields on a surface. We have also used high temperature ovens to erase dipole patterns from a permanent magnet by heating the surface to its Curie temperature. A number of test articles and prototypes have been developed using additive manufacturing methods. These prototypes have included hemispherical motors to test the drive algorithm, and a levitation test bed that demonstrates a magnetic bearing method based on attractive magnetic forces and ratiometric Hall effect sensors. We developed an array of electromagnetic dipoles on a printed circuit board (PCB) with individual H-bridges controlling each coil. This device created various flux density patterns and we measured their magnetic fields using a custom Hall effect 3-D probe and a LabVIEW virtual instrument. These data will serve as a benchmark for characterizing the accuracy of future models. Current work is focused on modeling the magnetic fields of our prototype arrays using COMSOL finite element analysis (FEA) and verifying the model against our test data. Accurate modeling will allow us to quickly test new patterns of electromagnets and their macro behavior. Eventually, the magnetic field models will be implemented in our controls simulations to facilitate precise control of the reaction sphere. Initial model results agree with field measurements to within 1 G (5% of measured flux density). Currently, we are testing different material properties of the electromagnets and their magnetic fields and thermal effects. These results will be used to refine the design of the electromagnetic dipoles. Our control efforts have centered on developing commutation, levitation, and field pattern shaping hardware in the form of breadboards and PCBs with software running on a local microcontroller. In addition, our partners developed MATLAB Simulink models to demonstrate a PID controller that mitigates disturbance forces resulting from the interaction of drive and levitation magnetics. Finally, we have designed a three-axis test stand that will be used in future work to demonstrate CELA’s orientation control capability.
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.
Abstract- 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 specific torque and 96% efficiency at 100 kW of power.
The NASA Revolutionary Vertical Lift Technology Project has created several Urban Air Mobility reference design vehicles to aid the burgeoning UAM industry. With over 700 conceptual designs already proposed, much interest has been generated across many unique configurations to bring vertical flight to the masses. The quadrotor configuration is one of the NASA reference vehicles, and does have some conceptual designs proposed in the industry. This study looks at the conceptual design of a coaxial quadrotor vehicle as an extension of the NASA RVLT quadrotor concept vehicle. The coaxial quadrotor has a similar layout to the quadrotor, but with a coaxial rotor at each of the four corners of the vehicle. Trade studies carried out using the NASA Design and Analysis of Rotorcraft (NDARC) tool analyzed the vehicle sizing, design gross weight, and performance for four design variants. The variants all use the baseline coaxial quadrotor layout, but analyze the effects of two major design choices: 1) variable pitch vs variable speed rotor control, and 2) motor to rotor power transmission via a gearbox vs direct-drive. The results indicate one design variant may have more benefits on some of the design objectives while another configuration may better satisfy the others.
A paradigm shift in rotorcraft design is being led by the prospect of propulsive forces being distributed across multiple rotors, such that each rotor can be directly driven by a dedicated electric motor. Crucially, some designers attempt to utilize these direct-drive mechanisms as the sole form of primary flight control. The feasibility of this design choice remains to be proven at the scales required for passenger transport. The paper presents a preliminary handling qualities analysis, for a six-passenger (1,200 lb payload) electric Hexacopter conceptual design, which shows that Level 1 handling qualities for limited agility operations are possible, provided that electric powertrains can deliver transient peak torques twice as high as the rated continuous torque of the conceptual design. Preliminary predictions are then substantiated by the results from a piloted handling qualities evaluation conducted in the NASA-Ames Vertical Motion Simulator (VMS). Three eVTOL configurations (a quadrotor, a hexacopter and a lift+cruise) with flight control laws implementing different levels of stability augmentation (Attitude Command-Attitude Hold and Translational Rate Command response types) were evaluated in four low speed and hover tasks requiring various levels of agility and precision.
The advent of electric propulsion is revolutionizing the paradigm of rotorcraft design, leading to new electric Vertical Take-Off and Landing (eVTOL) aircraft. Direct drive topologies are common within these new designs, and some designers have chosen to utilize this mechanism for Primary Flight Control (PFC), effectively utilizing the aircraft engines as PFC actuators to control the speed of the rotors. This decision integrates the propulsion and flight control systems, and intrinsically couples the aircraft sizing and control. Four separate tools were exercised throughout this study to conduct a conceptual design exploration of eVTOL aircraft handling qualities. The main tasks for these tools were: 1) aircraft sizing and performance analysis, including the calculation of trim; 2) flight dynamics modeling and analysis; 3) handling qualities-centric control law optimization; and 4) electric motor sizing. Sizing of an RPM- controlled Hexacopter concept explored the dependency of aircraft size to fundamental design parameters: 1) disk loading and 2) blade loading coefficient. Increasing the design disk loading resulted in designs with high agility, but at the cost of significant growth in the design gross weight. Finally, Categories II and III pilot-induced-oscillation (PIO) are known potentially-catastrophic handling qualities deficiencies of fly-by-wire flight control systems such as those expected of eVTOL aircraft. Consideration of PIO predictive metrics in conceptual design control synthesis led to increased PIO robustness.
Minimizing the mass in electric machines while maintaining superior performance has become a new requirement for the advancement of drivetrains used in wind energy and electric mobility. Topology optimization for light-weighting electric machines using traditional approaches typically explore a restricted design space allowed by standard parametrizable geometry and manufacturing, while advanced methods like cell-based density approaches suffer from a lack of robust manufacturability constraints during the optimization process. To overcome these drawbacks, we explore a grid-independent, boundary TO where the outer shape of the magnet is parameterized using Bezier curves. We conduct a design of experiments (DOE) to study the effect of different magnet shapes on machine performance by varying the control points on the Bezier curves. A machine-learning based surrogate model is constructed using the data from the DOE to quantify the relationship between the control points, air-gap torque and mass. The control points are then optimized to maximize the torque density. The approach is used for minimizing electrical steel mass in the IEA-15MW radial flux direct-drive wind turbine generator. The free-from boundary TO resulted in smooth and concise shapes that can be easily additively manufactured with upto 20-ton reduction in electrical steel mass.
Minimizing the mass in electric machines while maintaining superior performance is a new requirement for the advancement of drivetrains used in wind energy and electric mobility. Topology optimization (TO) for lightweighting electric machines using traditional approaches typically explores a restricted design space allowed by standard parametrizable geometry and manufacturing, while advanced methods, such as cell-based density approaches, suffer from a lack of robust manufacturability constraints during the optimization process. To overcome these drawbacks, we explore a grid-independent, boundary TO where the outer shape of the magnet is parameterized using Bezier curves. We conduct a design of experiments (DOE) to study the effect of different magnet shapes on machine performance by varying the control points on the Bezier curves. A machine-learning-based surrogate model is constructed using the data from the DOE to quantify the relationship between the control points, air-gap torque, and mass. The control points are then optimized to maximize the torque density. The approach is used for minimizing electrical steel mass in the International Energy Agency (IEA) 15-MW radial flux direct-drive wind turbine generator. The free-form boundary TO resulted in smooth and concise shapes that can be easily additively manufactured with up to a 20-ton reduction in electrical steel mass.
In recent years, the cost of small wind turbines for homes, farms, and small businesses has decreased dramatically thanks to advances in American technology made possible by research and development support from the U.S. Department of Energy. But further reductions are needed to realize the gigawatt-scale potential of distributed wind energy to help electrify rural America, reduce carbon emissions, and create jobs. Currently, for residential- and farm-scale wind turbines with direct-drive, permanent-magnet alternators, the alternator is the highest-cost component of the wind turbine (excluding the tower). The Bergey Windpower Excel 15 wind turbine incorporates advanced technology in its rotor and controls and will soon incorporate advanced power electronics - but its alternator is based on technology that is more than a decade old. To help reduce capital expenditures of the Excel 15 wind turbine, Bergey Windpower is developing an advanced, lower- cost, permanent-magnet alternator.
Over the past few years, advancements in closed-loop geothermal systems (CLGS), also called advanced geothermal systems (AGS), have sparked a renewed interest in these types of designs. CLGS have certain advantages over traditional and enhanced geothermal systems (EGS), including not requiring in-situ reservoir permeability, conservation of the circulating fluid, and allowing for different fluids, including working fluids directly driving a turbine at the surface. CLGS may be attractive in environments where water resources are limited, rock contaminants must be avoided, and stimulation treatments are not available (e.g., due to regulatory or technical reasons). Despite these advantages, CLGS have some challenges, including limited surface area for heat transfer and requiring long wellbores and laterals to obtain multi-MW output in conduction-only reservoirs. CLGS have been investigated in conduction-only systems. In this paper, we explore the impact of both forced and natural convection on the levels of heat extraction with a CLGS deployed in a hot wet rock reservoir. We bound potential benefits of convection by investigating liquid reservoirs over a range of natural and forced convective coefficients. Additionally, we investigate the effects of permeability, porosity, and geothermal temperature gradient in the reservoir on CLGS outputs. Reservoir simulations indicate that reservoir permeabilities of at least ~100 mD are required for natural convection to increase the heat output with respect to a conduction-only scenario. The impact increases with increasing reservoir temperature. When subject to a forced convection flow field, Darcy velocities of at least 10-7 m/s are required to obtain an increase in heat output.
Simulations predict that directly driven multi-shell targets can provide a robust alternative to conventional high-convergence implosion concepts by coupling two to three times more energy into the final igniting thermonuclear fuel assembly than indirect-drive concepts. The three-shell directly driven Revolver concept [K. Molvig, M. J. Schmitt, B. J. Albright, E.S. Dodd, N.M. Hoffman, G.H. McCall, and S.D. Ramsey, Phys. Rev. Lett. 116, 255003 (2016)] utilizes a design that maximizes laser energy conversion into inward kinetic energy of the outermost ablator shell (~9%) while minimizing the DT fuel convergence (~9) to reduce the mixing of material from the innermost shell into the fuel. Inherent in this design concept is the use of 192 narrow beams (with a 1/e laser beam-to-capsule diameter ratio of 0.33) from the National Ignition Facility laser pointed in a polar direct drive laser configuration. In this paper, we demonstrate that low average laser intensity at the capsule surface (≤300 TW/cm 2 ) limits the measured laser backscatter, indicating that a greater amount of laser energy is coupled into the target. Omega experiments have been performed to determine the coupling of laser energy to the outermost shell of a scaled Revolver target (i.e., the ablator shell) by measuring capsule implosion trajectories and scattered-light fractions for two different drive configurations. Comparisons of simulated shell trajectory and velocity profiles with experimental data obtained from self-emission images show good agreement and are consistent with measured scattered light data. Furthermore, the low levels of scattered light measured are consistent with post-shot simulation results that show high hydro-coupling efficiency. These results strengthen the case for using narrow beams at low intensity to drive large ablator capsules for future direct-drive, multi-shell ignition concepts.
NASA's Mars Exploration Rovers (MER) have collected a great geological diversity of science results, thanks in large part to their surface mobility capabilities.
Direct current torque amplifier for driving gyro-stabilized platform - amplifier design