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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 397 records · Page 22
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

A Single-Stage Multilevel AC-DC Bidirectional Converter With Natural Grid Harmonic Elimination

Generally, AC-DC converters have an AC-DC stage followed by a DC-DC stage. In these two stage approaches, the AC-DC stage is hard-switched, whereas the DC-DC stage is soft-switched. Therefore, the devices in the AC-DC stage can be switched only at tens of kHz to avoid excessive switching losses, thus limiting the bandwidth of the current control loop. Hence, the control of these converters with distorted grid voltages requires multiple harmonic compensation loops or other complex control algorithms in order for the grid currents to comply with IEEE standards. By integrating both the stages, the devices in the AC-DC stage can also be soft-switched, thus facilitating higher switching frequency, and thereby higher current control bandwidth. This paper proposes an integrated multilevel bidirectional AC-DC converter with improved control bandwidth and disturbance rejection. It is shown experimentally that the high bandwidth current control loop of the converter can reject grid harmonic current disturbances, without the need for any compensation loops or complex control techniques, and comply with IEEE standards.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2025

Heat Pipe Enhanced Thermal Management System for GaN Switches in an Integrated Modular Motor Drive for Aircraft Propulsion

This paper presents the process of sizing a heat pipe enhanced thermal management system (TMS) for GaN switches in an integrated modular motor drive (IMMD) powering a 250 kW aircraft propulsion electric motor. A test setup mimicking the TMS and GaN switches assembly is constructed. The condenser chamber of the TMS is modeled in ANSYS Fluent while the GaN switches assembly is modeled in ANSYS Thermal allowing us to verify heat spreader temperature under test conditions and estimate GaN temperatures under test and actual application operating conditions.

DIRECT ENERGY CONVERSION↗
DOE OSTI2020

Design of BLDC Motor Diagnostic Device Based on Surge Test for Phase to Ground Fault

BLDC motor is essential in the industrial world, especially it been used for an electric vehicle. The benefit of using BLDC motor is that it has high rate efficiency and low mechanical losses. However, to know the isolation condition of winding and increase reliability, it needs to be tested. With the implementation of surge test based fault detection device of BLDC motor, the condition of BLDC motor can be monitored and maintained according to analysis of its condition. The surge test method used because it is sensitive in detecting the initial damage in the isolation failure process on stator winding. A surge voltage is generated from the Cockroft-Walton and switching circuit with capacitors. The result is analyzed using Error Area Ratio (EAR). The test result shows that the higher the value of resistance and inductance, the smaller the frequency of the surge wave. When the BLDC motor in a parallel short circuit condition, the threshold value of the EAR test-reff has a minimum value of 5.28%, an average of 13.52%, and a maximum of 28.55%.

BLDC motor↗
DOE OSTI2020

Enabling Seamless Integration of EV Charging Infrastructure with Weak Electric Grids

Widespread adoption of Electric Vehicles (EVs) for light, medium, and heavy-duty applications has gained significant interest. Based on ownership and user preferences, light duty and local delivery medium-duty EVs are typically connected to grid distribution networks whereas larger medium duty and heavy-duty EVs are typically connected to distribution or even sub-transmission networks. Challenges with at-scale EVs and charging infrastructure supporting them include interoperability, distribution network upgrades, surge in demand charges, power quality issues, voltage stability, etc. Based on real-world data, steady-state and dynamic assessments of light-duty EV charging with a focus on DC Fast Charging (DCFC) for weak distribution grids is presented. Three main areas of contributions in this paper include - steady state and dynamic power quality measurements and assessments using real world data, transient assessments of light duty EV integration with weak distribution networks (IEEE 13 node feeder system) under grid-connected and microgrid modes, and formulation of an intelligent charging decision algorithm to enable an impact-minimal charging.

actionable intelligence↗
DOE OSTI2022

Reliability and Lifetime Prediction Model of Sintered Silver Under High-Temperature Cycling

Although excellent reliability has been reported for sintered silver as a die-attach material under both thermal and power cycling loads in power electronics applications, the promise of this material as a large-area attachment at temperatures beyond 200 degrees C needs to be investigated. This paper presents insights into the thermomechanical behavior and reliability of sintered silver under extreme thermal cycling conditions. In this study, we bonded sintered silver samples and subjected it to a thermal cycling profile of -40 °C to 200 °C with high ramp rates. We periodically monitored samples under thermal cycling to detect the presence of any failure mechanisms using a scanning acoustic microscope. We also included 95Pb5Sn solder in the study to obtain reference data. Results show the occurrence of cracks in sintered silver followed by a rapid rate of crack growth that exceeded the failure criterion in just 50 cycles. The predominant failure mechanism we observed was adhesive failure. As a large-area attachment, solder exhibited a higher reliability than sintered silver but failed within 100 cycles. Finally, we performed thermomechanical modeling to compute strain energy density values and correlated these with the experimentally observed crack growth rates to formulate a lifetime prediction model for sintered silver.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2021

Reliability Analysis of Large-Area, Low Pressure-Assisted Silver Sintering for Medium-Voltage Power Modules

Multi-layer insulating ceramic substrates can enable medium-voltage (MV) power modules with reduced peak electric field. This benefit is particularly important for MV silicon carbide (SiC) MOSFETs due to their higher operating voltages. Large-area, low-pressure assisted silver sintering is a potential solution for bonding substrates to create a multi-layer structure. The voiding content and defect density of the bond used to create the multi-layer substrate stack-up is critical to the reliability of the power module and the thermal performance, as this bond is in the primary path for heat dissipation in the power module structure. Here, samples of two-layer direct bonded aluminum (DBA) stacks have been fabricated and subjected to thermal cycling to analyze their reliability. Passive thermal cycling from -40 degrees C to 200 degrees C was performed. Cross-sections were cut at pre-determined intervals and imaged with Scanning Electron Microscopy (SEM). After 1000 thermal cycles, adhesive failures are observed between the sintered silver and the DBA surface. Cross-sections were cut and imaged via optical microscope and SEM. Thermal analyzer measurements are recorded on a 10-kV SiC power module utilizing the sintered DBA substrate stacks.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2023

Active Reconditioning of Retired Lithium-ion Battery Packs from Electric Vehicles for Second Life Applications

Utilizing the remaining capacity in retired lithium-ion (Li-ion) batteries from electric vehicles (EVs) for second-life applications has shown economic and environmental benefits. However, achieving homogeneity among the capacities of cells before their second life is critical to exploit the benefits. This article proposes a new active reconditioning approach with the potential to make short-term reconditioning of batteries before second life feasible. A control objective map determines each cell's state-of-charge (SOC) operating window based on its capacity relative to other cells. The SOC reference translates into distinct differential currents through the cells, wherein the higher-capacity cells undergo more frequent and deep charge and discharge cycles than their lower-capacity counterparts. The proposed solution achieves capacity homogeneity within the battery pack with low reconditioning time and minimal fade in the overall pack capacity. The feasibility of the reconditioning approach under varying load and environmental conditions is assessed through simulations, encompassing factors such as the number of cycles per day, depth-of-discharge, battery pack temperature, and cell resting time at different SOCs. Furthermore, the simulation model employs a battery pack with sixteen series-connected 75 Ah Kokam lithium nickel manganese cobalt oxide (NMC) cells with a 3.6% initial capacity imbalance. A reconditioning time of 1.3 months is achieved with a final capacity imbalance of 0.1% and an overall capacity fade of 0.005%, thereby confirming the viability of the reconditioning process. Moreover, experimental validation using eight retired battery cells from a Nissan Leaf demonstrates a substantial decrease in the capacity imbalance of cells from 9.4% to 2.15% within 78 days, effectively affirming the efficacy of the proposed reconditioning scheme.

25 ENERGY STORAGE↗
DOE OSTI2021

Integrated Models for Electrical Distribution Network Planning and District-Scale Building Energy Use

The increase of greenhouse emissions caused by a rise in global energy consumption is pushing the scientific community to develop tools that address key environmental, techno-economic and social issues. One specific area of focus is to create tools that enable the design of high-performance energy districts, including grid-interactive efficient buildings and electrical distribution infrastructure. This paper outlines the approach of integrating a synthetic distribution network tool (RNM-US) with URBANopt™, a modular and customizable software development kit for thermal and electrical modelling of buildings and energy systems at a district scale. First, we describe the algorithms implemented to integrate RNM-US with URBANopt to automatically generate the distribution network for the district considered. Following, we present a case study for the potential uses of the RNM-US integrations with URBANopt, highlighting the capabilities for economic and technical analysis of the distribution network built in relation to the electricity needs of the modelled buildings.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2022

Provably-Stable Overload Ride-Through Control for Grid-Forming Inverters Using System-Wide Lyapunov Function Analysis

A key challenge associated with a grid-forming (GFM) inverter based resource (IBR) is its behavior during severe grid disturbances: since a GFM inverter regulates voltage in the fast timescale instead of current or power, it may experience a transient overload of current, power and/or energy during a severe grid disturbance. While many promising control strategies for overload ride-through have been proposed over the past two decades, transient stability of the system during and after the transition to an overload ride-through control mode remains difficult to guarantee. In this work, a novel overload ride-through control strategy is proposed for a system of grid-forming inverters that takes both self-protection and system-wide transient stability into account. A proposed system-level supervisory control uses slow communication to pre-emptively assign a set of local ride through control parameters to individual GFM IBR, including a current-limiting virtual reactance, that guarantees that synchronism is still preserved for any set of anticipated grid disturbances. At the core of the supervisory control lies a Lyapunov-function-based routine capable of establishing a strong, albeit conservative, transient stability guarantee for the system. Here, the proposed overload ride-through control strategy is validated via numerical integration of a reduced-order model, as well as through detailed electromagnetic transient (EMT) simulation.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2021

A Bulk-Capacitance Reduction Method Using Self-Driven Thyristor for AC-DC Converters

Universal serial bus power delivery (USB-PD) fast chargers equipped with wide-bandgap devices are driven to higher power density and efficiency. Furthermore, the indispensable high-voltage bulk capacitors used to smooth the rectifier output could take 40% of the total system volume due to the large capacitance value required. This paper discussed a capacitor reduction method using a self-driven thyristor scheme comprised of only three components in total. No extra control circuit is needed. Circuit analysis and design equations are presented, and the design results are implemented in a 60-W GaN-based active-clamp flyback converter. The measurement results on the prototype show a 36.4% reduction of the bulk-capacitor size with similar efficiency compared to the conventional solution.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2022

Single-Phase Dielectric Fluid Thermal Management for Power-Dense Automotive Power Electronics

This paper describes the design and performance of a dielectric fluid cooling concept for automotive power electronics. The concept combines a low-thermal-resistance package (which eliminates metalized ceramic substrates) with a high-performance convective cooling strategy (slot jets impinging on finned surfaces). Modeling was first used to design the cooling system to maximize thermal performance and minimize pumping power. Additionally, a prototype was then fabricated, and experiments were conducted to validate the model predictions using three fluids at various fluid flow rates (16.7 cm 3 /s [1 L/min] to 68.3 cm 3 /s [4.1 L/min]) and inlet temperatures (30C and 70C). The final design was compact (120-cm 3 total volume, including heat exchanger and conceptual power modules) and cooled 12 devices (e.g., silicon carbide). The validated model was then used to predict the junction-to-fluid thermal resistance and pumping power for various conditions, including 40C fluid temperature. The results predict thermal resistance values as low as 19 mm 2 K/W are possible using the dielectric fluid cooling approach. The dielectric fluid cooling system is predicted to provide thermal resistance and pumping power values that are approximately 56% and 90% lower, respectively, compared to an automotive power electronics cooling system.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2022

Laminated Permanent Magnets Enable Compact Magnetic Components in Current-Source Converters

Magnetic components have become one of the primary barriers to high power density converters, especially to current-source converters (CSCs). In CSCs, the inductors/transformers have a predominantly dc flux to store energy, which can be offset by standard permanent magnets (PMs). However, eddy currents in standard PMs induce significant losses and thermal stress for medium-frequency applications. This article proposes using laminated PMs to offset the dc flux while reducing eddy currents, leading to significant reductions in the size, cost, and losses of inductors/transformers. Furthermore, the laminated PMs’ optimal location, orientation, and distribution are investigated to generalize this approach for maximum benefits. Here, three-dimensional finite-element analysis simulation and hardware experiments are presented to validate the effectiveness of the proposed approach in a medium-frequency transformer (MFT) for CSCs. Compared with standard PMs, the proposed use of laminated PMs reduces aggregate core-plus-PM losses by 85% in experiments, and thus, relaxes the MFT thermal design. Finally, the proposed approach is experimentally validated in a 40 kVA flyback-type MFT for a soft-switching solid-state transformer. Compared to the traditional design without any PMs, the proposed design increases the saturation current by 46% while inducing only 5% more losses, leading to significant savings in magnetics cost and size.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2024

Microgrid Service Restoration Incorporating Unmonitored Automatic Voltage Controllers and Net Metered Loads

Islanded microgrids may experience voltage and frequency instability due to uncontrolled state changes of voltage regulation devices and inaccurate demand forecasts. Uncontrolled state changes can occur if optimal microgrid restoration and dispatch algorithms, used for generating control commands for distributed energy resources, do not incorporate the behavior of automatic controllers of voltage regulation devices. Inaccurate demand forecasts may be encountered since post-outage demand of behind-the-meter net metered (NM) loads can vary significantly from their historical NM profiles. Here, this paper proposes an optimization formulation which allows optimal control of voltage regulators and capacitor banks without remote control and communication capabilities. A generalized demand model for NM loads is proposed which incorporates the cold load pickup phenomenon and their time varying post-outage demand in accordance with the IEEE 1547 standard. The time dependent optimal control formulation and the NM demand model are integrated in a sequential microgrid restoration algorithm by linearization of the involved logic propositions. A detailed case study on the unbalanced IEEE 123-node test system in OpenDSS validates the effectiveness of the proposed approach.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2023

Impacts to FeRAM design arising from interfacial dielectric layers and wake up modulation in ferroelectric hafnium zirconium oxide

As ferroelectric hafnium zirconium oxide (HZO) becomes more widely utilized in ferroelectric microelectronics, integration impacts of intentional and non-intentional dielectric interfaces and their effects upon the ferroelectric film wake up and circuit parameters become important to understand. In this work, the effect of the addition of a linear dielectric aluminum oxide, Al 2 O 3 , below a ferroelectric Hf 0.58 Zr 0.42 O 2 film in a capacitor structure for FeRAM applications with NbN electrodes was measured. Depolarization fields resulting from the linear dielectric is observed to induce a reduction of the remanent polarization of the ferroelectric. Addition of the aluminum oxide also impacts the wake up of the HZO with respect to the cycling voltage applied. Intricately linked to the design of a FeRAM 1C/1T cell, the metal-ferroelectric-insulator-metal (MFIM) devices are observed to significantly shift charge related to the read states based on aluminum oxide thickness and wake up cycling voltage. As a result, a 33% reduction in the separation of read states is measured, which complicates how a memory cell is designed and illustrates the importance of clean interfaces in devices.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2020

Process Failure Detection via Recurrence Quantification Analysis in a Slot-Rectangular Spouted Bed

A study was conducted to explore the applicability of recurrence and recurrence quantification analysis (RQA) to the detection of process failures in spouted bed reactor systems. Here, three different potential failure modes were examined in a transparent, cold flow slot-rectangular spouted bed. These being, a simulated air leak from a side wall of the reactor, a simulated gas leak from the top wall of the reactor, and simulated agglomeration of solids via introduction of larger “klinker” particles. Bed pressure drop time history data were collected and analyzed via generation of recurrence plots (RPs) and RQA parameters. In general, the simulated agglomeration case was quite easily detected via ever RQA Parameter examined, whereas the simulated air leaks were detected by only a single RQA parameter.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2022

Film Cooling Performance Prediction for Air and Supercritical CO 2

The current study explores the possibility of cooling the vanes and blades of a direct-fired sCO 2 turbine using film cooling. The operating conditions of a direct-fired sCO 2 cycle and thermophysical properties of the fluid at those conditions can alter the flow field characteristics of the coolant jet and its mixing with the mainstream. Very little information is present in the literature regarding the performance of film cooling geometries employing supercritical CO 2 . The objective of this study is to estimate the resulting film cooling effectiveness while also capturing the effects of the crossflow-to-mainstream velocity ratio on the coolant jet. Herein, a computational fluid dynamic model is used to study the coolant jet exiting a cylindrical hole located on a flat plate, with the coolant fed by an internal channel. Steady-state Reynolds-averaged Navier–Stokes equations were solved along with the (shear-stress transport) SST k–ω model to provide the turbulence closure. The operating conditions for the direct-fired sCO 2 turbine are obtained using an in-house Cooled Turbine Model. Numerical predictions revealed that the crossflow effects and jet lift-off were more pronounced in the case of sCO 2 when compared to air. Spatial distribution of flow field and cooling effectiveness are presented at different operating conditions.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2023

Physics-Informed Deep Learning-Based Proof-of-Concept Study of a Novel Elastohydrodynamic Seal for Supercritical CO 2 Turbomachinery

Supercritical carbon dioxide (sCO 2 ) power cycles show promising potential of higher plant efficiencies and power densities for a wide range of power generation applications such as fossil fuel power plants, nuclear power production, solar power, and geothermal power generation. sCO 2 leakage through the turbomachinery has been one of the main concerns in such applications. To offer a potential solution, we propose an elastohydrodynamic (EHD) seal that can work at elevated pressures and temperatures with low leakage and minimal wear. The EHD seal has a very simple, sleeve-like structure, wrapping on the rotor with minimal initial clearance at micron levels. Here, in this work, a proof-of-concept study for the proposed EHD seal was presented by using the simplified Reynolds equation and Lame’s formula for the fluid flow in the clearance and for seal deformation, respectively. The set of nonlinear equations was solved by using both the conventional Prediction–Correction (PC) method and modern Physics-Informed Neural Network (PINN). It was shown that the physics-informed deep learning method provided good computational efficiency in resolving the steep pressure gradient in the clearance with good accuracy. The results showed that the leakage rates increased quadratically with working pressures and reached a steady-state at high-pressure values of 15~20 MPa, where Q = 300 g/s at 20 MPa for an initial seal clearance of 255 μm. This indicates that the EHD seal could be tailored to become a potential solution to minimize the sCO 2 discharge in power plants.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2024

Effect of Substrate Temperature on the Electrochemical and Supercapacitance Properties of Pulsed Laser-Deposited Titanium Oxynitride Thin Films

Electrocatalytically active titanium oxynitride (TiNO) thin films were fabricated on commercially available titanium metal plates using a pulsed laser deposition method for energy storage applications. The elemental composition and nature of bonding were analyzed using X-ray photoelectron spectroscopy (XPS) to reveal the reacting species and active sites responsible for the enhanced electrochemical performance of the TiNO electrodes. Symmetric supercapacitor devices were fabricated using two TiNO working electrodes separated by an ion-transporting layer to analyze their real-time performance. The galvanostatic charge–discharge studies on the symmetric cell have indicated that TiNO films deposited on the polycrystalline titanium plates at lower temperatures are superior to TiNO films deposited at higher temperatures in terms of storage characteristics. For example, TiNO films deposited at 300 °C exhibited the highest specific capacity of 69 mF/cm 2 at 0.125 mA/cm 2 with an energy density of 7.5 Wh/cm 2 . The performance of this supercapacitor (300 °C TiNO) device is also found to be ~22% better compared to that of a 500 °C TiNO supercapacitor with a capacitance retention ability of 90% after 1000 cycles. Furthermore, the difference in the electrochemical storage and capacitance properties is attributed to the reduced leaching away of oxygen from the TiNO films by the Ti plate at lower deposition temperatures, leading to higher oxygen content in the TiNO films and, consequently, a high redox activity at the electrode/electrolyte interface.

30 DIRECT ENERGY CONVERSION↗