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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 55 records · Page 3

All sources NASA NTRS DOE OSTI

NASA NTRS2017

Propulsion Powertrain Real-Time Simulation Using Hardware-in-the-Loop (HIL) for Aircraft Electric Propulsion System

It is essential to design a propulsion powertrain real-time simulator using the hardware-in-the-loop (HIL) system that emulates an electrified aircraft propulsion (EAP) systems power grid. This simulator would enable us to facilitate in-depth understanding of the system principles, to validate system model analysis and performance prediction, and to demonstrate the proof-of-concept of the EAP electrical system. This paper describes how subscale electrical machines with their controllers can mimic the power components in an EAP powertrain. In particular, three powertrain emulations are presented to mimic 1) a gas turbo-=shaft engine driving a generator, consisting of two permanent magnet (PM) motors with brushless motor drives, coupled by a shaft, 2) a motor driving a propulsive fan, and 3) a turbo-shaft engine driven fan (turbofan engine) operation. As a first step towards the demonstration, experimental dynamic characterization of the two motor drive systems, coupled by a mechanical shaft, were performed. The previously developed analytical motor models1 were then replaced with the experimental motor models to perform the real-time demonstration in the predefined flight path profiles. This technique can convert the plain motor system into a unique EAP power grid emulator that enables rapid analysis and real-time simulation performance using hardware-in-the-loop (HIL).

turbo-electric propulsion↗

NASA NTRS2023

Modeling and Simulation of a Parallel Hybrid-Electric Propulsion System - Electrified Powertrain Flight Demonstration (EPFD) Program

Electrified aircraft propulsion concepts have been proposed to meet aggressive future performance and environmental goals for the next generation of aircraft. However, electrified aircraft present a unique modeling and simulation challenge as they introduce multiple energy sources to the propulsion system, providing various means to meet thrust requirements, compared to conventional gas turbine propulsion architectures where only fuel is available. Additionally, the introduction of an electric powertrain to the existing system enables multiple electrified flight modes to exist (i.e. eTaxi, climb boost, takeoff boost, etc.), further increasing the complexity of the modeling environment. As part of the Electrified Powertrain Flight Demonstration program, this paper presents a modeling and simulation framework for a parallel hybrid-electric propulsion concept using the Environmental Design Space simulation tool. Electrical components are modeled in NPSS, and an overall sizing methodology is introduced. Finally, various operational modes of the electric powertrain are modeled and tested and their impact on key performance parameters is evaluated.

hybrid electric propulsion↗

NASA NTRSDate not supplied

Hybrid Modeling of Unmanned Aerial Vehicle Electric Powertrain for Fault Detection and Diagnostics

This paper shows the application of hybrid physics-informed machine learning to a representative electric powertrain for unmanned aerial vehicles. The model is composed of physics-derived principles and empirical equations, as well as fully connected networks that are strategically placed within the model to substitute equations that are subject to large uncertainty. Polynomial fit driven by heuristics or empirical observations can be substituted by more flexible networks that can minimize the error between model predictions and observations without being restricted to a predefined functional form. This modeling strategy allows training of networks deep inside the model and unknown parameters in a single learning stage. It has already been applied to Li-ion batteries in the past, and in this work, we extend the applications to other components of an electric powertrain, namely electronic speed controller with pulse-width modulation, and brushless DC motor with connected propeller. Training and testing of the model is carried out using experimental data from Li-ion battery discharge and powertrain testing in a laboratory environment.

Physics-Informed Machine Learning↗

DOE OSTI2022

Enabling cooperative adaptive cruise control on strings of vehicles with heterogeneous dynamics and powertrains

Recent studies have shown that positive impact of Cooperative Adaptive Cruise Control (CACC) can only be guaranteed as market penetration rate increases. Removing the string homogeneity constraint is essential to encourage widespread adoption. In this work, a hierarchical architecture is proposed to enable CACC on vehicles with not only mixed dynamics but also different powertrain types. A low-level layer deals with the vehicle and powertrain dynamics to provide accurate and consistent reference speed tracking response. The high-level layer uses: (1) a Linear Parameter Varying feedback system to provide loop stability, robustness and enforce a variable time gap policy and (2) a feedforward system that processes Vehicle-to-Vehicle information to enhance string stability and response bandwidth, by dealing with the string heterogeneity. A gap management strategy is built on top of the CACC architecture to handle gap setting changes or cut-in/out situations, via a dynamics constrained time gap trajectory planning algorithm. We report the proposed work has been designed, developed and validated on three different real passenger vehicles on public highways and test tracks, showing the potential of the proposed algorithm to enable robust string stable CACC, despite the different dynamics and powertrains considered.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2021

Hardware-in-the-Loop Investigation of Emissions Challenges in Hybrid Medium- and Heavy-Duty Powertrains Using a Pre-Production Diesel-Electric Parallel Hybrid System With and Without Stop-Start Operation

Hybrid electric powertrains are a growing market in medium- and heavy-duty applications. There is a lack of available information to understand the challenges in the integration of engine platforms into electrified powertrains, such as cold-start, restart, and load-reduction effects on emissions and emission control devices. Results from the Heavy Heavy-Duty Diesel Truck (HHDDT) cycle using a conventional medium-duty diesel engine were compared with those of a parallel hybrid architecture. Oak Ridge National Laboratory in collaboration with the US Department of Energy and Odyne Systems, LLC developed a powertrain in a hardware-in-the-loop environment, integrating the Odyne Systems, LLC medium-duty parallel hybrid system, which was used for the hybrid portion of this study. Experiments under the HHDDT cycle showed increasing improvements in fuel consumption and engine-out emissions with the integration of stop/start, hybrid, and hybrid with stop/start. However, the effects of load reduction and exhaust temperature on the thermal management strategy have shown an increase in fueling in the second part of the HHDDT cycle. Four configurations of medium-duty electrification were studied and contributed to building a unique data set containing combustion, emissions, and system integration data. Each electrification level was compared with the conventional baseline. The calibration of the conventional engine was not altered for this study. Opportunities to tailor the combustion process were identified with the stop/start strategy.

Lerin, Chloe↗

DOE OSTI2026

Substitution or Shared Utilization? Intrahousehold Vehicle Use in Mixed-Powertrain Households

While previous research has focused heavily on understanding the factors deriving alternative fuel vehicle adoption rates, there remains a significant gap in understanding how households distribute mileage across different powertrains. This study utilizes data from the 2022 Next Generation National Household Travel Survey to investigate vehicle miles traveled within a sample of 150 plug-in electric vehicle (PEV)-owning households (in which at least one battery electric vehicle is present), characterizing how different powertrains are integrated into daily mobility. Leveraging a Seemingly Unrelated Regression (SUR) framework the study jointly models the utilization of PEVs, hybrid electric vehicles (HEV), and internal combustion engine vehicles (ICEVs) while accounting for household-level substitution effects. The results provide evidence of an asymmetric substitution effect. In households with mixed-powertrain configurations, the ICEV captures a substantially higher share of household miles (compared with the PEV), acting as a utility sponge. Conversely, the model identifies specific socioeconomic and geographic cohorts that prioritize PEV as the primary household workhorse, indicating a systematic sorting effect. Although the sample size limits broader generalizability, these findings suggest that PEVs are used for frequent, specific routine-intensive roles, whereas the ICEV remains a specialized utility vehicle. These insights highlight distinct intrahousehold vehicle use behaviors that are often obscured by aggregate fleetwide statistics.

25 ENERGY STORAGE↗

DOE OSTI2019

Ultra Efficient Light Duty Powertrain with Gasoline Low Temperature Combustion (Final Report)

This document details the work completed during Project DE-EE0006839 ‘Ultra Efficient Light Duty Powertrain with Gasoline Low Temperature Combustion’. All tasks from the project’s Statement of Project Objectives are discussed. Final demonstration data is also presented and discussed. Further project details can be found in the Quarterly Technicial Reports that were submitted during the course of the project and are stored on the EERE Project Management Center Website. The goal of this project was to develop, implement and demonstrate a low temperature combustion approach called Gasoline Direct Injection Compression Ignition (GDCI) that provides high thermal efficiency with low NOx and PM emissions. The project target was to demonstrate a 35% fuel economy improvement over the baseline vehicle while meeting Tier 3 emissions levels. At the start of this project, GDCI was a moderately mature combustion technology, due in large part to advances made during a Delphi Technologies program funded through an earlier Department of Energy Advanced Technology Powertrains (ATP) opportunity; under that earlier contract, DE-EE0003258, Delphi Technologies assembled a team with complementary industrial and academic experience, and led this team to advance the technology from the original fundamental work to the state of art embodied by a first-generation (Gen 1) multi-cylinder GDCI engine. Key activities during that project centered on engine and combustion chamber design, and development of fuel injection equipment, valvetrain and advanced controls. Performance results with the Gen 1 engine in a development vehicle demonstrated that GDCI had the capability to operate using Low Temperature Combustion (LTC) over a broad speed-load range. Based on benchmarking work, efficiency for the Gen 1 GDCI engine compared favorably overall to production light-duty diesel engines. The second DOE funded project, DE-EE0006839, focused on a number of technical risks and issues that were left to be resolved for GDCI to become a production-viable technology. These risks were:GDCI combustion system refinement to achieve near-ideal air/fuel mixture preparation for high efficiency and low HC and CO emissions; Transient control development for low temperature combustion with high EGR levels during real-world transient driving maneuvers and over a broader range of ambient conditions; Aftertreatment system design that is effective in dealing with the low-temperature challenges of a highly efficient engine. The project was executed in two phases. Phase 1 leveraged the development vehicle from the Advanced Technologies Powertrain 1 (ATP1) project, DE-EE0003258. That vehicle was used as an initial test bed in the development of a high performance low temperature exhaust aftertreatment system. The vehicle was also used to develop calibration refinements for improved exhaust emissions and fuel efficiency. Samples of a new GDCI development level engine, called Gen2 GDCI (and developed outside of the first DOE funded project), were also used during Phase 1 to develop refined controller hardware and control algorithms, as well as improved sensors and actuators. The Gen2 engine was then retrofitted into the development vehicle from the ATP1 project and used for controls refinement and calibration of GDCI to achieve improved cold start, drivability and robustness to real world environments and fuel variations. During Phase 2 of the project, Gen3 versions of the GDCI engine were designed and built specifically for this project based on experience from the earlier engines. These engines were designed to be production-like in construction and, when combined with refined control systems and project specific low temperature exhaust aftertreatment, were intended to support the goal of meeting Tier 3 emissions levels at a vehicle level. Though great progress had been made advancing the GDCI combustion process, and despite extensive presentations of our work on the technology at various conferences and in direct meetings with automotive companies, none of the US domestic automotive OEMs had shown an interest in adopting this combustion process as part of their technology planning as the project approached the Go/No-Go point at the end of Budget Period 3. As a result of this low-level of interest both the US Department of Energy and Delphi Technologies received in this technology from domestic auto manufactures, Delphi Technologies elected a ‘No-Go’ status for the gate between Budget Period 3 and Budget Period 4 which terminated the project without spending any Budget Period 4 funds. The project team concluded that the dynamometer mapping of the most recent level of hardware, combined with the vehicle level simulation by Argonne National Laboratory, was sufficient to document the capabilities and potential of the combustion process without spending the time and money to do the controls development and full calibration necessary for a demonstration vehicle.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2020

Medium-duty Urban Range Extended Connected Powertrain (Final Scientific Technical Report)

The project goal is to develop and demonstrate a Class 4 delivery vehicle that reduces fuel consumption by 50% or more when compared to an equivalent vehicle with a conventional internal combustion engine (ICE) powertrain driven on a comparable duty cycle. This shall be achieved using a plug-in hybrid electric (PHEV) configuration that optimizes the efficiency of the ICE. The proposed solution aims to be commercially viable for fleets to procure the system without additional incentives. To accomplish this, commercialized light-duty vehicle electric drive components shall be used. A PHEV configuration for Class 4 MD/HD vocational vehicles using commercialized light-duty vehicle electric drive components will require the development of a new topology for the hybrid powertrain applicable to medium-duty vehicles. Prior research indicates that an identified novel power split device could provide a fuel economy improvement potential of up to 51%. Utilizing an advanced battery management algorithm that will allow operation closer to the battery limits, the project will minimize battery capacity to achieve the desired performance results while maintaining the cost target for high commercialization. The solution must be cost effective to purchase and integrate into a Class 4 delivery vehicle, deliver the intended fuel economy improvement, and perform as well, or better, than the current conventional ICE powertrain. MD/HD vehicles typically require higher power, which is one factor that results in high costs for the powerful electric machines typical in larger HEV/PHEV systems. A key element in the project is the use of commercially available Bosch electric drive components (e.g., motors, batteries, and power electronics) from the larger passenger vehicle segment. This leverages the economies of scale to decrease cost and improve reliability beyond current purpose-built low-volume commercial vehicle components. These innovations will result in a game-changing PHEV system that meets DOE’s 50% fuel consumption reduction target, grants the vehicle an uncompromised driving range, and achieves the cost point for widespread adoption.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2025

Charting the Path to Electrification: Analyzing the Economic and Technological Potential of Advanced Vehicle Powertrains

The U.S. Department of Energy’s Vehicle Technologies Office (DOE-VTO) is driving advancements in highway transportation by targeting energy efficiency, environmental sustainability, and cost reductions. This study investigates the fuel economy potential and cost implications of advanced powertrain technologies using comprehensive system simulations. Leveraging tools such as Autonomie and TechScape, developed by Argonne National Laboratory, this study evaluates multiple timeframes (2023–2050) and powertrain types, including conventional internal combustion engines, hybrid electric vehicles (HEVs), plug-in hybrid electric vehicles (PHEVs), and battery electric vehicles (BEVs). Simulations conducted across standard regulatory driving cycles provide detailed insights into fuel economy improvements, cost trajectories, and total cost of ownership. The findings highlight key innovations in battery energy density, lightweighting, and powertrain optimization, demonstrating the growing viability of BEVs and their projected economic competitiveness with conventional vehicles by 2050. This work delivers actionable insights for policymakers and industry stakeholders, underscoring the transformative potential of vehicle electrification in achieving sustainable transportation goals.

Islam, Ehsan Sabri (ORCID:0000000200220180)↗

DOE OSTI2018

Vehicle Level Control Analysis for Voltec Powertrain

The next generation of the Volt vehicle with the new “Voltec” extended-range propulsion system was introduced into the market in 2016. The second-generation Volt’s powertrain architecture provides five modes of operation, including two electric vehicle operations and three extended-range operations. Vehicle testing was performed on a chassis dynamometer set within a thermal chamber at the Advanced Powertrain Research Facility at Argonne National Laboratory. The study first focused on assessing the improvement of the new Voltec system by comparing the system efficiency with the previous system. Second, control behavior and performance were analyzed under normal ambient temperature to understand the supervisory control strategy on the Voltec system based on the test data. The analysis focused on the engine on/off strategy, powertrain operation mode, energy management, and engine operating conditions. Third, test data from the control analysis were used to summarize the vehicle control logic.

Kim, Namdoo (ORCID:000000025201539X)↗

DOE OSTI2022

Developing Fuel Cell Electric Powertrain Architectures for Commercial Vehicles

Here, this article addresses the architecture development for a commercial vehicle fuel cell electric powertrain by establishing a clear multi-step formalized workflow that employs a unique technoeconomic solution for architecture selection. The power capability of the fuel cell, the energy capacity and chemistry of the electrical energy storage (battery), the DC-DC converter (including the input current rating and isolation resistance requirements), the traction drive solution, the on-board hydrogen storage solution, and the real-time power-split management of the fuel cell and the battery are all considered and developed in this effort. The methods were used to select architecture for Class 8 urban, regional, and line haul applications. When compared to traditional load-following power-split controllers, an energy management power-split controller can increase system energy efficiency by up to 19.5%. The energy-efficient power-split controller may increase the required battery capacity for an equivalent life by up to 2.6 times. The impact on the total cost of ownership (TCO) for a variety of financial cases demonstrates that high C-rate capable batteries have the potential to provide better TCO solutions over a six-year vehicle life than low C-rate capable batteries. To achieve TCO parity with the 600 A non-isolated DC-DC converter case, the specific choice of the fuel cell DC-DC converter to achieve a target power output based on current levels (from 500 A to 2400 A) shows that efficiency decreases and cost increases due to the higher current, requiring fuel cell prices to decrease by $50–$100/kW, $60–$110/kW, and $100–$220/kW for urban, regional, and line haul applications, respectively. Key recommendations for powertrain system architectures are provided, with specifics based on vehicle dynamics, mission and application characteristics, end customer use-case profile, critical powertrain component costs, and architecture selection cost function. This study rigorously demonstrates the interplay of the above parameters, with a focus on TCO, and provides application decision-makers with a mechanism and well-defined set of impact factors to consider as part of their architecture selection process.

25 ENERGY STORAGE↗

DOE OSTI2022

Real Time Predictive and Adaptive Hybrid Powertrain Control Development via Neuroevolution

The real-time application of powertrain-based predictive energy management (PrEM) brings the prospect of additional energy savings for hybrid powertrains. Torque split optimal control methodologies have been a focus in the automotive industry and academia for many years. Their real-time application in modern vehicles is, however, still lagging behind. While conventional exact and non-exact optimal control techniques such as Dynamic Programming and Model Predictive Control have been demonstrated, they suffer from the curse of dimensionality and quickly display limitations with high system complexity and highly stochastic environment operation. This paper demonstrates that Neuroevolution associated drive cycle classification algorithms can infer optimal control strategies for any system complexity and environment, hence streamlining and speeding up the control development process. Neuroevolution also circumvents the integration of low fidelity online plant models, further avoiding prohibitive embedded computing requirements and fidelity loss. This brings the prospect of optimal control to complex multi-physics system applications. The methodology presented here covers the development of the drive cycles used to train and validate the neurocontrollers and classifiers, as well as the application of the Neuroevolution process.

33 ADVANCED PROPULSION SYSTEMS↗

NASA NTRS2021

Revolutionary Vertical Lift Technology (RVLT) Side-By-Side Hybrid Concept Vehicle Powertrain Dynamic Model

The Side-by-Side (SBS) Hybrid is one of several Revolutionary Vertical Lift Technology (RVLT) concept aircraft identified by NASA to investigate Urban Air Mobility (UAM) requirements. This paper presents a dynamic model of the SBS Hybrid powertrain built using the Toolbox for the Modeling and Analysis of Thermodynamic Systems (T-MATS) and the Electrical Modeling and Thermal Analysis Toolbox (EMTAT). The model consists of the rotors, electrical power system, and turboshaft engines connected through freewheeling clutches, gearboxes, and multiple shafts. This research effort models the complex behavior of the powertrain, including the operation of the freewheeling clutches and electrical power system at the simulation time scale of the shaft dynamics. Several simulations highlight the key features present in the model and demonstrate its operation.

Powertrain↗

NASA NTRS2021

Revolutionary Vertical Lift Technology (RVLT) Side-By-Side Hybrid Concept Vehicle Powertrain Dynamic Model

powertrain↗

NASA NTRSDate not supplied

Advanced 2030 Single Aisle Aircraft Modeling for the Electrified Powertrain Flight Demonstration Program

The NASA Electrified Powertrain Flight Demonstration Program is aimed at advancing electrified powertrains for future aircraft platforms through flight demonstrations for various passenger classes and power levels. The objective of this paper is to establish non-electrified reference models for 2030 aircraft with advanced technologies for the large single aisle (150 passenger) and small single aisle (100 passenger) vehicle classes. Current state-of-art aircraft are first identified and modeled using a proprietary design tool called Environmental Design Space. Next, through a comprehensive literature review, engine, airframe and composite material technologies that are expected to be available by 2030 are identified, and their respective benefits are applied to the 2030 vehicles. The engine cycle and the aircraft design are then optimized to provide the maximum fuel burn benefit while meeting all the specified aircraft requirements. While the large single aisle aircraft range requirement is kept the same as the current state-of-art aircraft, the small single aisle aircraft is optimized for a reduced range of 1000 nmi. Expected fuel burn benefit from these technologies along with any propulsive, aerodynamic and weight benefit will be summarized in this paper.

single aisle aircraft↗

NASA NTRSDate not supplied

Design and Development of an Aircraft Electric Powertrain Test Stand

Recent advancements in battery technology and power electronics are enabling novel approaches to powered flight that rely on fully electric or hybrid-electric powertrain systems. To mitigate the risk surrounding such unproven systems, it is necessary to characterize their performance on a component-wide and system-wide basis. In this paper, we discuss the design and development of an electric powertrain test stand that can collect high-fidelity data of motor, controller, and battery performance, thereby allowing us to determine system performance, efficiencies, and thermal characteristics.

test stand↗

NASA NTRS2023

Modeling and Simulation of a Parallel Hybrid Electric Regional Aircraft for the Electrified Powertrain Flight Demonstration (EPFD) Program

This paper presents a parametric modeling and integrated aircraft sizing and synthesis approach for a charge depleting parallel hybrid electric architecture. The developed models are integrated within the baseline thin-haul and regional aircraft. In addition to the physical architecture, different modes of operation enabled by propulsion system electrification are also modeled parametrically. The modes of operation presented in this paper are the peak power shaving, climb power electric boost, in-flight battery recharging, and electric taxi. The sizing of the powertrain and the aircraft are performed within the multidisciplinary analysis and optimization environment, E-PASS. The consideration of the physical system and its operation together provides a holistic approach where the propulsion system and the airframe are designed under an optimized power and energy management strategy. The parametric nature of the work enables the design space exploration for electrification and lays the groundwork for future technology projection and uncertainty quantification studies. The developed capability is generic and can be applied on other aircraft classes. The work is done as part of the Electrified Powertrain Flight Demonstration program.

electrified powertrain flight demonstration↗

NASA NTRSDate not supplied

Optimal Control Allocation for Distributed Electric Propulsion in A Series/Parallel Partial Hybrid Powertrain

The SUbsonic Single Aft eNgine (SUSAN) Electrofan is a NASA concept transport aircraft representative of technology anticipated for a 2040 entry-into-service date. The powertrain consists of a single thrust-producing geared turbofan engine with generators driving a series/parallel partial hybrid power/propulsion system. The architecture includes 16 underwing contrarotating fans, eight on each side. The distributed fans can be used by the flight control system to augment or replace the rudder function. This paper sets up the optimal control problem of setpoint determination for individual wingfans in the distributed propulsion system, accounting for electrical string efficiencies, saturations, and failures. The solution minimizes power consumption while maintaining thrust and torque on the airframe for maneuvering. Additionally, thrust that would have been lost due to temporary fan speed or power saturation is optimally redistributed to maintain overall desired thrust and torque on the aircraft. A simulation of a coordinated turn utilizing the distributed electric propulsion for yaw rate control in a multiple wingfan failure scenario demonstrates the robustness of the powertrain design to failures and helps define its limitations.

Distributed Electric Propulsion↗