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At least 55 records · Page 3
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Optimizing Insulation Design for Transformers in Medium Voltage Power Conversion Systems

Medium-frequency transformers (MFTs) play a crucial role in medium-voltage (MV) solidstate transformer (SST) systems, particularly in extreme fast charging applications. Achieving partial discharge (PD)-free operation while maintaining high power density is a significant challenge due to the high electric field (E-field) stresses inherent in MV applications. This dissertation focuses on the insulation design and optimization of MFTs used in both the main power electronics circuits and auxiliary power supplies. The study begins with an overview of insulation testing methodologies, including high potential tests, basic insulation level tests, and PD tests, which are critical for evaluating MFT insulation reliability. Given the importance of PD-free operation for long-term reliability, particular emphasis is placed on understanding PD mechanisms, including void, corona, and surface discharge, and their mitigation strategies. A high voltage isolated auxiliary power supply is then introduced, utilizing a gapped transformer encapsulated in silicone gel. This design achieves PD-free insulation up to 18 kV RMS while maintaining low coupling capacitance to minimize common-mode current. The proposed solution ensures reliable operation in MV environments and offers a scalable approach for auxiliary power in cascaded SST architectures. To improve MFT insulation in main power conversion circuits, a novel structure is developed using polypropylene sheets and potting compounds to create a void-free air gap, effectively mitigating E-field intensity. A prototype transformer with this insulation structure is built and achieves PD-free operation up to 30 kV RMS. This design is experimentally validated in a resonant converter operating at 46 kW, demonstrating its feasibility for MV SST applications. Further optimization is implemented to enhance MFT performance for dual-active-bridge(DAB) converters by integrating a semiconductive shielding layer within the insulation structure. This shielding layer improves the magnetic coupling coefficient while effectively confining the E-field within high insulation materials, thereby reducing eddy current losses. The optimized MFT achieves PD-free operation at 12.6 kV RMS and is successfully tested in a DAB converter operating at 43 kW, which meets the insulation requirements for a 13.2 kV SST system. This dissertation advances MFT insulation design by introducing and experimentally validating novel approaches that improve high voltage insulation while optimizing magnetic coupling and manufacturability. The proposed insulation structures enable PD-free operation while minimizing insulation material usage and simplifying assembly, making them ideal for high power, high voltage applications.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2023

An Assessment of Additively Manufactured Bonded Permanent Magnets for a Distributed Wind Generator

In this paper, we examine and compare the performance of a generator design optimized using additively manufactured NdFeB-SmFeN in nylon-polymer-bonded permanent magnets (PMs) against a generator design with conventional NdFeB sintered PMs. To realize this, a commercially available 15-kW wind generator's rotor is re-optimized using both additively manufactured and sintered NdFeB magnets using simple geometric parameterization that allowed for two specific magnet shapes, namely, arc-shaped and crown-shaped designs. Results showed that for a similar generator performance, the designs with additively manufactured bonded PMs are more cost-competitive in terms of the estimated PM material cost and also have negligible eddy current magnet losses.

additive manufacturing↗
NASA NTRS2015

Fine-Filament MgB2 Superconductor Wire

Hyper Tech Research, Inc., has developed fine-filament magnesium diboride (MgB2) superconductor wire for motors and generators used in turboelectric aircraft propulsion systems. In Phase I of the project, Hyper Tech demonstrated that MgB2 multifilament wires (<10 micrometers) could reduce alternating current (AC) losses that occur due to hysteresis, eddy currents, and coupling losses. The company refined a manufacturing method that incorporates a magnesium-infiltration process and provides a tenfold enhancement in critical current density over wire made by a conventional method involving magnesium-boron powder mixtures. Hyper Tech also improved its wire-drawing capability to fabricate fine multifilament strands. In Phase II, the company developed, manufactured, and tested the wire for superconductor and engineering current density and AC losses. Hyper Tech also fabricated MgB2 rotor coil packs for a superconducting generator. The ultimate goal is to enable low-cost, round, lightweight, low-AC-loss superconductors for motor and generator stator coils operating at 25 K in next-generation turboelectric aircraft propulsion systems.

Cantu, Sherrie↗
DOE OSTI2022

Influence of twist pitch on hysteretic losses and transport J c in overpressure processed high J c Bi-2212 round wires

Abstract Bi-2212 is the only high field, high-temperature superconductor (HTS) available in the macroscopically isotropic, multifilament high J c round wire (RW) form capable of generating high uniformity fields with minimum-screening current errors. However, the heat treatment that enables impressively high J c (4.2 K, 30 T) values that can attain ∼5000 A mm −2 also produces significant filament bonding (bridging). Filament bridging appears to significantly enhance hysteretic losses of the filaments themselves by coupling neighboring, nominally independent filaments, enabling shielding currents to flow across multiple filaments as though they were one filament of much larger diameter. Wire twisting can be employed to reduce filament-to-filament eddy current coupling losses due to induced currents flowing across the matrix, but twisting is less effective in reducing increased losses from bridging. Here, we compare the twist-pitch dependence of the losses of overpressure processed (OP) high J c Bi-2212 RWs with partially bridged filaments to those found in OP Bi-2212 RWs with discrete, not-bridged filaments. We show that filament sub-bundles in standard, partially-bridged wires that have some superconducting connections between filaments can exhibit significant coupling (much larger effective filament diameter), but twisting still reduces their hysteretic losses to values close to or below the ITER Nb 3 Sn wire loss specification, even though Bi-2212 wires have significantly larger J c values. Although it has been reported that twisting can reduce wire J c by damaging filaments, we found no reduction in transport J c , even for nominal twist pitches of 12 mm in 0.8 mm diameter wires. Evaluation of more-recent, higher J c Engi-Mat powder wires showed that their reduced filament bridging and improved longitudinal connectivity significantly improved transport J c and reduced the J c normalized losses, signaling that J c can be further improved without commensurate increase in losses. This important result strengthens the argument for production of high field, low loss HTS magnets made with Bi-2212 RWs.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2020

Test Results of Fast Decaying Current-Induced AC Losses in SHMS Superconducting Magnets at Jefferson Lab

The 11 GeV Super High Momentum Spectrometer (SHMS) of Hall C, part of the recent 12 GeV accelerator Upgrade at Jefferson Lab, was successfully commissioned in 2017. Fast current discharges of the SHMS Q2, Q3 quadrupoles and dipole superconducting magnets experienced some level of operational difficulty, during commissioning and normal operation. Measurements and analyses demonstrate that the fast current discharge leads to substantial AC losses in the conductor and subsequently triggers a quench-back effect. The details of the measurements and analyses have been reported previously. This paper focuses on the test results of the magnets using a reduced value of the protection dump resistor for each magnet to lower the current decay rate. Finally, the test results confirmed that the reduced dump resistances eliminated the quench-back effect for the SHMS Q2, Q3 and Dipole magnets, thus improving their cryogenic operability.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
NASA NTRS1996

A Wide Bandwidth Model for the Electrical Impedance of Magnetic BearingS

Magnetic bearings are often designed using magnetic circuit theory. When these bearings are built, however, effects not included in the usual circuit theory formulation have a significant influence on bearing performance. Two significant sources of error in the circuit theory approach are the neglect of leakage and fringing effects and the neglect of eddy current effects. This work formulates an augmented circuit model in which eddy current and flux leakage and fringing effects are included. Through the use of this model, eddy current power losses and actuator bandwidth can be derived. Electrical impedance predictions from the model are found to be in good agreement with experimental data from a typical magnetic bearing.

Meeker, David C.↗
NASA NTRS1983

Magnetic Bearings for Inertial Energy Storage

The selection of a noncontacting bearing technique with no wear out phenomena and which is vacuum compatible which is the decisive factor in selecting magnetic bearings for kinetic energy storage was investigated. Unlimited cycle life without degradation is a primary goal. Storage efficiency is a key parameter which is defined as the ratio of the energy remaining to energy stored after a fixed time interval at no load conditions. Magnetic bearings, although noncontacting, are not perfectly frictionless in that magnetic losses due to eddy currents and hysteresis can occur. Practical magnetic bearings, however, deviate from perfect symmetry and have discontinuities and asymmetric flux paths either by design or when controlled in the presence of disturbances, which cause losses. These losses can be kept smaller in the bearings than in a high power motor/generator, however, are a significant factor in selecting the magnetic bearing type.

Studer, P. A.↗
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↗
NASA NTRS1995

Effects of atomic oxygen on polymeric materials flown on EOIM-3

Diverse polymeric materials, including several variations of Kapton, were flown on STS-46 as part of the Evaluation of Oxygen Interaction with Materials Experiment (EOIM-3). These materials were flown in the cargo bay and exposed to the space environment July 31 - August 8, 1992, including 40 hours of direct atomic oxygen impingement. The atomic oxygen exposure was approximately 2.2 x 10(exp 20) atoms/sq cm. Polymeric materials flown on EOIM-3 include coated and uncoated Kapton, Tefzel ETFE, Lexan, FEP and TFE Teflon, bulk Halar and PEEK, S383 silicone and Viton elastomeric seal material. Analyses performed included thickness measurements using Dektak and eddy current methods, mass loss, resistance, permeability, hardness, and FTIR. The effects of stress and the space environment on Kapton were also evaluated. Previous EOIM missions on STS-5 and STS-8 and the Long Duration Exposure Facility also contained polymeric material samples. Data from these previous flights are shown for comparison, as well as ground simulation of space environment effects using both thermal energy flow tubes and 5 eV neutral atomic oxygen beam facilities. Reaction efficiencies for the various atomic oxygen exposure conditions are discussed.

Kamenetzky, Rachel R.↗
DOE OSTI2021

Laminated Permanent Magnets Enable Compact Magnetic Components in Current Source Converters

Magnetic components play a key role in determining the size, cost, efficiency of a power converter. They are more significant in current source converters, where the dc-link energy is stored in an inductor/transformer. In such cases, the magnetics have a predominantly DC flux, superimposed by an AC flux at switching frequency. Previously, permanent magnets have been proposed to offset the DC flux and thereby reduce the size, cost, and losses of the inductors/transformers. This paper starts by analyzing the issue of eddy currents when using such standard permanent magnets, especially in medium frequency applications, making them practically unusable. Alternatively, the paper proposes the use of laminated permanent magnets to reduce these eddy currents and thereby realize the benefits of offsetting the DC flux to reduce the size, cost, and loss of inductors/transformers. Using a soft-switching solid-state transformer as an example, experimental results are presented to show the impact of eddy currents in standard permanent magnets when used with a medium frequency transformer. Here, experimental results showing the benefits of using laminated magnets in reducing the eddy currents are presented.

30 DIRECT ENERGY CONVERSION↗
NASA NTRS2001

Low loss pole configuration for multi-pole homopolar magnetic bearings

A new pole configuration for multi-pole homopolar bearings proposed in this invention reduces rotational losses caused by eddy-currents generated when non-uniform flux distributions exist along the rotor surfaces. The new homopolar magnetic bearing includes a stator with reduced pole-to-pole and exhibits a much more uniform rotor flux than with large pole-to-pole gaps. A pole feature called a pole-link is incorporated into the low-loss poles to provide a uniform pole-to-pole gap and a controlled path for pole-to-pole flux. In order to implement the low-loss pole configuration of magnetic bearings with small pole-to-pole gaps, a new stator configuration was developed to facilitate installation of coil windings. The stator was divided into sector shaped pieces, as many pieces as there are poles. Each sector-shaped pole-piece can be wound on a standard coil winding machine, and it is practical to wind precision layer wound coils. To achieve maximum actuation efficiency, it is desirable to use all the available space for the coil formed by the natural geometric configuration. Then, the coils can be wound in a tapered shape. After winding, the sectored-pole-pieces are installed into and fastened by bonding or other means, to a ring of material which encloses the sectored-pole-pieces, forming a complete stator.

Blumenstock, Kenneth A.↗
NASA NTRS1995

Stability mechanical considerations, and AC loss in HTSC monoliths, coils, and wires

For monolithic high-T(sub c) superconductors (HTSC's) calculations are presented of: (1) the initial flux jump field, H(sub fj), in melt-processed YBCO based on a field and temperature dependent J(sub c), and (2) the radial and circumferential stresses in solid and hollow cylinders containing trapped magnetic flux. For model multi filamentary (MF) HTSC/Ag strands calculations are presented of: (1) the limiting filament diameters for adiabatic and dynamic stability, and (2) the hysteretic and eddy current components of AC loss. Again for MF HTSC/Ag composite strands the need for filamentary subdivision and twisting is discussed.

Sumption, M. D.↗
DOE OSTI2025

Additive manufacturing of amorphous metal soft magnetic composites

Soft magnet alloys are used as magnetic cores for electric motors, transformers, wind turbines and other power generation systems. Soft magnetic cores are expensive and time consuming to manufacture in the complex shapes required for next-generation devices using conventional press and sinter powder metallurgy. The objective of this effort is to additively manufacture high performance soft magnets, with reduced cost and reduced material waste and 10x lower energy (core) loss at the high operating frequencies of many electric machines. Laser powder bed fusion additive manufacturing is used as the fabrication method. Electrical steel and amorphous alloys atomized powders are used as a feedstock materials. Magnetic cores are printed in topology optimized structures such as the Hilbert curve because this has been shown to reduce energy losses by minimizing the eddy currents that circulate within the magnet at high frequencies. In our project, we succeed in printing FeSi 3.5wt% and FeSi 6.5wt% electrical steels, and iron-based soft magnetic amorphous alloys in the shape of Hilbert and Peano curve topology optimized structures. We found that the Peano curve has a higher cut-off frequency than the Hilbert curve, and that amorphous alloys have high cut-off frequencies and higher mechanical hardness than electrical steels. Processing conditions such as laser power, scan speed, and hatching pattern were optimized to achieve high density prints, and optimize magnetic performance. We find that the printing of amorphous alloy soft magnetic cores may be technoeconomically feasible for large scale applications such as transformers, for which supply chain issues and the labor costs of manual fabrication of magnetic cores is prohibitive in some cases.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Cabling method of superconducting flat wires

A structure and method provide cables of high-temperature superconducting flat tape and/or filament wires, with a small bending diameter. A cable has a former having cross section that includes a rectangle having rounded ends (i.e. an obround), and the flat tape is wound around the surface of the former at an angle to minimize bending. The former surface may have raised helical ribs or lowered grooves to provide tape registration in multi-layer configurations. Tape may be wound from a spool onto the former under tension, and cut with a laser cutter to produce fine filaments immediately before winding. The former may be slit longitudinally to prevent loop eddy currents and reduce AC losses. The wound cable may be jacketed to provide a cable-in-conduit conductor (CICC), and coolant channels may be provided in the jacket or in the former.

Takayasu, Makoto↗
NASA NTRS1987

Space station power semiconductor package

A package of high-power switching semiconductors for the space station have been designed and fabricated. The package includes a high-voltage (600 volts) high current (50 amps) NPN Fast Switching Power Transistor and a high-voltage (1200 volts), high-current (50 amps) Fast Recovery Diode. The package features an isolated collector for the transistors and an isolated anode for the diode. Beryllia is used as the isolation material resulting in a thermal resistance for both devices of .2 degrees per watt. Additional features include a hermetical seal for long life -- greater than 10 years in a space environment. Also, the package design resulted in a low electrical energy loss with the reduction of eddy currents, stray inductances, circuit inductance, and capacitance. The required package design and device parameters have been achieved. Test results for the transistor and diode utilizing the space station package is given.

Balodis, Vilnis↗
NASA NTRS1993

Characteristics of Ferromagnetic Flux Focusing Lens in the Development of Surface/Subsurface Flaw Detector

Electromagnetic NDE techniques have in the past steered away from the use of ferromagnetic materials. Although their high permeabilities lead to increased field levels, the properties of ferrous elements in the presence of alternating magnetic fields are difficult to determine. In addition, their use leads to losses which can be minimized through the use of low conductivity ferrites. In fact, the eddy current probes which do incorporate ferromagnetic materials have focused on these losses and the shielding which can be obtained by surrounding a probe with a high permeability, conducting material. Eddy current probes enclosed in conducting and magnetic shields have been used to prevent the generated fields from interacting with materials in the vicinity of the probe, such as when testing near material boundaries. A recent invention has used ferromagnetic shielding to magnetically separate individual concentric eddy current probes in order to eliminate cross-talk between the probes so that simultaneous detection of different types of flaws at different depths can be achieved. In contrast to the previous uses of ferromagnetic materials purely as magnetic shields, an electromagnetic flaw detector recently developed at NASA Langley Research Center takes advantage of the flux focusing properties of a ferromagnetic mild steel in order to produce a simple, effective device for the non-destructive evaluation of conducting materials. The Flux Focusing Eddy Current Probe has been shown to accurately measure material thickness and fatigue damage. The straight forward flaw response of the probe makes the device ideal for rapid inspection of large structures, and has lead to its incorporation in a computer controlled search routine to locate fatigue crack tips and monitor experimental fatigue crack growth experiments.

Wincheski, Buzz↗
NASA NTRS1996

Ultralow Friction in a Superconducting Magnetic Bearing

Passive levitation by superconducting magnetic bearings can be utilized in flywheels for energy storage. Basic design criteria of such a bearing are high levitation force, sufficient vertical and horizontal stability and low friction. A test facility was built for the measurement and evaluation of friction in a superconducting magnetic bearing as a function of operating temperature and pressure in the vacuum vessel. The bearing consists of a commercial disk shaped magnet levitated above single grain, melt-textured YBCO high-temperature superconductor material. The superconductor was conduction cooled by an integrated AEG tactical cryocooler. The temperature could be varied from 50 K to 80 K. The pressure in the vacuum chamber was varied from 1 bar to 10(exp -5) mbar. At the lowest pressure setting, the drag torque shows a linear frequency dependence over the entire range investigated (0 less than f less than 40 Hz). Magnetic friction, the frequency independent contribution, is very low. The frequency dependent drag torque is generated by molecular friction from molecule-surface collisions and by eddy currents. Given the specific geometry of the set-up and gas pressure, the molecular drag torque can be estimated. At a speed of 40 Hz, the coefficient of friction (drag-to-lift ratio) was measured to be mu = 1.6 x 10(exp -7) at 10(exp -5) mbar and T = 60 K. This is equivalent to a drag torque of 7.6 x 10(exp -10) Nm. Magnetic friction causes approx. 1% of the total losses. Molecular friction accounts for about 13% of the frequency dependent drag torque, the remaining 87% being due to eddy currents and losses from rotor unbalance. The specific energy loss is only 0.3% per hour.

Bornemann, Hans J.↗
NASA NTRS1977

Low-loss energy storage flywheel

Magnetically-levitated, ironless-armature spokeless rotor is used. Ironless armature construction eliminates core losses due to hysteresis and eddy currents. Device combines features of homopolar salient poles and stationary ironless electronically commutated armature.

Evans, H. E.↗