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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 541 records · Page 30
All sourcesNASA NTRSDOE OSTI
NASA NTRS2012

Robust, Rework-able Thermal Electronic Packaging: Applications in High Power TR Modules for Space

The higher output power densities required of modern radar architectures, such as the proposed DESDynI [Deformation, Ecosystem Structure, and Dynamics of Ice] SAR [Synthetic Aperture Radar] Instrument (or DSI) require increasingly dense high power electronics. To enable these higher power densities, while maintaining or even improving hardware reliability, requires improvements in integrating advanced thermal packaging technologies into radar transmit/receive (TR) modules. New materials and techniques have been studied and are now being implemented side-by-side with more standard technology typically used in flight hardware.

Hoffman, James Patrick↗
NASA NTRS2009

A High Power Density Power System Electronics for NASA's Lunar Reconnaissance Orbiter

A high power density, modular and state-of-the-art Power System Electronics (PSE) has been developed for the Lunar Reconnaissance Orbiter (LRO) mission. This paper addresses the hardware architecture and performance, the power handling capabilities, and the fabrication technology. The PSE was developed by NASA s Goddard Space Flight Center (GSFC) and is the central location for power handling and distribution of the LRO spacecraft. The PSE packaging design manages and distributes 2200W of solar array input power in a volume less than a cubic foot. The PSE architecture incorporates reliable standard internal and external communication buses, solid state circuit breakers and LiIon battery charge management. Although a single string design, the PSE achieves high reliability by elegantly implementing functional redundancy and internal fault detection and correction. The PSE has been environmentally tested and delivered to the LRO spacecraft for the flight Integration and Test. This modular design is scheduled to flight in early 2009 on board the LRO and Lunar Crater Observation and Sensing Satellite (LCROSS) spacecrafts and is the baseline architecture for future NASA missions such as Global Precipitation Measurement (GPM) and Magnetospheric MultiScale (MMS).

Hernandez-Pellerano, A.↗
DOE OSTI2016

Thermal Performance Benchmarking

The goal for this project is to thoroughly characterize the thermal performance of state-of-the-art (SOA) in-production automotive power electronics and electric motor thermal management systems. Information obtained from these studies will be used to: evaluate advantages and disadvantages of different thermal management strategies; establish baseline metrics for the thermal management systems; identify methods of improvement to advance the SOA; increase the publicly available information related to automotive traction-drive thermal management systems; help guide future electric drive technologies (EDT) research and development (R&D) efforts. The thermal performance results combined with component efficiency and heat generation information obtained by Oak Ridge National Laboratory (ORNL) may then be used to determine the operating temperatures for the EDT components under drive-cycle conditions. In FY16, the 2012 Nissan LEAF power electronics and 2014 Honda Accord Hybrid power electronics thermal management system were characterized. Comparison of the two power electronics thermal management systems was also conducted to provide insight into the various cooling strategies to understand the current SOA in thermal management for automotive power electronics and electric motors.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2017

Thermal Performance Benchmarking: Annual Report

In FY16, the thermal performance of the 2014 Honda Accord Hybrid power electronics thermal management systems were benchmarked. Both experiments and numerical simulation were utilized to thoroughly study the thermal resistances and temperature distribution in the power module. Experimental results obtained from the water-ethylene glycol tests provided the junction-to-liquid thermal resistance. The finite element analysis (FEA) and computational fluid dynamics (CFD) models were found to yield a good match with experimental results. Both experimental and modeling results demonstrate that the passive stack is the dominant thermal resistance for both the motor and power electronics systems. The 2014 Accord power electronics systems yield steady-state thermal resistance values around 42- 50 mm to the 2nd power K/W, depending on the flow rates. At a typical flow rate of 10 liters per minute, the thermal resistance of the Accord system was found to be about 44 percent lower than that of the 2012 Nissan LEAF system that was benchmarked in FY15. The main reason for the difference is that the Accord power module used a metalized-ceramic substrate and eliminated the thermal interface material layers. FEA models were developed to study the transient performance of 2012 Nissan LEAF, 2014 Accord, and two other systems that feature conventional power module designs. The simulation results indicate that the 2012 LEAF power module has lowest thermal impedance at a time scale less than one second. This is probably due to moving low thermally conductive materials further away from the heat source and enhancing the heat spreading effect from the copper-molybdenum plate close to the insulated gate bipolar transistors. When approaching steady state, the Honda system shows lower thermal impedance. Measurement results of the thermal resistance of the 2015 BMW i3 power electronic system indicate that the i3 insulated gate bipolar transistor module has significantly lower junction-to-liquid thermal resistance as compared to the other systems. At a flow rate of 12 liters per minute, the thermal resistance of the i3 systems is only 30 percent of the Accord system and 15 percent of the LEAF system.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2021

Deadband Voltage Control and Power Buffering for Extreme Fast Charging Station

Voltage fluctuation is one of the most common challenges that electric vehicle charging station (EVCS) may introduce to the power grid. Local reactive power compensation (Q-compensation) capability of bi-directional electric vehicle (EV) chargers can mitigate the steady-state voltage violations caused by the EV charging itself or changes in the neighboring loads. Power buffering, using energy storage system (ESS), can be utilized to address the voltage transients (sags and swells) as a result of EV charging at the EVCS. To address PI controller’s ‘hunting’ issue, this paper proposes a Q-sign triggered deadband voltage control (V-control) method at the point of common coupling (PCC). In addition, to ensure the ramp rate of EV charging is within the allowable limits set forth by the grid code, a ramp rate control is proposed that uses the ESS as a ‘power buffer’. Lastly, different from most reported work in the literature where no explicit limit of the power electronic converters (PECs) is considered, this work considers a reasonable apparent power capacity limit of the PECs when achieving the V-control. This limit also affects the amount of active power that can be obtained from the grid, and subsequently may require ESS to function as ‘load sharing’ device to provide supplemental active power to satisfy EV load. A case study simulated in MATLAB (interfaced with PLECS) is presented to demonstrate the effectiveness of the proposed approaches for EVCS operation.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2018

Initial beam dynamics simulations of a high-average-current field-emission electron source in a superconducting radiofrequency gun

High-power electron beams are sought-after tools in support to a wide array of societal applications. This paper explores the production of high-power electron beams by combining a high-current field-emission electron source to a superconducting radio-frequency (SRF) cavity. We especially carry out beam-dynamics simulations that demonstrate the viability of the scheme to form ~ 300 kW average-power electron beam using a 1+1/2-cell SRF gun.

43 PARTICLE ACCELERATORS↗
DOE OSTI2019

Formation of Power-law Electron Energy Spectra in Three-dimensional Low- β Magnetic Reconnection

While observations have suggested that power-law electron energy spectra are a common outcome of strong energy release during magnetic reconnection, e.g., in solar flares, kinetic simulations have not been able to provide definite evidence of power-laws in energy spectra of nonrelativistic reconnection. By means of 3D large-scale fully kinetic simulations, we study the formation of power-law electron energy spectra in nonrelativistic low-β reconnection. We find that both the global spectrum integrated over the entire domain and local spectra within individual regions of the reconnection layer have power-law tails with a spectral index p ~ 4 in the 3D simulation, which persist throughout the nonlinear reconnection phase until saturation. In contrast, the spectrum in the 2D simulation rapidly evolves and quickly becomes soft. We show that 3D effects such as self-generated turbulence and chaotic magnetic field lines enable the transport of high-energy electrons across the reconnection layer and allow them to access several main acceleration regions. This leads to a sustained and nearly constant acceleration rate for electrons at different energies. Here, we construct a model that explains the observed power-law spectral index in terms of the dynamical balance between particle acceleration and escape from main acceleration regions, which are defined based upon a threshold for the curvature drift acceleration term. This result could be important for explaining the formation of power-law energy spectrum in solar flares.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2016

Performance and Reliability of Bonded Interfaces for High-Temperature Packaging. Annual Report

Current generation automotive power electronics packages utilize silicon devices and lead-free solder alloys. To meet stringent technical targets for 2020 and beyond (for cost, power density, specific power, efficiency and reliability), wide-bandgap devices are being considered since they offer advantages such as operation at higher frequencies, voltages, and temperatures. Traditional power electronics packages must be redesigned to utilize the full potential of wide-bandgap devices, and the die- and substrate-attach layers are key areas where new material development and validation is required. Present solder alloys do not meet the performance requirements for these new package designs while also meeting cost and hazardous substance restrictions. Sintered silver (Ag) promises to meet the needs for die- and substrate-attach interfaces but synthesis optimization and reliability evaluation must be completed. Sintered Ag material was proposed as an alternative solution in power electronics packages almost 20 years back. However, synthesis pressure requirements up 40 MPa caused a higher complexity in the production process and more stringent flatness specifications for the substrates. Recently, several manufacturers have developed sintered Ag materials that require lower (3-5 MPa) or even no bonding pressures. Degradation mechanisms for these sintered Ag materials are not well known and need to be addressed. We are addressing these aspects to some extent in this project. We are developing generalized (i.e., independent of geometry) stress intensity factor versus cycles-to-failure relations for sintered Ag. Because sintered Ag is a relatively new material for automotive power electronics, the industry currently does not have a good understanding of recommended synthesis parameters or expected reliability under prescribed conditions. It is an important deliverable of this project to transfer findings to industry to eliminate barriers to using sintered Ag as a viable and commercialized die- and substrate-attach material. Only a few manufacturers produce sintered Ag pastes and may consider some processing conditions as proprietary. It is the goal of this project to openly explore and define best practices in order to impact the maximum number of power electronics module manufacturers and suppliers.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2018

On a Future for Smart Inverters with Integrated System Functions

The modern electric power grid is gradually evolving to include high penetration power electronics in a distributed architecture which will pose pressing new challenges on power quality, system control, and operation. The state-of-the-art smart inverters for solar photovoltaics may not be sufficient to address some of the stability and control challenges such as harmonic resonances due to the interactions of multiple power electronics converters. This paper discusses a future of smart inverters with integrated system functions and its associated challenges, and identifies smart inverter research trends and features in the context of flexible control architectures. Future power electronics research will shift from hardware solutions to more control solutions with integrated system functions under distributed power grid scenarios with small-scale power electronics interfaced with distributed generations and loads.

Xue, Yaosuo↗
DOE OSTI2022

WBG-Enabled Current-Source Inverters for Integrated PM Motor Drives

This project takes advantage of the special capabilities of wide-bandgap (WBG) power semiconductor devices to develop innovative power electronics in the form of new current-source inverters (CSIs) that offer promising advantages over the dominant voltage-source inverter (VSI) topology. These CSIs, in turn, are extremely well-suited for integration into the housings of permanent magnet synchronous machines (PMSMs) to form integrated motor drives (IMDs). These new IMDs offer great promise for achieving major energy savings in a wide variety of applications that benefit from adjustable-speed control, including air conditioners, laundry appliances, industrial pumps/compressors, electric vehicles, and aerospace drives. WBG devices play a critical enabling role in these new IMDs because of their transformative features including much higher switching frequencies, lower losses, and compatibility with high operating temperatures. When incorporated into new CSI-based IMDs with PM machines, these WBG switches open the door to achieving major increases in power density, drive system efficiency, and fault tolerance, as well as substantial reductions in electromagnetic interference (EMI), manufacturing cost, and temperature-induced failures. The higher operating temperature capability of WBG devices compared to conventional silicon power devices is very appealing in IMD applications because the power electronics is mounted in close proximity to the motors which typically operate at temperatures well above the maximum limits of today’s silicon-based power electronics. This project has succeeded in designing, building, and testing multiple prototype versions of this CSI-IMD that have overcome many technical challenges in order to demonstrate the impressive performance improvements that can be achieved by the WBG-enabled CSI-IMD. The preliminary demo and bench-top versions of the current-source inverter developed during the first two years of the project were critical to laying the technical foundations for the 3 kW prototype CSI-IMD unit that was successfully built and tested during the third year. This prototype CSI-IMD unit was designed to fit within the housing envelope of the original permanent magnet (PM) synchronous machine in order to meet the demanding power density requirements that were set at the beginning of the project. All of the remaining performance objectives set for the prototype CSI-IMD unit including efficiency and electromagnetic interference (EMI) were also met. The last 18 months of the project were devoted to developing further enhancements of the WBG-enabled CSI-IMD technology that better prepare it for commercial production. More specifically, an upgraded version of the prototype CSI-IMD unit was developed that moved the power electronics into the same machine housing chamber as the motor, substantially raising the thermal demands on the power electronics. Tests with five different combinations of motor enclosure types and air cooling configurations were evaluated. Importantly, this work confirmed that the power electronics can deliver its full rated power and still operate well within its maximum temperature limits even for worst-case conditions when the housing is “totally-enclosed” without any openings for air to enter or exit the enclosure, and no blower/fan is provided to blow air over the outside surface of the enclosure. Reaching the full performance and energy-savings potential of this disruptive CSI-IMD motor drive technology is highly consistent with ARPA-E’s stated mission to “enhance the economic and energy security of the United States” while also supporting its commitment to “ensure that the U.S. maintains a technological lead in developing and deploying advanced energy technologies”. Follow-on projects are under way to explore the scalability of WBG-enabled CSI-IMD technology to 100 kW (peak) electric vehicle traction drives and fault-tolerant modular motor drives for future electrified aircraft propulsion applications.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
NASA NTRSDate not supplied

Spacecraft Charging as an Asset to Interplanetary Small Spacecraft

Small spacecraft operate on a far more limited power budget than their larger counterparts, a problem compounded for interplanetary spacecraft in the outer solar system. The reduced solar flux beyond Earth’s orbit makes solar panels less effective for spacecraft exploring the gas giants and can they are susceptible to damage by intense radiation belts. Radioisotope thermoelectric generators are expensive and bulky compared to their power output. Interplanetary small satellite missions benefit from both alternative energy sources and low-power electronics to power their buses and scientific payloads. Traditionally, spacecraft engineers treat the space environment as a hazard, but it nevertheless offers a potential solution. Currents from space plasmas charge spacecraft to high potentials and can cause electrical arcing to occur between differentially charged surfaces. The spacecraft can harvest a small amount of power —<10 mW/m2at Jupiter — from the electric field between these surfaces to do useful work, either by charging a battery or directly powering an instrument or actuator. While using the energy directly has limited use due to the low electron density and temperature of most space plasmas, it can nevertheless be used in situations where solar panels are not desirable, such as high radiation environments. Two applications — a Langmuir probe and an attitude control actuator — exploit the disparate current-voltage characteristics between surfaces with different material properties and require minimal input power to operate.

Spacecraft↗
NASA NTRSDate not supplied

Spacecraft Charging as an Asset to Interplanetary Small Spacecraft

Small spacecraft operate on a far more limited power budget than their larger counterparts, a problem compounded for interplanetary spacecraft in the outer solar system. The reduced solar flux beyond Earth’s orbit makes solar panels less effective for spacecraft exploring the gas giants and they are susceptible to damage by intense radiation belts. Radioisotope thermoelectric generators are expensive and bulky compared to their power output. Interplanetary small satellite missions benefit from both alternative energy sources and low-power electronics to power their buses and scientific payloads. Traditionally, spacecraft engineers treat the space environment as a hazard, but it nevertheless offers a potential solution. Currents from space plasmas charge spacecraft to high potentials and can cause electrical arcing to occur between differentially charged surfaces. The spacecraft can harvest a small amount of power —<10 mW/m2at Jupiter — from the electric field between these surfaces to do useful work, either by charging a battery or directly powering an instrument or actuator. While using the energy directly has limited use due to the low electron density and temperature of most space plasmas, it can nevertheless be used in situations where solar panels are not desirable, such as high radiation environments. Two applications — a Langmuir probe and an attitude control actuator — exploit the disparate current-voltage characteristics between surfaces with different material properties and require minimal input power to operate.

spacecraft charging↗
DOE OSTI2015

Modeling Microinverters and DC Power Optimizers in PVWatts

Module-level distributed power electronics including microinverters and DC power optimizers are increasingly popular in residential and commercial PV systems. Consumers are realizing their potential to increase design flexibility, monitor system performance, and improve energy capture. It is becoming increasingly important to accurately model PV systems employing these devices. This document summarizes existing published documents to provide uniform, impartial recommendations for how the performance of distributed power electronics can be reflected in NREL's PVWatts calculator (http://pvwatts.nrel.gov/).

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2019

Electrothermal Modeling and Analysis of Gallium Oxide Power Switching Devices: Preprint

Gallium oxide is an emerging wide band-gap material that has the potential to penetrate the power electronics market in the near future. In this paper, a finite-element gallium oxide semiconductor model is presented that can predict the electrical and thermal characteristics of the device. The finite element model of the two-dimensional device architecture is developed inside the Sentaurus environment. A vertical FinFET device architecture is employed to assess the device's behavior and its static and dynamic behavior. Enhancement-mode device operation is realized with this type of device architecture without the need for any selective area doping. The dynamic thermal behavior of the device is characterized through its short-circuit behavior. Based on the device static and dynamic behavior, it is envisioned that reliable vertical transistors can be fabricated for the power electronics applications.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2018

Time-dependent orbital-free density functional theory for electronic stopping power: Comparison to the Mermin-Kohn-Sham theory at high temperatures

Electronic stopping power in warm dense matter can affect energy transport and heating in astrophysical processes and internal confinement fusion. For cold condensed matter systems, stopping power can be modeled from first-principles using real-time time-dependent density functional theory (DFT). However, high temperatures (10's to 100's of eV) may be computationally prohibitive for traditional Mermin-Kohn-Sham DFT. New experimental measurements in the warm dense regime motivates the development of first-principles approaches, which can reach these temperatures. Here, we have developed a time-dependent orbital-free density functional theory, which includes a novel nonadiabatic and temperature-dependent kinetic energy density functional, for the simulation of stopping power at any temperature. The approach is nonlinear with respect to the projectile perturbation, includes all ions and electrons, and does not require a priori determination of screened interaction potentials. Finally, our results compare favorably with Kohn-Sham for temperatures in the WDM regime, especially nearing 100 eV.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
NASA NTRS2019

Modular Standards for Space Power Systems

This presentation presents an approach to provide commonality for future space power systems through a set of modular power standards. The approach presented breaks down the electrical power conversion and distribution system into the lowest level functions, which are represented by power electronics modules, and serve as the foundational building blocks of the system. A series of Modular Power Standards has been developed to define the functions and interfaces of the lowest level of the electrical power system, or for each type of power electronics module. The power electronics modules, when integrated with a common chassis and backplane, can then be built up into modular electronics assemblies, which have been demonstrated and characterized in a relevant ground test environment.

Gardner, Brent G.↗
DOE OSTI2022

A Reliable, Cost-Effective Transformerless Medium-Voltage Inverter for Grid Integration of Combined Solar and Energy Storage

The goal of this project is to utilize an innovative holistic power electronic inverter design approach, which can leverage best-in-class silicon carbide (SiC) power modules, novel multi-level power electronic circuits, high frequency transformers, switching sequence based control and co-designed electro-thermal management methods, to realize a 300 kW transformerless medium-voltage (MV) inverter system. The system cost of the inverter is considered as a primary design objective alongside high power density, efficiency, low electromagnetic interference (EMI) and long lifespan. This design-oriented research activity, especially the proposed multi-objective optimization approach, will have broad impacts in holistic power electronic system design methods and in technologies that can be commercialized into a wide variety of wide bandgap power electronic applications.

14 SOLAR ENERGY↗
DOE OSTI2026

A Unified Design Theory for Multi-Port Polyphase Transformers Enabling Scalable Power-Multiplexed EV Fleet Charging Systems

This paper presents a unified analytical design theory for multi-port polyphase transformers, targeting scalable and isolated high-power Electric Vehicle (EV) fleet charging systems with power multiplexing capability. As fleet electrification accelerates, conventional one-to-one charger architectures face significant challenges in infrastructure cost, peak power demand, and low utilization of installed power electronics. Power-multiplexed charging architectures, which dynamically distribute power from a shared pool of converter modules across multiple vehicles, have emerged as a promising solution. However, such architectures require scalable, isolated multi-port power interfaces capable of routing energy among multiple inputs and outputs, whose design remains complex and dependent on iterative modeling. To address this gap, the proposed theory provides closed-form expressions for self-inductance, leakage inductance, and mutual coupling terms for arbitrary multi-phase, multi-port transformer structures. The formulation enables direct synthesis of isolated multi-input and multi-output resonant converter systems without reliance on geometry-specific finite-element analysis or extensive parameter extraction. This capability is particularly critical for power-multiplexed systems, where modular converter structures must interface with multiple vehicles while maintaining galvanic isolation and flexible power allocation. The effectiveness of the proposed framework is demonstrated through the design of a 360 kW multi-phase system operating over a 700–900 VDC input and 400–1250 VDC output range. PLECS simulation results confirm accurate prediction of system behavior and validate the applicability of the approach to multi-port, power-multiplexed charging scenarios. The proposed method significantly reduces design complexity while enabling scalable, cost-effective, and fully utilized EV fleet charging infrastructure.

Asa, Erdem [ORNL] (ORCID:0000000190884812)↗