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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 73 records · Page 4
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

Primary Frequency Control Using Motor Drives for Short Term Grid Disturbances

Industrial motor systems make up a quarter of all electric sales in the United States. Variable speed drives (VSDs) can provide energy efficiency savings to the customer by regulating motor speed based on specific and varying needs. In addition to the benefits provided to the customer, VSDs can provide support to the grid through ancillary services. The Center for Ultra-Wide-Area Resilient Electric Energy Transmission Networks (CURENT) developed a power electronics converter-based grid emulator to allow testing of various power system architectures and demonstration of key technologies in monitoring, control, actuation, and visualization. This paper proposes using an active front-end VSD's connected motor load to provide frequency regulation to a large scale power grid. Each part of the emulator is described including motor and power electronics model and control. The proposed frequency regulation is implemented in VSDs and modeled in both a transmission system in EMTDC/PSCAD and verified on CURENT's hardware testbed.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2023

A Nitrogen Out-of-Plane (NOOP) Mechanism for Imine-Based Light-Driven Molecular Motors

Light-driven molecular motors have generated considerable interest due to their potential applications in material and biological systems. Recently, Greb and Lehn reported a new class of molecular motors, chiral N-alkyl imines, which undergo unidirectional rotation induced by light and heat. The mechanism of unidirectional motion in molecular motors containing a C═N group has been assumed to consist of photoinduced torsion about the double bond. In this work, we present a computational study of the photoisomerization dynamics of a chiral N-alkyl imine motor. We find that the location and energetics of minimal energy conical intersections (MECIs) alone are insufficient to understand the mechanism of the motor. Furthermore, a key part of the mechanism consists of out-of-plane distortions of the N atom (followed by isomerization about the double bond). Dynamic effects and out-of-plane distortions are critical to understand the observed (rather low) quantum yield for photoisomerization. Finally, our results provide hints as to how the photoisomerization quantum yield might be increased, improving the efficiency of this class of molecular motors.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
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 OSTI2023

Comprehensive Efficiency Analysis of Seven-Switch Current-Source Inverter Based on Voltage-Boost Function and Genetic Algorithm

This paper investigates the voltage-boost features of the emerging seven-switch current-source inverter (H7-CSI) to improve the efficiency of the CSI-based motor drive system. The switching transient and power loss model of the H7-CSI topology during voltage-boost operation are analyzed in detail. The effects of the boost function on the switching and conduction loss of the H7-CSI topology are investigated. A genetic algorithm has been introduced that makes it possible to optimize the H7-CSI’s modulation index to minimize its power loss. Experimental results for the H7-CSI unit show that this optimization can reduce the power loss by 10.6%.

42 ENGINEERING↗
DOE OSTI2020

SR19036 Improve TRP Cutter Head Performance

The Target Rod Preparation (TRP) cutter head motor suffers from overheating problems during Tritium Producing Burnable Absorber Rods (TPBAR) breaching operations. The TRP cell cutter head drive motor must remain below the administrative limit of 100°C during breaching operations. If temperatures in excess of 100°C are reached, work must be stopped, and the motor allowed to cool. The work stoppage due to overheating of the drive motor directly and drastically lowers the efficiency of the TPBAR breaching process, reducing the production of Tritium gas. Due to the increased need for Tritium gas, the overheating problem must be addressed to improve the overall efficiency of the TPBAR breaching process.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2024

Next Generation High Efficiency Boosted Engine Concept

This report summarizes a collaborative research project between Ford Motor Company, FEV North America, and Oak Ridge National Laboratory to develop a next-generation, high-efficiency, boosted spark-ignited engine. The goal was to achieve a 23% improvement in fuel economy and a 15% reduction in engine weight compared to a 2016 Ford F150. The team utilized advanced technologies including a high compression ratio, cooled exhaust gas recirculation (EGR), early intake valve closing, and a novel active pre-chamber ignition system. The final engine prototype met the fuel economy goal and demonstrated a 4.3% weight reduction, with further opportunities identified to reach the full 15% target.

Fuel economy↗
DOE OSTI2023

Performance Characterization and Energy Savings Assessment of a Radial Flux Surface Permanent Magnet Motor Technology

This project is part of the National Renewable Energy Laboratory's (NREL's) "Commercialization Assistance Program" to provide technical expertise to help emerging companies overcome technical barriers to commercialization. In this study, NREL has evaluated the efficiency and energy saving potential of a novel motor technology designed by ZEUS Motor Inc. located in Wheat Ridge, Colorado. The motor expands on permanent magnet AC motor (PMAC) design to create a new "radial flux, surface PMAC", or RF-sPMAC motor that is expected to outperform other novel motor technologies on the market. Here, the motor showed considerable energy benefits over typical induction motors. The motor benefits from a tightly-packed magnetic steel and copper stator that allows the motor size to be reduced to a thin disc with an internal cavity 1/30th the size of a traditional induction motor. The housing is also aluminum which is magnetically benign. This eliminates the need for external cooling (up to 25 HP), in addition to reducing power consumption.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2021

Development of Gyrosole™ and Solar Thermal HVAC Technology for 20-60kW Applications, Final Report, CRADA No. TC02164.0

This was a collaborative effort between Lawrence Livermore National Security, LLC as manager and operator of Lawrence Livermore National Laboratory (LLNL) and Sol Xorce LLC to develop LLNL’s Gyrosole™ solar thermal energy system. The original scope of the CRADA project was to develop LLNL’s Gyrosole™thermal-powered motor technology for solar thermal energy system use, and was originally entitled, "Development of Gyrosole™ Solar Thermal Technology for 20-60 kW Applications". The scope and title of the project were later modified under Amendment One to the CRADA. The technical objective of this CRADA project was to develop Gyrosole™ motor technology so that it is marketplace-ready, and to produce a motor prototype that: Produces 50kW power at >22% efficiency; Operates oil-free; Has sufficient reliability and lifetime to be suitable for both commercial and residential applications; Costs less than $100 per kW installed to produce at scale; and, Can be combined cost-effectively to produce 200kW. The motor prototype would be integrated into model systems that provide electricity generation in combination with air/water heating, heat-pump driven cooling, desiccant dehumidification, and light industrial heat supply.

14 SOLAR ENERGY↗
DOE OSTI2026

On High-Temperature Dynamometer Test Stand Development

RePED is a novel prototype alternator that has been designed and built to operate at 35 kW under 250 degrees C ambient temperature conditions. The operating efficiency will be measured using a 225-kW motor to drive the machine in a back-to-back configuration. The goal is to determine if the RePED alternator can deliver 35 kW at a rotational speed of 1,000 rpm while operating in 250 degrees C ambient temperature and have a minimum efficiency of 60%. Dynamometer testing of a high-temperature alternator for geothermal drilling presents several unique challenges, especially around maintaining and managing the various sources and types of energy passing through the system without impacting data quality. The objectives of this report are to (1) describe the test stand in detail, the relative orientation of each major component, and the data acquisition system and (2) discuss the behavior of the test stand components such that this report can serve as a reference document for future projects.

15 GEOTHERMAL ENERGY↗
DOE OSTI2021

Experimental Validation of Subsystem Models for a Novel Variable Displacement Hydraulic Motor

A novel, variable displacement, low-speed high-torque hydraulic motor is being developed that is expected to be highly efficient across a broad operating range. To ensure the final hardware achieves the expected performance, the models used in the development of the motor must be experimentally validated and revised, as necessary. The specific focus in this work is on mechanical energy loss models that were used to guide the design of a single-cylinder motor prototype and on experimental tests used for model validation. Ideally each model, whether friction loss in a piston/cylinder interface or energy loss due to leakage in a valve , would be individually validated by an independent test. This granular approach would remove any question of where the error lies and result in highly accurate models. However, many motor components have multiple forms of energy loss, creating difficulty in validating individual losses. Additionally, it is not physically realizable to divide many components into an individual model equivalent test. Testing the motor as a full assembly is possible, but pinpointing the source of discrepancies between the model and the hardware becomes difficult with dozens of models potentially being partially responsible. A compromise was found by separating the motor into functional component groups that are characterized by the type of loss and ability to test each subcomponent independently. By checking for correlation between test observations and model predictions, revisions could be implemented into the models. This allows future solutions to be more accurately predicted in the design phase to drive the design of better machines.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2020

Saving Energy: A QuickStart Guide for Small/Medium Manufacturers

The Quick Start Guide aims to serve as an introduction to energy efficiency for small to medium manufacturers, explaining why energy management is important and achievable for all organizations, not just well-resourced, energy-intensive large organizations. It also makes connections to the tools and resources available from DOE to help small to medium manufacturers drive energy savings and sustain the progress. Finally, it provides a list of common energy efficiency opportunities for energy consuming systems such as steam, process heating, and motor-driven systems. Explore the guide to see how smaller manufacturing companies can get started with energy efficiency.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2025

Power Electronics and Electric Machines for Advanced Aircraft

Power electronics and electric machines are critical components of efficient, high-performance aircraft - from fixed-wing turbine to electric vertical takeoff and landing aircraft and beyond. Improvements to these components create enormous energy efficiencies, enable cost savings, and ensure fail-safe operations. National Renewable Energy Laboratory researchers are developing innovative power electronics, electric motors, integrated electric traction drives, and thermal management systems to build highly efficient, lightweight, ultrareliable powertrains for aircraft.

42 ENGINEERING↗
DOE OSTI2022

Joint routing of conventional and range-extended electric vehicles in a large metropolitan network

Range-extended electric vehicles combine the higher efficiency and environmental benefits of battery-powered electric motors with the longer mileage and autonomy of conventional internal combustion engines. This combination is particularly advantageous for time-constrained delivery routing in dense urban areas, where battery recharging along routes can be too time-consuming to economically justify the use of all-electric vehicles. However, switching from electric to conventional fossil fuel modes also results in higher costs and emissions and lower efficiency. This paper analyzes this heterogeneous vehicle routing problem and describes two solution methods: an exact branch-price-and-cut algorithm and an iterated tabu search metaheuristic. From a methodological perspective, we find that the exact algorithm consistently obtains tight lower bounds that also serve to certify the metaheuristic solutions as near-optimal. From a policy standpoint, we examine a large-scale real-world case study concerning parcel deliveries in the Chicago metropolitan area and quantify various operational metrics including energy costs and vehicle miles traveled. We find that by deploying roughly 20% of range -extended vehicles with a modest all-electric range of 33 miles, parcel distributors can save energy costs by up to 17% while incurring less than 0.5% increase in vehicle miles traveled. Increasing the range to 60 miles further reduces costs by only 4%, which can alternatively be achieved by decreasing the average service time by 1 minute or increasing driver working time by 1 hour. In conclusion, our study reveals several key areas of improvement on which vehicle manufacturers, distributors, and policy makers can focus their attention.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2024

A Hybrid Heavy Duty Diesel Power System for Off-Road Applications—Concept Validation

A multiyear power system R&D program was completed with the objective of developing an off-road hybrid heavy duty diesel engine with front end accessory drive-integrated energy storage. This system was validated to deliver 10.5–25.6% reduction in fuel consumption over current Tier 4 Final-based 18L diesel engines, over various off-road machine application cycles. The power system consisted of a downsized heavy-duty diesel 13L engine containing advanced combustion technologies, capable of elevated peak cylinder pressures and thermal efficiencies, thermal barrier coatings, exhaust waste heat recovery via SuperTurbo™ turbocompounding, and hybrid energy assisting and recovery through both mechanical and electrical systems. Following the concept definition, design, and analysis phases of the program, the final phase focused on building and validating the performance and efficiency in laboratory tests. While aspects of the system such as start/stop and reduced off-road cooling package energy losses were only analytically evaluated, the main 13L concept engine with full hybrid system was successfully built and tested in steady-state and in transient certification and real-world application cycles. Extensive simulations in Caterpillar's DYNASTY™ software environment utilized the validation test data to assess performance more fully and confidently over varied cycles and strategies. An average fuel consumption reduction of 17.9% was realized, and the majority (~13%) of the benefit stemmed from the core concept 13L engine. In conclusion, a total cost of ownership analysis provides context to commercial viability and where adoption focus should be placed.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2026

GaN Core-shell Nanofin Vertical Transistor (CoNVerT): A New Direction for Power Electronics (Final Scientific/Technical Report)

A novel power transistor architecture, the GaN c ore-shell n anofin ver tical transistor (CoNVerT) to address fundamental challenges in realizing the ultimate limit of GaN power transistor performance was explored experimentally. This technology promises ultra-high-efficiency high voltage/high power applications (e.g. DC/DC converters, motor control, fast charging, actuation), as well as to operate in harsh environments. The device exploits a vertical superjunction structure based on an experimentally-validated core-shell nanofin growth process in which lateral p-n heterojunctions are formed in a single growth step, while still maintaining vertical current flow for compact die size and low cost. The concept leverages the best properties of GaN for mid-range voltage applications: high mobility, high breakdown voltage, and native heterojunction enhancement-mode operation. Due to the crystallographic nature of the nanofin growth by molecular beam epitaxy, the sidewall heterojunctions occur on non-polar planes, resulting in ultra-smooth interfaces for high mobility, no sidewall etch damage and related surface/interface states, and elimination of piezoelectric effects that can limit reliability in conventional structures. This also facilitates superjunction formation for maximum device performance, and the selective-area growth of the nanofin results in dislocation-free growth, even on low-cost Si (111) substrate. In this program, core-shell nanofins were grown by molecular beam epitaxy, test structures to evaluate the doping, resistivity, and other electrical properties were fabricated, and the material and test structures were characterized in detail. The work identified clear potential (e.g., the doping was well controlled as required for superjunction concepts), but also additional areas that require additional effort to resolve (some unexpected crystal defects were encountered that require additional engineering to overcome). Simulation studies of the proposed concept validate that the fundamental approach is very promising, but additional effort in experimental realization is needed.

42 ENGINEERING↗
DOE OSTI2022

Multi-Kernel Adaptive Support Vector Machine for Scalable Predictive Maintenance

Application of data-driven solutions across an industry is challenging, since the data are often stored locally, and increasing privacy and security concerns restrict access to the data. In addition, it is highly unlikely that all potential data patterns are captured in a single data source. Because it is highly unlikely that all potential data patterns are captured in a single data source, machine learning (ML) models developed from a single source cannot be robust enough. An alternative is to train the ML model at each source and develop a distributed knowledge discovery and aggregation approach to build global knowledge. In this paper, we develop and demonstrate a distributed ML model, federated transfer learning (FTL), using a multi-kernel-based adaptive support vector machine (MK-A-SVM). For federated learning (FL), the multi-kernel (MK) approach enables feature-specific model aggregation under data heterogeneity; whereas for transfer learning (TL) the adaptive model enables utilization of an aggregated model from a different task. The proposed approach is validated using nuclear power plant (NPP) vertical motor-driven pump data to predict the health condition of vertical motor-driven pumps as an anomaly detection. The efficiency of the proposed approach is also quantified and compared with neural network.

42 ENGINEERING↗
DOE OSTI2023

Reliable, High Power Density Inverters for Heavy Equipment Applications

With this final report, the combined team of the University of Arkansas (UA), University of Illinois, Urbana-Champaign (UIUC), Wolfspeed, Caterpillar, and Ampaire have successfully met all of their project objectives. Noteworthy for the heavy equipment portion of the project with Caterpillar is that the team made its project milestones two years into the project by designing a power dense motor drive for a permanent magnet synchronous machine. Upon finding out that Caterpillar had pivoted to switched-reluctance machines (SRMs), the team subsequently redesigned and implemented the SRM drive with a coolant temperature of 105°C! The other major task that the UA, UIUC, and Wolfspeed teams took on was the design of a PMSM drive for a hybrid aircraft that was flown on Feb. 20, 2023 by Ampaire after extensive testing and evaluation. While there were also technical objectives in thermal management, integrated gate drivers, reliability studies, and high temperature capacitors with integrated bussing, each of these have been fully reported on in quarterly reports. In brief, advances in thermal management and high temperature capacitors were utilized in order to achieve a 105°C motor drive. The integrated gate driver work resulted in a higher density drive with no loss of efficiency. Most of the last year, during a no-cost extension, was spent waiting for the Ampaire motor drive to be tested (outside of our project). Many months passed with the device just sitting in California while the company dealt with battery-related issues. This delayed the integration and testing activities until Fall 2022. Once those began, then the process took about 4-5 months to complete culminating in the test flight in Feb. 2023. By providing technical advances and integration into final platforms, the barrier to economic impact has been lowered. This project benefits the public by overcoming key technical barriers to electrified and hybrid electric heavy equipment and aircraft. This, in turn, leads to lower greenhouse gas emissions and a cleaner environment. This final report summarizes the integrated gate driver work and the Ampaire hybrid electric aircraft integration and test flight efforts. All other information has been previously reported in quarterly reports. A summary of the motor drives created during this project is provided along with a listing of publications.

42 ENGINEERING↗
DOE OSTI2023

Strengthening Cybersecurity for Industrial Control Systems: Innovations in Protecting PLC-Based Infrastructure

In this paper, we propose two new approaches aimed at enhancing the security of industrial control systems (ICS) that utilize programmable logic controllers (PLCs) for the control of critical processes. The first approach involves the addition of a unique digital watermark to the PWM control that adjusts the motor speed to control the critical process. This enables efficient detection and identification of any unauthorized modifications to the sensor signals responsible for controlling the plant. The second approach focuses on monitoring the input current (i.e power) drawn by the PLC during the execution of critical process control tasks. Malicious intrusions to change the PLC parameters and/or unauthorized firmware updates can be rapidly detected. Both approaches demonstrate a substantial improvement in the security of ICS, effectively safeguarding against potential cyber-attacks. Experimental results from a laboratory scale water tank level controlled via PLC showcases rapid intrusion detection capabilities.

Huang, Peng-Hao↗