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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 811 records · Page 45
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

Electromagnetic Shielding Design for 200 kW Stationary Wireless Charging of Light-Duty EV

Wireless power transfer (WPT) is a developing technology with the advantage of convenience and flexible charging. SAE recommended practice J2954 defines typical size and geometry with aluminum or ferrite plate shielding to limit leakage electromagnetic (EM) fields for WPT with power levels lower than 22 kVA from the input side. However, as the WPT power goes up to 100- or 200-kW level, EM safety surrounding the WPT becomes a critical concern. To address this oncoming safety challenge, a novel ferrite shielding design is proposed in this paper. Different misalignment scenarios in accordance with definitions in SAE J2954 are also taken into consideration to ensure EM safety under various operation scenarios. Simulation results, which are preliminarily verified by magnetic field measurements at 1.1 m from the center of the vehicle side coil under 100 kW operation, indicate that the magnetic field leakage can be maintained below the limits defined in SAE J2954 for 200 kW operation. A 3.3 kW scale-down test was also carried out and compared to parallel scale-down simulations. 26.8% field emission reduction is observed from the scale-down test, which supports the effectiveness of the proposed shielding design.

Zhang, Bo↗
DOE OSTI2020

Control of Output Power in Primary Side LCC and Secondary Series Tuned Wireless Power Transfer System without Secondary Side Sensors

The output power of a wireless power transfer (WPT) system varies with load and coupling factor of the inductively coupled coils. This paper presents a method to control the output power of primary side LCC and secondary side series tuned WPT system using information of primary side variables. In this approach, a secondary side control system or secondary side sensors are not needed. Detailed mathematical derivations are given to identify and justify the suitable primary side variable that accomplishes the desired purpose without the need of any secondary side communications. Simulation results presented validate the proposed scheme.

Mukherjee, Subho↗
DOE OSTI2023

Cooling Strategies for an Electric Motor with Additively Manufactured Hollow Conductors and Distributed Power Electronics Integrated with Heat Pipes

This paper discusses design tradeoffs and thermal modeling explored in cooling strategies for an aircraft propulsion electric motor with additively manufactured coils and distributed power electronics integrated with heat pipes. Design tradeoffs include heat pipe Qmax performance related to inclination, condenser configuration, coolant type, coolant flow path complexity, and ease of access to modular power electronics. Three cooling strategies were selected and realized into CAD models. These models were further evaluated using 3D thermal FEA and optimization tools to explore cooling geometry details that include fin thickness, spacing and count with the objective to minimize fin mass under a set of constraints. Lastly, motorette test data is presented comparing air versus liquid cooling of heat pipes.

additive manufacturing↗
DOE OSTI2020

Contoured PPM-EMAT Design for Ultrasonic Communication On Metallic Pipe Channels

Ultrasonic guided waves can be used as the carriers of information in ultrasonic communication for pipe or plate channels. Permanent Periodic Magnet (PPM) Electromagnetic Acoustic Transducer (EMAT) can potentially provide unique capabilities for a communication system as a non-contact transmitter and receiver, which can selectively generate different modes of shear-horizontal (SH) waves. The SH wave shows the potentials in achieving high bitrate without error in ultrasonic communication. However, when a steel pipe is used as the communication channel, especially one with a radius comparable to the size of the transducer, no guided wave signal can be excited or detected by existing PPM-EMAT's with flat coupling surface. In this paper, a 3D printed magnet holder is designed which can shape the magnet array. Also, the transmitter/receiver coils are made of flexible printed circuit which can fit over the curvature of the pipe channels. The contoured PPM-EMAT transmitter and receiver can conform to the surface of the steel pipe channel in order to generate and detect torsional waves. Experimental tests of signal transmission with PPM-EMAT on a 160cm-long stainless steel pipe determine the optimal frequency for communication to be 916KHz. Information transmission experimental results confirm the validity of contoured PPM-EMAT for communication with a bitrate of 5kbps.

Huang, Xin↗
DOE OSTI2020

A Tradeoff Analysis of Series / Parallel Three-Phase Converter Topologies for Wireless Extreme Chargers

In this paper, extreme fast charging (XFC) technology is studied considering the charge rates of 300 kW for wireless power transfer (WPT) applications. Tradeoff analysis of series and parallel connection of three-phase WPT system are presented by comparisons of voltage and current stresses on power electronics active / passive components. In addition, star (Y) / delta (Δ) connection configurations for three-phase wireless power transfer coupling coils are analyzed with series and LCC resonant compensation circuits. The system series and parallel connection controllability is also reviewed considering voltage and current balance techniques with output control. In a conclusion of evaluation analysis, it is revealed that each component of 300 kW wireless charging network must be designed for high fast charging system and the overall system operation need to be strategically planned for high power charging and infrastructure deployment.

Asa, Erdem↗
DOE OSTI2021

Modular Design of Receiver Side Power Electronics for 200 kW High Power Dynamic Wireless Charging System

Dynamic wireless power transfer (DWPT) can provide energy to EVs in motion and extend the drive range. By upscaling the charging power to 200 kW (High Power DWPT), the percentage of electrified roadway reduces and the solution becomes cost-effective. However, coil coupling-coefficient variation during vehicle movement fluctuates the transferred power which is unfavorable for vehicle battery. Secondary regulation design can smooth the power but the converter design becomes very challenging due to requirement in high power, high efficiency, fast control, as well as high power density since the unit will be onboard. This paper provides the modular design approach of a 200 kW secondary side unit to achieve high performance and scalability. The DC/DC converter using SiC devices demonstrated 98.3% efficiency.

Xue, Lincoln↗
DOE OSTI2021

A Novel Three Phase Oak Ridge DC / AC Converter for Wireless Grid Tied Applications

In this study, a novel three phase oak ridge dc to ac converter is introduced for wireless mobility energy storage (WMES) applications to support the grid demand during peak times. The proposed topology can be used in a bi-directional operation between ac grid and dc terminals of energy storage by accomplishing unity power factor. Inherent merit of the technology can directly merge dc input to the high frequency and 60 Hz grid frequency by superimposing through the wireless coils. Theoretical and simulation results are validated by the simulation analysis for 20 kW output power. The functionality of the proposed three phase system is established by using 6 inches air gap between the couplers with the input of 675 V DC and output of 277 V AC, RMS . The system overall design analysis is demonstrated for simulation analysis and simulation results are presented achieving 3% current total harmonic distortion (THD) and 0.99 power factor (PF) at full load 20 kW wireless power transfer.

Asa, Erdem↗
DOE OSTI2022

A 100-kW Wireless Power Transfer System Development Using Polyphase Electromagnetic Couplers

Wireless power transfer (WPT) is an essential technology enabling automated charging of electric vehicles with safety, convenience, and flexibility while having high efficiencies. High-power wireless charging systems will be one of the dominating charging technologies for electric vehicles (EVs) in an effort to eliminate range anxiety and reduce charging times similar to that of gas station refueling practice. Polyphase electromagnetic coupler with rotating fields is a new bipolar wireless charging pad technology that can significantly increase the surface power density (kW/m2) of wireless charging coils. This study proposes a 100-kW wireless power transfer system with a compact vehicle-side (receiver) coupler that reaches to about 0.905 MW/m2 surface power density with a transmitter rated for up to 300 kW with 0.68 MW/m2. High-frequency power electronics including the inverter and rectifier designs are included in this digest along with the hardware prototype developments and preliminary experimental results.

Onar, Omer↗
DOE OSTI2024

Concept Study of Robotic Camera-Based Foreign Object Detection for EV Wireless Charging

Wireless charging of an electric vehicle (EV) is an emerging charging technology promising convenient, autonomous, and highly efficient EV charging without requiring heavy gauge cables. However, due to the strong electromagnetic field created by this process that surrounds the wireless charger, the presence of foreign objects can detrimentally interact with it, thus affecting wireless power transfer (WPT) performance or leading to harmful and unwanted safety risks. This paper presents the results for a concept study on a robotic camera-based foreign object detection (FOD) system, as a supplement to the industry-existing overlapped FOD coil array method, for EV wireless charging. A Raspberry PI 4 control board and compatible Raspberry PI Camera Module 2 are used to implement camera-based object detection. The FOD program was developed using a state-of-the-art deep learning object detection model with the OpenCV and Pytorch library and is compatible with camera module hardware. A dry-run test with Raspberry PI and a camera module was conducted and the preliminary FOD function was verified. The feasibility assessment is also validated by comparing the performance of five existing state-of-the-art deep learning object detection models for vehicles, animals, persons, and metals subsets, respectively. Satisfactory performance on the benchmark datasets is observed by the tests, but further improvements are needed in future work when detecting small-sized metallic objects. A programable robotic car is also under development as ongoing work for carrying the Raspberry PI and camera module while moving for the maintenance process.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2026

Supervised Learning-Based Spatial Position Estimation with Vertical Displacement for Hovering UAV Wireless Power Transfer

This study presents a supervised learning-based spatial position estimation approach for wireless power transfer (WPT) systems supporting hovering unmanned aerial vehicle (UAV) charging. Unlike stationary charging scenarios, hovering UAVs introduce continuous lateral misalignment and vertical displacement, leading to variations in magnetic coupling and reduced power transfer efficiency. To address this challenge, the proposed method estimates the relative spatial position of the receiver coil using only electrical measurements obtained at the secondary side. A supervised learning model is trained to map output voltage and current features to spatial coordinates, enabling position awareness without requiring external sensors, vision systems, or communication links. The sensing functionality is inherently integrated into the WPT system, allowing simultaneous power transfer and localization through the same magnetic interface. Experimental validation is conducted on a laboratory-scale prototype under varying lateral offsets and air-gap conditions. In addition, spline-based interpolation is employed to increase spatial data density for training. The results demonstrate that the proposed framework can capture spatial variations associated with both lateral and vertical displacement, providing reliable position estimation under hovering conditions. This work establishes a hardware-efficient, sensorless solution for UAV wireless charging and serves as a baseline for advanced data-driven position estimation methods in dynamic WPT systems.

Asa, Erdem [ORNL] (ORCID:0000000190884812)↗
DOE OSTI2020

Passive Digital Sensing Method and Its Implementation on Passive RFID Temperature Sensors

Benefitting from the advancement of digital electronics in the 20 th century, sensors have also gradually evolved from analog to digital. As semiconductor components are required in digital sensors, a power supply is still needed for the sensor. To eliminate the need for a power supply a concept of passive digital sensing is proposed. Different from the semiconductor-based electrical digital sensing method, the parameter to be measured is first converted to a mechanical signal, then the mechanical signal is encoded to multiple digital bits by a passive digitizer, where each bit is identified as open or short state that is detectable by general IO ports. To demonstrate the proposed sensing concept, a passive RFID temperature sensor is implemented using a bimetallic coil as the temperature sensing unit. The 6-bit binary codes are acquired and transmitted by a passive RFID that is powered by an energy harvester. Furthermore, the test results show that the temperature sensor has a measurement sensitivity of 1.32 °C/bit and a working distance over 10 meters.

47 OTHER INSTRUMENTATION↗
DOE OSTI2025

Design and Analysis of a Mutual Inductance Level Sensor for Liquid Metals

Here, this article describes the design and analysis of an electromagnetic level sensor for use in high-temperature liquid metal systems. The mutual inductance level sensor (MILS) described in this work was fabricated using two single-conductor mineral insulated cables wrapped in a bifilar fashion around a stainless steel tube core and was housed in an isolating thimble that preserved the pressure boundary of the test vessel. Two sensor variations were fabricated that differ only in active length, 1016 and 1778 mm. Experimental data were collected using the 1016-mm sensor (MILS-MKII-040) that demonstrated a sensitivity of 9.2 μ V/mm in a room temperature testing stand that used solid aluminum as a surrogate for liquid metal. Experimental data were collected using the 1778-mm sensor (MILS-MKII-070) that demonstrated a sensitivity of 6.9 μ V/mm in the high-temperature (300 ° C) liquid sodium environment at the mechanisms engineering test loop (METL) of Argonne National Laboratory. The sensor performance was found to be repeatable over the course of several months, with roughly ±1% deviation from nominal output. Finite element models were developed in COMSOL Multiphysics that fully describe each test setup, and the models were validated using experimental data. The validated COMSOL models were used to perform an array of analyses that examined the performance of the sensor in differing environments. Maximizing the coil diameter inside the isolating thimble was found to maximize the signal and sensitivity of the sensor. An optimal operating frequency was found near 1000 Hz using both experimental data and COMSOL. The influence of a metallic thimble surrounding the sensor and a metallic sensor core was quantified and found to be negligible at the optimal operating frequency. The sensitivity of the sensor was quantified when monitoring the level of additional liquid metals. These include lead, lead-bismuth eutectic (LBE), sodium-potassium alloy (NaK), and lithium (in addition to sodium). The sensitivities were quantified using liquid metal properties at 350 ° C and 650 ° C. The geometry of the test stand model, all material properties used in the model, and the results are presented in a manner that allows the reader can replicate the model and perform additional analyses.

COMSOL↗
DOE OSTI2020

SuperCIC: Enhanced Winding Current Density for Hybrid Windings of Tokamaks

The design is presented for a new approach to cable-in-conduit (SuperCIC) for use in the high-field windings of tokamaks. Two layers of high-field superconductor wires are cabled onto a thin-wall perforated center tube. An overwrap is applied and the cable is inserted as a loose fit into a sheath tube. The sheath tube is drawn down onto the cable to compress the wires onto the center tube and immobilize them. The SuperCIC is then co-wound with a high-strength armor extrusion, which is kerf-cut so that the co-winding onto a coil mandrel can be made without deformation within the armor or the CIC. SuperCIC facilitates hybrid windings, in which subwindings of NbTi are used where B < 7 T, Nb 3 Sn where B < 14 T, and Bi-2212where B > 14 T to minimize superconductor cost. Demount-able splices are used to interconnect layers. A conceptual design has been prepared for a tokamak with aspect ratio A ~ 2.0, magnetic field of 17.4Tat the inner windings and 6.7 T at the plasma,and winding current density ~140 A/mm 2 -sufficient for optimizing the fusion power density in a compact spherical tokamak.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2020

Interactions Observed Between Torus and Solenoid Superconducting Magnets at JLab

The Jefferson Lab 12 GeV Upgrade of Experimental End Station Hall B required a new detector system that would be more sensitive to forward going particles and able to handle higher luminosity. This new detector is CLAS12 and includes two superconducting iron-free magnets – a torus and an actively-shielded solenoid. The torus magnet consists of 6-trapezoidal racetrack-type coils while the solenoid is an actively shielded 5 T magnet. The torus and the solenoid are located in close proximity to one another and are surrounded by sensitive particle detectors. In this work, the torus and solenoid, operating at 3770 A and 2416 A respectively, were commissioned successfully and are operating normally. This paper presents observed electromagnetic interactions which include induced static mechanical loads and inductive coupling as well as a summary of some of the cryogenic interactions and how they are mitigated.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2021

Mechanical Comparison of Short Models of Nb$_3$ Sn Low-$\beta$ Quadrupole for the Hi-Lumi LHC

MQXF is the Nb 3 Sn Low-β quadrupole magnet that the HL-LHC project is planning to install in the LHC interaction regions in 2026 to increase the LHC integrated luminosity. The magnet will be fabricated in two different lengths: 4.2 m for MQXFA, built in the US by the Accelerator Upgrade Project (AUP), and 7.15 m for MQXFB, fabricated by CERN. In order to qualify the magnet design and characterize its performance with different conductors, cable geometries and pre-load configurations, five short model magnets, called MQXFS, were fabricated, assembled and tested. We compare the mechanical behavior of short model magnets using experimental data and new numerical models that take into account the measured coil sizes as a function of position.

43 PARTICLE ACCELERATORS↗
DOE OSTI2021

Exploring New Resin Systems for Nb3Sn Accelerator Magnets

Epoxy resins have long been a focus of magnet design. They provide strength and stability to the superconductor, to allow coil fabrication and consistent magnet performance. They are often cited as a main contributor to magnet performance, often as a limiting factor, from epoxy cracking and energy release. New resin systems are being designed to improve magnet quench and training performance through several means. Baseline candidate resin systems are evaluated for neat resin mechanical properties as well as behavior in Nb 3 Sn subscale composites. Furthermore, this data feeds additional resin system tuning to meet the goals stated above.

43 PARTICLE ACCELERATORS↗
DOE OSTI2021

Progress in the Development of the Nb 3 Sn MQXFB Quadrupole for the HiLumi Upgrade of the LHC

The high-luminosity upgrade of the Large Hadron Collider (HL-LHC) requires new high field and large-aperture quadrupole magnets for the low-beta inner triplets (MQXF). With a nominal operating gradient of 132.2 T/m in a 150 mm aperture and a conductor peak field of 11.3 T, the new quadrupole magnets are based on Nb 3 Sn superconducting technology. After a series of short models constructed in close collaboration by LARP (LHC Accelerator Research Program) and CERN, the development program is entering in the series production phase with CERN on one side and the US Accelerator Upgrade Project (US-AUP) on the other side assembling and testing full-length magnets. This paper describes the status of the development activities at CERN, in particular on the cold powering test of the first MQFXB prototype and on the construction of the second full scale prototype. Critical operations such as reaction heat treatment, coil impregnation and magnet assembly are discussed. Finally, the plan towards the series production is described.

43 PARTICLE ACCELERATORS↗
DOE OSTI2022

Assembly and Pre-Loading Specifications for the Series Production of the Nb 3 Sn MQXFA Quadrupole Magnets for the HL-LHC

We report the High Luminosity LHC (HL-LHC) Project is planning to install 16 cold-masses made with Nb 3 Sn quadrupole magnets in the LHC Interaction Regions to significantly increase its luminosity. Half of these cold masses are fabricated at BNL, FNAL, and LBNL under the US Accelerator Research Program (AUP). Each cold mass includes two identical Nb 3 Sn quadrupole magnets, called MQXFA with a magnetic length of 4.2 m. Currently, the AUP project has completed the fabrication and test of the first 5 pre-series magnets, and is working on the following 16 magnets for the series production. The brittleness and strain sensitivity of the Nb 3 Sn superconducting material requires a careful definition of the allowable maximum stress in the windings during magnet assembly and pre-load, and a tight control of their variation within the whole coil length. Therefore, a series of assembly and pre-load specifications have been defined with the goals of minimizing the risk of conductor degradation and providing the mechanical support required to reach the nominal current during powering. In this paper we present the specifications defined for the MQXFA magnets and applied during the different assembly phases and during the pre-load process of the first 5 pre-series magnets.

43 PARTICLE ACCELERATORS↗