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At least 829 records · Page 46
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Validation and Parametric Investigations of an Internal Permanent Magnet Motor Using a Lumped Parameter Thermal Model

One of the key challenges for the electric vehicle industry is to develop high-power-density electric motors. Achieving higher power density requires efficient heat removal from inside the motor. In order to improve thermal management, a multiphysics modeling framework that is able to accurately predict the behavior of the motor, while being computationally efficient, is essential. This paper first presents a detailed validation of a lumped parameter thermal network (LPTN) model of an Internal Permanent Magnet synchronous motor within the commercially available MOTOR-CAD modeling environment. The validation is based on temperature comparison with experimental data and with more detailed finite element analysis (FEA). All critical input parameters of the LPTN are considered in detail for each layer of the stator, especially the contact resistances between the impregnation, liner, laminations, and housing. Finally, a sensitivity analysis for each of the critical input parameters is provided. A maximum difference of 4% - for the highest temperature in the slot-winding and the end-winding - was found between the LPTN and the experimental data. Comparing the results from the LPTN and the FEA model, the maximum difference was 2% for the highest temperature in the slot-winding and end-winding. As for the LPTN sensitivity analysis, the thermal parameter with the highest sensitivity was found to be the liner-to-lamination contact resistance.

42 ENGINEERING↗
DOE OSTI2023

Development of a 300 MWe Utility Scale Oxy-Fuel sCO2 Turbine

A 300 MWe direct-fired supercritical carbon dioxide (sCO2) oxy-fuel turbine is being developed that will burn natural gas-fired, coal syngas and even hydrogen mixtures capable of 1,150ºC turbine inlet temperature at 300 bar. This design will significantly improve the state-of-the-art for thermal efficiency and results in a high-pressure stream of CO2 with 98%+ carbon capture, making the power plant near emission-free and more efficient than Natural Gas Combined Cycle (NGCC) plants with carbon capture. This power plant will be capable of burning coal through gasification and cleanup of the synthesis gas (syngas). sCO2 power cycles are a transformational technology for the energy industry, providing higher efficiency heat source energy conversion for conventional and alternative energy sources. This novel cycle significantly reduces capital costs because of smaller equipment footprints, design modularity, and allows for rapid cyclic load and source following to balance solar and wind energy power swings. Oxy-fuel sCO2 cycles take these advantages even further, utilizing higher firing temperatures, improved efficiency, and simpler carbon capture strategies. This turbine will require cooled turbine nozzles and blades as well as advanced thermal management systems to accommodate these high temperatures. The cooled blade heat transfer correlations required new test programs at higher Reynolds number than air-breathing gas turbines for impingement, serpentine, and pin-fin regions. Novel blade optimization was performed to maximize aerodynamic efficiency, while minimizing cooling flows. A turbine layout was generated utilizing individual combustor cans with cooled liners feeding into a 6-stage axial flow turbine with cooled stator nozzles and turbine blades. The case design and thermal management preliminary design will be described.

Moore, Jeffrey↗
DOE OSTI2025

Detailed Design and Cost Estimation of a 300 MWe Oxy-Fuel sCO2 Turbine

The detailed design of a 300 MWe, utility scale oxy-fuel turbine has been completed for purposed operation in the sCO2 direct fired Allam-Fetvedt cycle, targeting near-zero emissions and a 50% LHV system efficiency. The turbine and its supporting plant aim to offer a lower levelized cost of energy than a natural gas combined cycle plant employing carbon capture. The oxy-fuel turbine conditions include an inlet temperature of 1150°C and inlet pressure of 305 bar, representing temperatures near that of a gas turbine simultaneously with pressures near an ultra-supercritical steam turbine. The combustor housing and turbine designs were completed according to the ASME BPVC; the turbine case specifically incorporates a multi-body design with inner high-pressure barrel case and low-pressure (30 bar) horizontally split outer case of low-chromium steel material. Lateral rotordynamic evaluation demonstrated acceptable vibration response for a range of imbalance conditions per API standards. The cooling flow required in the six-stage turbine flowpath for 30,000 hr. blade and stator lifetime is predicted through thermal and structural modeling of the first stage. The provided cost estimate of the turbine is formed through a combination of scaled up-costs from procured 10 MWe scale sCO2 turbomachinery hardware, and vendor provided budgetary quotes of larger components including the turbine case requiring casting, welding, and final machining processes. The performance and cost estimation of the oxy-fuel turbine predicted for the completed detailed design provides important information towards future development needs for market penetration of utility scale direct fired sCO2 power cycles.

Marshall, Michael [Southwest Research Institute, S↗
DOE OSTI2020

Performance Evaluation of Three RTU Energy Efficiency Technologies

This project was part of an effort by CLEAResult and ComEd to evaluate the energy saving potential of emerging technologies in the Chicago area. This project focused on evaluating emerging technologies related to rooftop units (RTUs). An RTU with a single-stage compressor and a constant-speed fan with an induction motor was selected as the baseline for technology comparison. Three retrofit strategies were investigated. The first two involved replacing the single-stage compressor of an RTU by either a two-stage or variable-speed compressor and adding a variable frequency drive (VFD) to the constant speed fan. The use of a multi-/variable-stage compressor improves the part-load efficiency of the compressor which will ultimately result in annual energy savings as well as peak demand shaving in some cases where the design capacity of the RTU is larger than the maximum cooling load of the building space that it is serving. The third technology was the use of a high rotor pole switched reluctance motor (SRM) as a replacement for the constant-speed supply fan. The SRM was applied in single-speed, two-stage and variable-speed compressor RTUs. SRM motors run via reluctance torque. Their stator poles are driven by direct current (DC) power and require an inverter as well as active control when using alternating current (AC) power. This inherent property results in high efficiency over a range of operating conditions. It also exhibits higher efficiency compared to variable frequency drives (VFDs) since its switching frequency is much slower (SCE, 2018).The three technologies investigated are summarized below: 1) Replacing the single-speed compressor with a two-stage compressor and adding a VFD to the supply fan. 2)Replacing the single-speed compressor with a variable-speed compressor and adding a VFD to the supply fan. 3) Replacing the constant-speed induction motor of the supply fan with a high rotor pole SRM. DOE’s building simulation platform EnergyPlus and its graphical user interface OpenStudio were used to evaluate the energy-saving potential of upgrading RTUs, by leveraging experimental data from previous research.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2021

LA-R43S6-L1 Postshot Report [Slides]

The Ranchero LA-R43S6-L1 test (formerly referred to as LA-43S-L1. The R specifically designates it is a Ranchero device and the 6 indicates a 6” high explosive charge diameter in anticipation of using larger diameters in the future.) was conducted on 3/8/17 with good success. The experiment was the first test of a “Swooped” Ranchero flux compression generator (FCG), and the load for the test was an aluminum imploding liner. In addition to the swoop, the stator was anodized to provide an insulating layer instead of one or more layers of polyethylene as had been the case for all earlier Ranchero tests. Using the Firing point TA-39-88 capacitor bank, 3.5 MA was delivered to the FCG for the initial magnetic field, and 36.4 MA were delivered to the load having an initial inductance of 2.5 nH. Implosion speeds over 1.1 cm/us were recorded, which exceeds previous LANL solid liner experimental results. The test was diagnosed with 18 PDV channels, 12 of which recorded liner implosion data, and the other 6 of which tracked the FCG armature during flux compression. These armature expansion data recorded during flux compression are the first of their kind, and it was previously unknown, due to unknown effects of the SF 6 in the flux compression volume, whether or not the expansion could be recorded using the PDV technique. Post shot 2D MHD calculations employed a complete external circuit model, and an improved flux diffusion model not available prior to the test. Results from these simulations show very good agreement with the experimental result. Four PDV channels recorded the liner implosion viewed radially outward from the center of the liner. All four of these probes recorded implosion velocities greater that 1 cm/µs, with the cylindrical center displaced by ~2 mm from actual center. Four PDV channels looked at +10° angles from the CMU wall, and four looked at -10° angles. A glide plane interaction is shown moving toward the center of the liner in MHD calculations, and PDV probes provide confirmation. The high explosive (HE) in the LA-R43S6-L1 test was PBX 9501 which had to be glued together in many pieces, and the test was preceded by a camera test to verify that the PBX 9501 could be assembled with acceptable tolerance in glue joints to prevent severing the armature during expansion. The camera test verified an acceptable armature performance, and results are given in complete detail in a post shot report LA-UR-19-20124, and summarized here. This report provides complete detail of the considerable body of data obtained on the test and in the post shot calculations. It is prepared in Power Point for ease of preparation and future review. Shot documentation available in the LANL on-line library are included as references, and non-referenceable documents will be cited and stored in an LA- R43S6-L1 post shot folder stored on an M-6 shared drive. Fabrication drawings are also maintained in an M-6 shared drive and paper files are available from M-6 personnel. This report will be maintained as a PowerPoint document on the shared drive, as well, since included movies will play and graphs from Excel files retain information in the PowerPoint versions. PDF versions are required for clearance and are not to large to send by e-mail.

42 ENGINEERING↗
DOE OSTI2021

Data Challenges for Structural Health Monitoring of Electrical Machines [Slides]

Induction motors (ID) consist of a stator and a rotor. Induction motor slip decreases with decreasing load. Induction motor slip decreases with decreasing load. This talk will focus on removing closely coupled power grid frequencies in an effort to observe the true dynamic response signature of induction motors. Using the time difference between the zeros, we found the frequency as it changes over time for each of the 3 phases. The frequencies of the 3 phases were averaged to reduce the effects of sidebands on the instantaneous frequency. The frequencies of the 3 phases were averaged to reduce the effects of sidebands on the instantaneous frequency. The Kalman filter rapidly synchronizes with the expected output. The sidebands were recreated using spectral subtraction. The frequency domain shows the reduction in magnitude of the power grid frequency the Kalman output was subtracted out. Kalman filtering also reveals important data about the sidebands in healthy motors. The Continuous Wavelet Transform is an alternative to a Bandpass IIR filter used in the analysis of the acceleration data. Analysis of the acceleration data reveals 4 sidebands around the slip frequency.

42 ENGINEERING↗
DOE OSTI2021

Ultra High Speed High Temperature Motor

The goal of this project was to develop a high-speed, high-temperature motor capable of operating at 650 ºC, 60,000 rpm, and 125 kW with 50 kW/L. Key objectives to achieve this goal were to develop a suitable high-temperature wire, designing and fabricating rotor and stator subassemblies, designing an inverter assembly, and thermomechanical validation of the fully assembled motor. Four candidates for high-temperature wire were evaluated using test solenoid structures and finite element analysis modeling. The best candidate was a silicone-enameled copper wire suitable for continuous operation at 593 ºC. The rotor for the motor was designed to use a composite material comprised of 74% iron and 26% mullite by volume. This material would be suitable for 3D printing of the rotor. At the end of the project a vacuum mixer was under construction to produce the bubble-free material needed to achieve the highest strength composite after 3D printing. Rotor testing at 60,000 rpm would have commenced immediately following the additive manufacturing process. The project abruptly ended when key personnel left the project without notice.

42 ENGINEERING↗
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 OSTI2023

Wind Turbine Generator Reliability Analysis to Reduce Operations and Maintenance (O&M) Costs

Wind turbine major systems (blades, pitch, main bearing, gearbox, and generator) are integrated into a composite system. Specifications for these systems and components are developed to achieve symmetry of operation, avoiding negative interaction. For instance, the main bearing, gearbox, and generator (drivetrain) components are interdependent, functioning in unison for efficient energy production. Hence, wind resource and grid interactions affecting the drivetrain impact the performance and reliability of the turbine generator. This paper discusses generator reliability covering the technology evolution over the last 20 years. EPRI's Wind Network for Enhanced Reliability (WinNER) web-based tool and Shermco Industries databases are presented, and conclusions are drawn regarding failures specific to generator design, manufacturing, and operating conditions. Additionally, this paper compares the life expectancy of stator-fed configurations and doubly fed generator systems.

17 WIND ENERGY↗
DOE OSTI2023

Vibration Analysis - Presented to the MMWG Predictive Maintenance User’s Group [Slides]

Vibration Analysis monitors the condition of rotating equipment by focusing on the mechanical vibration the equipment transmits. For very little investment (a few thousands) you can protect millions of dollars of assets. Vibration Analysis is used to monitor fans, pumps, motors, compressors, chillers, and fixed structures. It is used to detect bearing problems, belt problems, bent shaft, misalignment, oil whirl, resonance, cavitation, recirculation, gear problems, mechanical looseness, sheave problems, unbalance, and some electrical problems including broken rotor bars and loose stators.

42 ENGINEERING↗
DOE OSTI2025

Deployment of Digital Twins and Advanced Instrumentation to Identify Looseness Between Rotor Spider Arms and Rim Attachment in Hydro Turbines

The project aimed to develop a Virtual Sensor Digital Twin (VS-DT) to monitor rotor rim float displacement (RRFD) in legacy hydropower turbines. RRFD, if undetected, can cause rotor and stator damage, leading to costly repairs and safety concerns. The purpose of the VS-DT was to predict RRFD signals using existing conventional sensors instead of installing dedicated, costly physical sensors, thereby reducing operational costs and enhancing safety.

13 HYDRO ENERGY↗
DOE OSTI2026

Design, Manufacturing, and Validation of an Optimized Electric Machine Enabled by 3D Printing

The collaboration between the National Laboratory of the Rockies (NLR) and LaunchPoint Electric Propulsion Solutions, Inc. (LaunchPoint) focuses on manufacturing and additive design of electric machines enabled by DOE’s program for three-dimensional printing (MADE3D) as applied to advanced drivetrains and their impact on turbine capital cost and lifetime energy production. Initial efforts will focus on the rotor structure and rotor core of the drivetrain including the active materials (electrical steel and magnets) and could later expand to the stator. The verification activities will be conducted with an instrumented electric machine and a small dynamometer.

17 WIND ENERGY↗
DOE OSTI2025

Development of a bench-scale dissolution concept for the direct extraction of nuclear fuel

Current used nuclear fuel reprocessing efforts utilize a hydrometallurgical approach in which the UNF is dissolved in hot nitric acid followed by solvent extraction into an organic solvent to harvest target nuclides. Previous studies have shown that the dissolution and loading process could be combined into a single organic dissolution/extraction step, producing loaded organic in a single step process. This single step process also includes the advantage of selectively targeting key nuclides in the dissolution while leaving undesirable constituents as part of the undissolved solids. This process is referred to hereafter as direct extraction. Ongoing research from multiple national labs has proven the effectiveness of this technique at research scale. Therefore, potential methods to implement direct extraction at both bench and industrial scale have been developed. The key features of potential dissolver system designs were identified via the team at Pacific Northwest National Laboratory and several designs based on industrial counterparts were assessed for feasibility. This report summarizes the advantages and disadvantages of multiple methods, concluding with a path forward to create multiple unique dissolver designs. The first design will be a single stage recirculating eductor mixer. The second design recommendation is a stator rotor static mixing flow loop design. Each dissolver could be utilized separately, simultaneously, or in series to answer questions surrounding reaction kinetics including residence time, provide a proof of concept for targeted extractions of specific nuclides, and inform needs for industrial scale implementation

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2023

Novel Rotated Virtual Synchronous Generator Control for Power-Sharing in Microgrids with Complex Line Impedance

Virtual synchronous generator (VSG) control is based on the fact that the line impedance in a microgrid is highly inductive. This assumption was made due to the emulation of the stator winding of an electrical machine. This concept can affect the controllability of a microgrid with complex line impedance, generating deviations in the chosen operation point. To overcome this issue, additional techniques must be implemented. This paper describes a novel mathematical approach that uses the power line characteristics in a microgrid to rotate the power control reference frame and proposes a new control method called a “Rotated Virtual Synchronous Generator” (RVSG). This RVSG control approach integrates the effect of complex impedance on the microgrid’s operation and adjusts the reference frame accordingly to improve the system’s stability and performance. The use of this proposed mathematical approach in microgrids allows the further emulation of virtual inertia in microgrids that lack inertia. Finally, a comparison between RVSG control and the classical virtual synchronous generator method is carried out to show that it allows the improvement of the transient power response, power quality, stability, and performance, mainly in microgrids with complex line impedance.

42 ENGINEERING↗
DOE OSTI2024

Design and Characterization of Highly Diffusive Turbine Vanes Suitable for Transonic Rotating Detonation Combustors

In rotating detonation engines the turbine inlet conditions may be transonic with unprecedented unsteady fluctuations. To ensure an acceptable engine performance, the turbine passages must be suited to these conditions. This article focuses on designing and characterizing highly diffusive turbine vanes to operate at any inlet Mach number up to Mach 1. First, the effect of pressure loss on the starting limit is presented. Afterward, a multi-objective optimization with steady RANS simulations, including the endwall and 3D vane design is performed. Compared to previous research, significant reductions in pressure loss and stator-induced rotor forcing are obtained, with an extended operating range and preserving high flow turning. Finally, the influence of the inlet boundary layer thickness on the vane performance is evaluated, inducing remarkable increases in pressure loss and downstream pressure distortion. Employing an optimization with a thicker inlet boundary layer, specific endwall design recommendations are found, providing a notable improvement in both objective functions.

Grasa, Sergio↗
DOE OSTI2025

Experiments in 3D Printing Electric Motors

This paper catalogues a series of experiments we conducted to explore how to 3D print a DC electric motor. The individual parts of the electric motor were 3D printed but assembled by hand. First, we focused on a rotor with soft magnetic properties, for which we adopted ProtoPasta TM , which is a commercial off-the-shelf PLA filament incorporating iron particles. Second, we focused on the stator permanent magnets, which were 3D printed through binder jetting. Third, we focused on the wire coils, for which we adopted a form of laminated object manufacture of copper wire. The chief challenge was in 3D printing the coils, because the winding density is crucial to the performance of the motor. We have demonstrated that DC electric motors can be 3D printed and assembled into a functional system. Although the performance was poor due to the wiring problem, we showed that the other 3D printing processes were consistent with high performance. Nevertheless, we demonstrated the principle of 3D printing electric motors.

3D printed motor↗
NASA NTRS1968

Compensation circuit improves operation of inductive coupling transformers

Circuitry eliminates undesirable modulation effects in rotary transformers which transfer electrical energy to and from angular rate transducers on a gyroscope. It cancels the error by feeding back compensation signals through a tertiary winding on the stator of the output rotary transformer.

Source record↗