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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 91 records · Page 5
All sourcesNASA NTRSDOE OSTI
NASA NTRSDate not supplied

Thermal Vacuum Chamber Demonstration of a Cryocooled, HTS Rotor for a 1.4 MW Electric Machine for Electrified Aircraft Propulsion

Aircraft with electrified propulsion systems require electric machines that are very lightweight and highly efficient. Advancements to the state of the art are required to meet this demand. This is particularly true for large transport aircraft with more than about 150 passengers, which will require electric machines with power ratings in the 1 to 30+ MW range. At this scale of power, superconducting technology becomes attractive for electrified aircraft propulsion to increase efficiency and reduce mass [1]. A mass reduction relative to non-superconducting machines can result from an increase in the specific power of the machine and indirectly through a significant reduction in the amount of waste heat generated on the aircraft, which reduces the mass of the thermal management system [2]. NASA’s high efficiency megawatt motor (HEMM) is a 1.4 MW partially superconducting machine that is being developed to achieve an efficiency greater than 98% and electromagnetic specific power greater than 16 kW/kg. HEMM contains a copper stator operating at an average temperature around 423 K and a superconducting rotor composed of no-insulation 2nd generation high temperature superconducting (HTS) coils that operates around 60 K. The superconducting coils are conductively cooled by a pulse tube cryocooler embedded inside and rotating with the rotor shaft. This paper presents a full-scale demonstration of the rotor in a thermal vacuum chamber at the designed operating temperature. The test was designed to validate the design of HEMM’s rotor, namely the ability to operate the 2G HTS coils at their rated direct current in a relevant thermal environment while being conductively cooled.

high temperature superconductors↗
NASA NTRSDate not supplied

Thermal, Structural, and Rotordynamics Refinements to the Superconducting Rotor of A 1.4 Mw Partially Superconducting Machine for Electrified Aircraft

NASA is developing the high efficiency megawatt motor (HEMM), a 1.4 MW partially superconducting machine, to ad-dress the need for highly efficient, lightweight, MW-class ma-chines to support aviation sustainability efforts. This paper presents progress on the thermal, structural, and rotordynamics aspects of HEMM’s superconducting rotor. Emissivity measurements of gold coated cobalt iron and titanium parts are presented and then used to correlate a thermal model of the rotor to existing data from a thermo-electrical test of the full-scale rotor. Lessons learned from the correlated model are presented, including a rank ordering of the contributors to the temperature of the superconducting coils. An updated structural design of the HEMM rotor is presented and compared to the prior design. Finite element analysis demonstrates that the updated design improves stress margins while reducing magnetic flux leakage and retaining thermal performance. The key conclusions of the rotordynamics design are presented.

electrified aircraft propulsion↗
NASA NTRS1984

Road load simulator tests of the Gould phase 1 functional model silicon controlled rectifier ac motor controller for electric vehicles

The test results for a functional model ac motor controller for electric vehicles and a three-phase induction motor which were dynamically tested on the Lewis Research Center road load simulator are presented. Results show that the controller has the capability to meet the SAE-J227a D cycle test schedule and to accelerate a 1576-kg (3456-lb) simulated vehicle to a cruise speed of 88.5 km/hr (55 mph). Combined motor controller efficiency is 72 percent and the power inverter efficiency alone is 89 percent for the cruise region of the D cycle. Steady state test results for motoring, regeneration, and thermal data obtained by operating the simulator as a conventional dynamometer are in agreement with the contractor's previously reported data. The regeneration test results indicate that a reduction in energy requirements for urban driving cycles is attainable with regenerative braking. Test results and data in this report serve as a data base for further development of ac motor controllers and propulsion systems for electric vehicles. The controller uses state-of-the-art silicon controlled rectifier (SCR) power semiconductors and microprocessor-based logic and control circuitry. The controller was developed by Gould Laboratories under a Lewis contract for the Department of Energy's Electric and Hybrid Vehicle program.

Gourash, F.↗
DOE OSTI2021

U.S. Industrial and Commercial Motor System Market Assessment Report Volume 2: Advanced Motors and Drives Supply Chain Review

Electric motors in commercial and industrial applications account for almost a third of total electric grid load in the United States. With these applications representing such a significant level of energy use, increasing efficiency in these applications can help substantially increase resilience and lower total energy costs. This report examines stationary high-efficiency electric motor technologies and their supply chains.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
NASA NTRS1998

"Long life" DC brush motor for use on the Mars surveyor program

DC brush motors have several qualities which make them very attractive for space flight applications. Their mechanical commutation is simple and lightweight, requiring no external sensing and control in order to function properly. They are extremely efficient in converting electrical energy into mechanical energy. Efficiencies over 80% are not uncommon, resulting in high power throughput to weight ratios. However, the inherent unreliability and short life of sliding electrical contacts, especially in vacuum, have driven previous programs to utilize complex brushless DC or the less efficient stepper motors. The Mars Surveyor Program (MSP'98) and the Shuttle Radar Topography Mission (SRTM) have developed a reliable "long life" brush type DC motor for operation in low temperature, low pressure CO2 and N2, utilizing silver-graphite brushes. The original intent was to utilize this same motor for SRTM's space operation, but the results thus far have been unsatisfactory in vacuum. This paper describes the design, test, and results of this development.

Braun, David↗
DOE OSTI2023

Electric and Hydraulic Propel Torque Modulation for a Compact Track Loader With the Hybrid Hydraulic Electric Architecture (HHEA)

Abstract The Hybrid Hydraulic Electric Architecture (HHEA) has previously been proposed for off-highway vehicles to reap the efficiency and controllability benefits of electrification without needing very large electric motors. This is achieved with the use of a set of selectable common pressure rails to transmit the majority of power and small electric motors to modulate that power. Previous work has shown significant energy savings for the work circuits of a variety of machines. In this paper, the energy saving potential of HHEA for the propel circuit of a compact track loader is studied. The ports of the track hydraulic motors are selectably connected to the common pressure rails, and instead of using the electric assist motors to buck/boost pressure, as in HHEA for linear actuators, small electric assist motors are used to add/subtract torque directly. The interplay between the torque limits of the electric motors and the ability of the hydraulic motor to vary displacements is studied, along with the effect these factors have on energy saving potential. It is found that the ability to vary the displacement of the hydraulic motor allows for: more efficient electric motor operating conditions, reduced electric torque requirement, and reduced pressure rail switching events. All three of these advantages can be achieved at once using variable displacements; but trade-offs exist between these advantages (i.e. improved efficiency can be achieved at the expense of a larger electric torque requirement). Overall, the HHEA can reduce energy consumption by ∼ 36% compared to the stock machine, depending on the hydraulic motor’s ability to vary displacements, and assuming the electric motor torque is limited to 20% of that required in a direct electrification scheme.

24 POWER TRANSMISSION AND DISTRIBUTION↗
NASA NTRS2022

Specific Power and Efficiency Projections of Electric Machines and Circuit Protection Exploration for Aircraft Applications

The purpose of this paper is to generate specific power and efficiency projections through the year 2050 for electric machines for aircraft applications. A general literature review was performed to identify the types of electric machines that are commonly used and which types have the biggest potential for future aircraft applications due to their high specific power and efficiency. A database with historical data was built to include parameters such as weight [kg], rated power [kW], specific power [kW/kg], RPM, efficiency, year, motor cooling type, application type and motor type to allow for trend identification and accurate projections. Once the data was gathered, multiple curve fits on the historical data were generated and extrapolated to produce the projections for specific power according to conservative, nominal and aggressive projection scenarios. A different process was followed for the efficiency projections due to the scattered nature of the data. A state of the art (SoA) value for efficiency was identified through literature review and was used to create the conservative, nominal and aggressive projections for the time frames of 2030, 2040, and 2050. The efficiency and the specific power projections of EMs for 2050 are 0.989 and 50kW/kg respectively. This paper will also be examining circuit protection as it is an additional component of electric powertrains.

electric machines↗
NASA NTRS2023

Concept Design for a 5 MW Partially Superconducting Generator

This paper presents a concept design for the 5 MW generators on NASA’s SUSAN hybrid electric flight concept. The performance targets for this machine are 25 kW/kg and 99% efficiency. The concept design is a partially superconducting machine that builds on NASA’s past work on its High Efficiency Megawatt Motor (HEMM). A partially superconducting machine design tool is used to create a preliminary concept design capable of achieving the target specifications for the SUSAN generator. Higher fidelity design and analysis is applied to the preliminary design. After high fidelity analysis the machine is predicted to achieve 22.3 kW/kg and 99.1% efficiency. Lessons learned from this concept design will be incorporated in the next iteration of the machine.

Thomas Tallerico↗
NASA NTRS2023

Concept Design of a 5 MW Partially Superconducting Generator

This paper presents a concept design for the 5 MW generators on NASA’s SUSAN electric flight demonstrator concept vehicle. The performance targets for this machine are 25 kW/kg and 99% efficiency. The concept design is a partially superconducting machine that builds on NASA’s past work on its High Efficiency Megawatt Motor(HEMM). A partially superconducting machine design tool is used to create a preliminary concept design capable of achieving the target specifications for the SUSAN generator. Higher fidelity design and analysis is applied to the preliminary design. After high fidelity analysis the machine is predicted to achieve 22.3 kW/kg and 99.1% efficiency. Lessons learned from this concept design will be incorporated in the next iteration of the machine.

Thomas Tallerico↗
DOE OSTI2021

Regal Beloit Final Technical Report

The original project proposal submitted from NovaTorque Inc (NovaTorque) in 2016 was to improve the existing motor with 95% efficiency by reducing the losses by 21% to achieve 96%. A few months after the proposal was submitted, NovaTorque lost funding and went out of business. The assets of NovaTorque were then acquired by Regal Beloit Corporation (“Regal Beloit” or “Regal”). When the NovaTorque proposal was selected, the project was transferred to Regal Beloit. Once we had production samples from the new Regal production line, they were tested at the Regal Beloit test lab in Wausau, WI. The original NovaTorque motor had an efficiency of 95%, but when the technology was transferred to Regal Beloit, there were multiple manufacturing improvements made, even though the basic electromagnetic design did not change. The test results in Wausau showed that the motors made at the Regal Beloit plant had an efficiency of 96%. Since the goal of the project was to reduce the losses by 21%, a new efficiency target of 96.8% became the project objective. In the first budget period, motors were tested to get the baseline performance. We then used FEA modeling with ANSYS Maxwell to model the existing motor to get correlation between the FEA simulations and the actual test results. Once the model was validated, we evaluated some changes that could be made to the stator to reduce the losses and improve efficiency without changing the rotor or stator housing, keeping the modifications easy to implement. The changes were primarily in the area of making the stator axially shorter and adding Soft Magnetic Composite (SMC) tooth tips. In the second budget period, we proceeded to design and build the new stator that was identified above and identified additional improvements in the process that included a stator machining modification and the use of rectangular wire. When we actually built the motor, the choice of rectangular wire turned out to be a problem. The wire was made by squishing round wire to get the rectangular shape, which caused work hardening, making the wire too stiff to make the desired coils. We shifted to annealed square wire which was better, but we still could not maintain the proper coil envelope. The result was that we had reduced cross section area for stator laminations. We also had to have a radial offset resulting in a radial misalignment between the stator and rotor because of the oversized coils. After the motor was completed, it was shipped to Texas A&M University for testing. With the loss of flux from these issues, the measured motor efficiency was only 96.3%. The primary focus of this motor was to make sure our FEA simulation model predicted the measured losses and overall efficiency, this we moved on to the FEA simulation. The FEA simulations of the motor “as built” with misalignments had good correlation with the test results, so the next step was to use that model to optimize the design of the motor for a final build. This time we considered changes to the stator and rotor and also minor changes to the housing diameter. In the third budget period, we did the detailed design and construction of the final prototypes. The final prototypes had a slight increase in the stator diameter to fit in a standard Regal Beloit housing. We shortened the stator and use more layers of wire in the coils. We also increased the cone angle of the rotor and stator from the original 110 degrees to 130 degrees to get some additional efficiency and optimized the stator cross section. The predicted efficiency from the FEA simulations was 96.9%. When completed, the motors were tested. We were a little short of reaching our target efficiency goal of 96.8%. We were only able to get to 96.7% efficiency. While it may be possible with additional iterations in designs and future builds to gain that additional 0.1%, we believe that we are close to the best we can achieve from a practical viewpoint, and additional iterations would be more work than the potential gains would be worth. No other motor in this class can even reach the 96% that we started with.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
NASA NTRS2010

NASA Puffin Electric Tailsitter VTOL Concept

Electric propulsion offers dramatic new vehicle mission capabilities, not possible with turbine or reciprocating engines; including high reliability and efficiency, low engine weight and maintenance, low cooling drag and volume required, very low noise and vibration, and zero emissions. The only penalizing characteristic of electric propulsion is the current energy storage technology level, which is set to triple over the next 5-10 years through huge new investments in this field. Most importantly, electric propulsion offers incredible new degrees of freedom in aircraft system integration to achieve unprecedented levels of aerodynamic, propulsive, control, and structural synergistic coupling. A unique characteristic of electric propulsion is that the technology is nearly scale-free, permitting small motors to be parallelized for fail-safe redundancy, or distributed across the airframe for tightly coupled interdisciplinary functionality without significant impacts in motor-controller efficiency or specific weight. Maximizing the potential benefit of electric propulsion is dependent on applying this technology to synergistic mission concepts. The vehicle missions with the most benefit include those which constrain environmental impact (or limit noise, exhaust, or emission signatures) are short range, or where large differences exist in the propulsion system sizing between takeoff and cruise conditions. Electric propulsion offers the following unique capabilities that other propulsion systems can t provide for short range Vertical Takeoff and Landing (VTOL) aircraft; elimination of engine noise and emissions, drastic reduction in engine cooling and radiated heat, drastic reduction in vehicle vibration levels, drastic improvement in reliability and operating costs, variable speed output at full power, for improved cruise efficiency at low tip-speed, elimination of high/hot sizing penalty, and reduction of engine-out penalties.

Moore, Mark D.↗
NASA NTRSDate not supplied

Feasibility Study of an All-Electric 150 Passenger Aircraft

Among the potential future technologies for low-carbon transport aircraft, all-electric concepts stand out environmentally, yet their feasibility and cost-effectiveness at scale remain uncertain. This paper examines the conceptual design of an all-electric 150-passenger aircraft with a range of 840 NM based on assumed future battery cell-level specific energy of1620Wh/kg. The tube and wing design is propelled by open rotors driven by four electric motors per nacelle and utilizes advanced structural materials for weight reduction. Powertrain technology gaps are identified. The conceptual design shows that all-electric aviation could supplant about 30% of current fossil fuel use by transport aircraft and potentially more with air-traffic-control modifications.

electric aircraft↗
NASA NTRS1981

Straight and chopped dc performance data for a General Electric 5BT 2366C10 motor and an EV-1 controller

Performance data on the General Electric 5BT 2366C10 series wound dc motor and EV-1 Chopper Controller is supplied for the electric vehicle manufacturer. Data is provided for both straight and chopped dc input to the motor, at 2 motor temperature levels. Testing was done at 6 voltage increments to the motor, and 2 voltage increments to the controller. Data results are presented in both tabular and graphical forms. Tabular information includes motor voltage and current input data, motor speed and torque output data, power data and temperature data. Graphical information includes torque-speed, motor power output-speed, torque-current, and efficiency-speed plots under the various operating conditions. The data resulting from this testing shows the speed-torque plots to have the most variance with operating temperature. The maximum motor efficiency is between 86% and 87%, regardless of temperature or mode of operation. When the chopper is utilized, maximum motor efficiency occurs when the chopper duty cycle approaches 100%.

Edie, P. C.↗
NASA NTRS1999

Rotary Motors Actuated by Traveling Ultrasonic Flexural Waves

Efficient miniature actuators that are compact and consume low power are needed to drive space and planetary mechanisms in future NASA missions. Ultrasonic rotary motors have the potential to meet this NASA need and they are developed as actuators for miniature telerobotic applications. These motors have emerged in commercial products but they need to be adapted for operation at the harsh space environments that include cryogenic temperatures and vacuum and also require effective analytical tools for the design of efficient motors. A finite element analytical model was developed to examine the excitation of flexural plate wave traveling in a piezoelectrically actuated rotary motor. The model uses 3D finite element and equivalent circuit models that are applied to predict the excitation frequency and modal response of the stator. This model incorporates the details of the stator including the teeth, piezoelectric ceramic, geometry, bonding layer, etc. The theoretical predictions were corroborated experimentally for the stator. In parallel, efforts have been made to determine the thermal and vacuum performance of these motors. Experiments have shown that the motor can sustain at least 230 temperature cycles from 0 C to -90 C at 7 Torr pressure significant performance change. Also, in an earlier study the motor lasted over 334 hours at -150 C and vacuum. To explore telerobotic applications for USMs a robotic arm was constructed with such motors.

Bar-Cohen, Yoseph↗
DOE OSTI2025

Lanthanide Sulfate Recovery by Synergistic Dimethyl Ether and Na 2 SO 4 Fractional Crystallization

Lanthanides (Lns) are important to many technologies including magnets used in high-efficiency traction motors and generators. While commonly occurring in the environment and industrial waste streams, Ln are generally present at low concentrations. This work demonstrates synergistic Ln recovery from an aqueous magnet leachate to single ppm concentrations using Na 2 SO 4 addition and subsequent dimethyl ether-driven fractional crystallization (DME-FC) treatment. It is found that combining DME-FC with low concentrations of Na 2 SO 4 (≈0.1 M) results in synergistic isolation of Lns while making use of Na 2 SO 4 , an excessive byproduct of hydrometallurgical metal production. Combined Na 2 SO 4 + DME reduces Ln metal ion (Pr, Nd, Sm, Gd, Dy, and Ho) solubilities by 700–27,000x with final concentrations ranging from 2 ppm to 200 ppm. Separately, Na 2 SO 4 0.1 M provides a 10–200x reduction and DME provides a 90–1,400x reduction in Ln solubilities. Final Ln concentrations of the combined process are 99.8% lower than what is achieved with each individual process.

dimethyl ether↗
DOE OSTI2023

Decoupling the effects of texture and composition on magnetic properties of Fe-Si sheet processed by shear deformation

Soft magnetic Fe-Si alloys (electrical steels) possess exceptional functional properties such as high permeability, low coercivity, and low core loss, which generally improve with increasing Si content in the alloy. However, Fe-Si alloys containing > 3.5 wt% Si are also characterized by prohibitively low workability and poor ductility that have prevented their efficient commercial production in sheet form by rolling. This has limited their use for improving efficiency of motors and transformers. In this study, hybrid cutting-extrusion (HCE) is used as a single-step thermomechanical processing method to produce continuous Fe-Si alloy sheet with high Si compositions of 4 wt% to 6.5 wt%. HCE sheet is shown to have a homogeneous annealed grain structure and simple-shear crystallographic textures. By controlling the HCE deformation path, varied crystallographic shear textures are created in the sheet. Quasi-static magnetic properties of the HCE sheet are evaluated to decouple the effects of sheet texture and Si composition on resultant permeability and coercivity properties. The results suggest that HCE, with suitable process scaling, is a viable route for production of high-Si content electrical steel sheet for next-generation motors and transformers.

36 MATERIALS SCIENCE↗
NASA NTRS1979

Study of advanced electric propulsion system concept using a flywheel for electric vehicles

Advanced electric propulsion system concepts with flywheels for electric vehicles are evaluated and it is predicted that advanced systems can provide considerable performance improvement over existing electric propulsion systems with little or no cost penalty. Using components specifically designed for an integrated electric propulsion system avoids the compromises that frequently lead to a loss of efficiency and to inefficient utilization of space and weight. A propulsion system using a flywheel power energy storage device can provide excellent acceleration under adverse conditions of battery degradation due either to very low temperatures or high degrees of discharge. Both electrical and mechanical means of transfer of energy to and from the flywheel appear attractive; however, development work is required to establish the safe limits of speed and energy storage for advanced flywheel designs and to achieve the optimum efficiency of energy transfer. Brushless traction motor designs using either electronic commutation schemes or dc-to-ac inverters appear to provide a practical approach to a mass producible motor, with excellent efficiency and light weight. No comparisons were made with advanced system concepts which do not incorporate a flywheel.

Younger, F. C.↗