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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 109 records · Page 6
All sourcesNASA NTRSDOE OSTI
NASA NTRS1992

The Bearingless Electrical Machine

Electromagnetic bearings allow the suspension of solids. For rotary applications, the most important physical effect is the force of a magnetic circuit to a high permeable armature, called the MAXWELL force. Contrary to the commonly used MAXWELL bearings, the bearingless electrical machine will take advantage of the reaction force of a conductor carrying a current in a magnetic field. This kind of force, called Lorentz force, generates the torque in direct current, asynchronous and synchronous machines. The magnetic field, which already exists in electrical machines and helps to build up the torque, can also be used for the suspension of the rotor. Besides the normal winding of the stator, a special winding was added, which generates forces for levitation. So a radial bearing, which is integrated directly in the active part of the machine, and the motor use the laminated core simultaneously. The winding was constructed for the levitating forces in a special way so that commercially available standard ac inverters for drives can be used. Besides wholly magnetic suspended machines, there is a wide range of applications for normal drives with ball bearings. Resonances of the rotor, especially critical speeds, can be damped actively.

Bichsel, J.↗
NASA NTRS2007

Experimental Performance Evaluation of a High Speed Permanent Magnet Synchronous Motor and Drive for a Flywheel Application at Different Frequencies

This paper presents the results of an experimental performance characterization study of a high speed, permanent magnet motor/generator (M/G) and drive applied to a flywheel module. Unlike the conventional electric machine the flywheel M/G is not a separated unit; its stator and rotor are integrated into a flywheel assembly. The M/G rotor is mounted on a flywheel rotor, which is magnetically levitated and sealed within a vacuum chamber during the operation. Thus, it is not possible to test the M/G using direct load measurements with a dynamometer and torque transducer. Accordingly, a new in-situ testing method had to be developed. The paper describes a new flywheel M/G and drive performance evaluation technique, which allows the estimation of the losses, efficiency and power quality of the flywheel high speed permanent magnet M/G, while working in vacuum, over wide frequency and torque ranges. This method does not require any hardware modification nor any special addition to the test rig. This new measurement technique is useful for high-speed applications, when applying an external load is technically difficult.

Nagorny, Aleksandr S.↗
NASA NTRS2008

Mechanical Description of the Mars Climate Sounder Instrument

This paper introduces the Mars Climate Sounder (MCS) Instrument of the Mars Reconnaissance Orbiter (MRO) spacecraft. The instrument scans the Martian atmosphere almost continuously to systematically acquire weather and climate observations over time. Its primary components are an optical bench that houses dual telescopes with a total of nine channels for visible and infrared sensing, and a two axis gimbal that provides pointing capabilities. Both rotating joints consist of an integrated actuator with a hybrid planetary/harmonic transmission and a twist cap section that enables the electrical wiring to pass through the rotating joint. Micro stepping is used to reduce spacecraft disturbance torques to acceptable levels while driving the stepper motors. To ensure survivability over its four year life span, suitable mechanical components, lubrication, and an active temperature control system were incorporated. Some life test results and lessons learned are provided to serve as design guidelines for actuator parts and flex cables.

rotating joints↗
DOE OSTI2025

Low Cost High-Performance HRE-Free 3-in-1 Electric Drive Unit

The project team completed work to expand upon American Axle & Manufacturing’s (AAM) baseline technology and develop a high-speed, AC induction electric drive unit (EDU) with total direct-oil-cooling and integrated power electronics. The project accelerated advancements in EDU technology by allowing AAM to build upon the progress made in developing the underlying baseline technologies. The following seven improvements to AAM’s baseline technology were implemented in this research and development program: 1) Increased speed (30k RPM) AC induction motor, 2) Silver-sintering of discrete silicon carbide (SiC) metal-oxide-semiconductor field-effect transistors (MOSFET) to heat sinks, 3) Electrically insulated rotor bars, 4) Optimized lamination steel, 5) EDU-integrated 650VDC inverter package, 6) Over-molded stator with molded liners, and 7) 650VDC power-dense stator design. The successful development of the technology resulted in a meaningful cost reduction for EDU systems in the market. Coupled with falling battery system costs, lower EDU costs will likely accelerate the market acceptance and related production scaling of battery electric vehicles. The objective of this project was to research, develop, and test a Heavy Rare Earth (HRE)-free 3-In-1 electric drive unit (EDU) that has class leading power density and cost. The key technologies to be developed were anticipated to meet or exceed the Department of Energy (DOE) targets of a cost ≤ $\$$7/kilowatt (kW), power density ≥ 12 kW/liter, and operating voltage ≥ 600 VDC.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2024

hkl-projects/ioc-hkl

HKL-IOC is an open source EPICS IOC that performs real‑time crystallographic HKL calculations for diffractometers and scattering instruments. It integrates the Python hkl library with EPICS through PyDevice, exposing HKL calculations and diffractometer geometry transformations as standard EPICS process variables. This allows beamline and laboratory control systems to convert between motor positions and reciprocal‑space coordinates, configure diffractometer geometries, and drive scans directly in HKL space. The software is written in Python and designed to run alongside existing EPICS deployments without requiring changes to core EPICS components. It is intended for use at synchrotron and neutron scattering facilities, as well as laboratory X‑ray diffractometers, where reliable and reproducible HKL calculations are needed for experiment control, data collection, and automation. HKL-IOC is distributed under the GNU General Public License v3.0 (GPL‑3.0) and contributions and extensions for additional geometries and beamlines are welcomed.

Baekey, Alex↗
NASA NTRS1974

The AIROscope pointing and stabilization system

The AIROscope pointing and stabilization system is described. The system is configured with three gimbal axes and rate integrating gyro stabilization to provide a stable platform for infrared astronomy. Error signals for on and off-axis pointing are derived from a video sensor which also drives a ground station display. Other features of the system include direct drive torque motors and electronic suspension damping. Results of analysis and simulations used to design the control loops, and a pointing error analysis are presented.

Murphy, J. P.↗
NASA NTRS2005

Multipurpose Hyperspectral Imaging System

A hyperspectral imaging system of high spectral and spatial resolution that incorporates several innovative features has been developed to incorporate a focal plane scanner (U.S. Patent 6,166,373). This feature enables the system to be used for both airborne/spaceborne and laboratory hyperspectral imaging with or without relative movement of the imaging system, and it can be used to scan a target of any size as long as the target can be imaged at the focal plane; for example, automated inspection of food items and identification of single-celled organisms. The spectral resolution of this system is greater than that of prior terrestrial multispectral imaging systems. Moreover, unlike prior high-spectral resolution airborne and spaceborne hyperspectral imaging systems, this system does not rely on relative movement of the target and the imaging system to sweep an imaging line across a scene. This compact system (see figure) consists of a front objective mounted at a translation stage with a motorized actuator, and a line-slit imaging spectrograph mounted within a rotary assembly with a rear adaptor to a charged-coupled-device (CCD) camera. Push-broom scanning is carried out by the motorized actuator which can be controlled either manually by an operator or automatically by a computer to drive the line-slit across an image at a focal plane of the front objective. To reduce the cost, the system has been designed to integrate as many as possible off-the-shelf components including the CCD camera and spectrograph. The system has achieved high spectral and spatial resolutions by using a high-quality CCD camera, spectrograph, and front objective lens. Fixtures for attachment of the system to a microscope (U.S. Patent 6,495,818 B1) make it possible to acquire multispectral images of single cells and other microscopic objects.

Mao, Chengye↗
NASA NTRS2012

Miniaturization of Planar Horn Motors

There is a great need for compact, efficient motors for driving various mechanisms including robots or mobility platforms. A study is currently underway to develop a new type of piezoelectric actuators with significantly more strength, low mass, small footprint, and efficiency. The actuators/motors utilize piezoelectric actuated horns which have a very high power density and high electromechanical conversion efficiency. The horns are fabricated using our recently developed novel pre-stress flexures that make them thermally stable and increases their coupling efficiency. The monolithic design and integrated flexures that pre-stresses the piezoelectric stack eliminates the use of stress bolt. This design allows embedding solid-state motors and actuators in any structure so that the only macroscopically moving parts are the rotor or the linear translator. The developed actuator uses a stack/horn actuation and has a Barth motor configuration, which potentially generates very large torque and speeds that do not require gearing. Finite element modeling and design tools were investigated to determine the requirements and operation parameters and the results were used to design and fabricate a motor. This new design offers a highly promising actuation mechanism that can potentially be miniaturized and integrated into systems and structures. It can be configured in many shapes to operate as multi-degrees of freedom and multi-dimensional motors/actuators including unidirectional, bidirectional, 2D and 3D. In this manuscript, we are reporting the experimental measurements from a bench top design and the results from the efforts to miniaturize the design using 2x2x2 mm piezoelectric stacks integrated into thin plates that are of the order of3 x 3x 0.2 cm.

horn actuation↗
NASA NTRS2000

Performance of The Far Ultraviolet Spectroscopic Explorer Mirror Assemblies

The Far Ultraviolet Spectroscopic Explorer is a NASA astrophysics satellite which produces high-resolution spectra in the far-ultraviolet (90.5-118.7 nm bandpass) using a high effective area and low background detectors. The observatory was launched on its three-year mission from Cape Canaveral Air Station on 24 June 1999. The instrument contains four coaligned, normal incidence, off-axis parabolic mirrors which illuminate separate Rowland circle spectrograph channels equipped with holographically ruled diffraction gratings and delay line microchannel plate detectors. The telescope mirrors have a 352 x 387 mm aperture and 2245 mm focal length and are attached to actuator assemblies, which provide on-orbit, tip, tilt, and focus control. Two mirrors are coated with silicon carbide (SiC) and two are coated with lithium fluoride over aluminum (Al:LiF). We describe mirror assembly in-flight optical and mechanical performance. On-orbit measurements of the far-ultraviolet point spread function associated with each mirror are compared to expectations based on pre-flight laboratory measurements and modeling using the Optical Surface Analysis Code and surface metrology data. On-orbit imaging data indicate that the mirrors meet their instrument-level requirement of 50 percent and 95 percent slit transmission for the high- and mid-resolution spectrograph entrance slits, respectively. The degradation of mirror reflectivity during satellite integration and test is also discussed. The far-ultraviolet reflectivity of the SiC- and AlLiF-coated mirrors decreased about six percent and three percent, respectively, between coating and launch. Each mirror is equipped with three actuators, which consist of a stepper motor driving a ball screw via a two-stage planetary gear train. We also discuss the mechanical performance of the mirror assemblies, including actuator performance and thermal effects.

Ohi, Raymond G.↗
NASA NTRS2013

Mechanism for Deploying a Long, Thin-Film Antenna from a Rover

Observations with radio telescopes address key problems in cosmology, astrobiology, heliophysics, and planetary science including the first light in the Universe (Cosmic Dawn), magnetic fields of extrasolar planets, particle acceleration mechanisms, and the lunar ionosphere. The Moon is a unique science platform because it allows access to radio frequencies that do not penetrate the Earth's ionosphere and because its far side is shielded from intense terrestrial emissions. A radio antenna can be realized by using polyimide film as a substrate, with a conducting substance deposited on it. Such an antenna can be rolled into a small volume for transport, then deployed by unrolling, and a robotic rover offers a natural means of unrolling a polyimide film-based antenna. An antenna deployment mechanism was developed that allows a thin film to be deposited onto a ground surface, in a controlled manner, using a minimally actuated rover. The deployment mechanism consists of two rollers, one driven and one passive. The antenna film is wrapped around the driven roller. The passive roller is mounted on linear bearings that allow it to move radially with respect to the driven roller. Springs preload the passive roller against the driven roller, and prevent the tightly wrapped film from unspooling or "bird's nesting" on the driven spool. The antenna deployment mechanism is integrated on the minimally-actuated Axel rover. Axel is a two-wheeled rover platform with a trailing boom that is capable of traversing undulated terrain and overcoming obstacles of a wheel radius in height. It is operated by four motors: one that drives each wheel; a third that controls the rotation of the boom, which orients the body mounted sensors; and a fourth that controls the rover's spool to drive the antenna roller. This low-mass axle-like rover houses its control and communication avionics inside its cylindrical body. The Axel rover teleoperation software has an auto-spooling mode that allows a user to automatically deploy the thin-film antenna at a rate proportional to the wheel speed as it drives the rover along its trajectory. The software allows Axel to deposit the film onto the ground to prevent or minimize relative motion between the film and the terrain to avoid the risk of scraping and antenna with the terrain.

Lazio, Joseph↗
NASA NTRS2007

Control Code for Bearingless Switched-Reluctance Motor

A computer program has been devised for controlling a machine that is an integral combination of magnetic bearings and a switched-reluctance motor. The motor contains an eight-pole stator and a hybrid rotor, which has both (1) a circular lamination stack for levitation and (2) a six-pole lamination stack for rotation. The program computes drive and levitation currents for the stator windings with real-time feedback control. During normal operation, two of the four pairs of opposing stator poles (each pair at right angles to the other pair) levitate the rotor. The remaining two pairs of stator poles exert torque on the six-pole rotor lamination stack to produce rotation. This version is executable in a control-loop time of 40 s on a Pentium (or equivalent) processor that operates at a clock speed of 400 MHz. The program can be expanded, by addition of logic blocks, to enable control of position along additional axes. The code enables adjustment of operational parameters (e.g., motor speed and stiffness, and damping parameters of magnetic bearings) through computer keyboard key presses.

Morrison, Carlos R.↗
NASA NTRS1982

A lightweight electronically commutated dc motor for electric passenger vehicles

A functional model breadboard converter and a rare-earth-cobalt, permanent magnet motor; as well as an engineering model converter and PM motor suitable for vehicle installations were developed and tested. The converter and motor achieved an 88% peak efficiency, a maximum output of 26 kW at 26,000 rpm, and a continuous rating of 15 kW. The system also generated power to the source during braking, with a demonstrated peak power available at the converter terminals of approximately 26 kW at 88% efficiency. Major conclusions include: (1) the SAE J227a(D) driving cycle efficiency for the converter/motor is 86% to 88% when energy available for recovery at the converter terminals is included; (2) the converter initial cost is approximately five times that of the permanent magnet motor, but can be reduced by means of LSI logic and integrated liquid cooled semiconductor packages; and (3) an electronically commutated motor with a liquid cooled converter will operate reliably without service or maintenance for the life of a passenger vehicle.

Echolds, E. F.↗
DOE OSTI2026

World’s First Vertical GaN based High Power (200 kW) Multi-level Traction Electric Drive Design

Vertical GaN (vGaN) technology leverages a fully conductive 3D semiconductor structure, enabling superior power density compared to GaN-on-Si and other wide bandgap devices. It offers a pathway to surpass cost and efficiency limitations of Si and SiC devices in traction applications. However, scaling for high-voltage, high-power systems remains challenging. This paper presents the design of an 800V, 200kW traction inverter utilizing vertical GaN devices. The inverter achieves ultra-high efficiency (> 99.5%) through advanced power module integration and employs multilevel neutral-point-less X-type (NPL.X) inverter topology to ensure optimal traction drive system performance. These innovations demonstrate the potential of vGaN for next￾generation electric propulsion systems.

Alam, Khorshed [General Motors LLC, Detroit, MI (U↗
DOE OSTI2025

Real-Time Lifetime Prediction of Semiconductor Devices Using Hardware-in-the-Loop

This paper presents a unique approach to enable real-time lifespan prediction of semiconductor power modules using a Hardware-in-the-Loop (HIL) system. By integrating the module's overall loss characteristics-specifically switching and conduction losses-with a thermoelectric model of the thermal management system, this research demonstrates that the model can dynamically estimates the junction temperature profile of the semiconductor devices in response to a changing torque demand profile for the motor drive system. This capability enables continuous monitoring of the module's operational time and cumulative stress induced on the devices to compute accumulated remaining lifetime or time-to-failure (TTF). This study provides an architectural framework for the HIL system with high-fidelity component models of multiple physical domains, allowing simulation of dynamic behaviors of a closely-coupled motor drive system. The advanced real-time computation and measurement functionalities of the HIL system allow for both dynamic lifetime calculations based on simulated data and aggregate lifetime predictions utilizing historical data. Moreover, this paper details an algorithm that not only computes cumulative damage but also synthesizes these data into a comprehensive aggregated lifetime metric. This methodology can enhance the maintenance scheduling strategies and operational reliability of semiconductor devices in critical applications, ultimately extending their service life while optimizing performance.

hardware-in-the-loop (HIL)↗
NASA NTRS2010

In-Situ Focusing Inside a Thermal Vacuum Chamber

Traditionally, infrared (IR) space instruments have been focused by iterating with a number of different thickness shim rings in a thermal vacuum chamber until the focus meets requirements. This has required a number of thermal cycles that are very expensive as they tie up many integration and test (I&T)/ environmental technicians/engi neers work ing three shifts for weeks. Rather than creating a test shim for each iteration, this innovation replaces the test shim and can focus the instrument while in the thermal vacuum chamber. The focus tool consists of three small, piezo-actuated motors that drive two sets of mechanical interface flanges between the instrument optics and the focal- plane assembly, and three optical-displacement metrology sensors that can be read from outside the thermal vacuum chamber. The motors are used to drive the focal planes to different focal distances and acquire images, from which it is possible to determine the best focus. At the best focus position, the three optical displacement metrology sensors are used to determine the shim thickness needed. After the instrument leaves the thermal vacuum chamber, the focus tool is replaced with the precision-ground shim ring. The focus tool consists of two sets of collars, one that mounts to the backside of the interface flange of the instrument optics, and one that mounts to the backside of the interface flange of the focal plane modules. The collars on the instrument optics side have the three small piezo-actuated motors and the three optical displacement metrology systems. Before the instrument is focused, there is no shim ring in place and, therefore, no fasteners holding the focal plane modules to the cameras. Two focus tooling collars are held together by three strong springs. The Orbiting Carbon Observatory (OCO) mission spectrometer was focused this way (see figure). The motor described here had to be moved five times to reach an acceptable focus, all during the same thermal cycle, which was verified using pupil slicing techniques. A focus accuracy of .20.100 microns was achieved.

Liebe, Carl Christian↗
NASA NTRS1989

Electronically Variable Pressure Regulator (EVPR)

A new programmable electronically variable pressure regulator (EVPR) concept accurately controls the local outlet or remote system pressure. It uses an integral pulse width modulated rare earth permanent magnet motor operating in response to redundant pressure transducer feedback signals. The EVPR is a simple single stage device that does not use dynamic seals or pilot valving. Conversion of partial revolution motor torque to poppet lifting force is accomplished by pure flexure action to avoid using bearings. The flexure drive (called the ROTAX) has a variable lead to minimize motor weight and power consumption. Breadboard tests were completed successfully on two critical design elements of the EVPR: the ROTAX and the motor. The ROTAX cable system was tested for 250,000 cycles without failure. The breadboard motor met the basic design requirements including the design torque and power consumption. Prototype parts were fabricated, and testing of the prototype EVPR has started. It is PC computer controlled to facilitate programming, data acquisition and analysis. A lightweight dedicated microprocessor is planned for the flightweight EVPR.

Reinicke, R. H.↗
NASA NTRS2015

RoboGlove-A Grasp Assist Device for Earth and Space

The RoboGlove is an assistive device that can augment human strength, endurance or provide directed motion for use in rehabilitation. RoboGlove is a spinoff of the highly successful Robonaut 2 (R2) system developed as part of a partnership between General Motors and NASA. This extremely lightweight device employs an actuator system based on the R2 finger drive system to transfer part or the entire grasp load from human tendons to artificial ones contained in the glove. Steady state loads ranging from 15 to 20 lbs. and peaks approaching 50 lbs. are achievable. Work is underway to integrate the RoboGlove system with a space suit glove to add strength or reduce fatigue during spacewalks. Tactile sensing, miniaturized electronics, and on-board processing provide sufficient flexibility for applications in many industries. The following describes the design, mechanical/electrical integration, and control features of the glove in an assembly-line configuration and discusses work toward the space suit application.

Diftler, M. A.↗
DOE OSTI2022

Modeling of RMS Current in CSI Filter Capacitor and Minimum Conduction Loss Operation of CSI-Fed PMSM Drives for Traction Applications

This paper presents a new minimum conduction loss (MCL) torque control algorithm for current source inverter- (CSI-) fed permanent-magnet synchronous machine drives that improves the overall machine drive efficiency by minimizing the combined conduction losses in the inverter and machine at each operating point. First, analytical models of conduction losses in CSI-fed motor drives are presented, and a closed-form expression for optimal d-axis stator current to achieve MCL operation is derived. An expression for the rms current in both wye- and delta-connected CSI output capacitors is derived. A detailed simulation model that emulates the operation of a 100 kW SiC CSI-fed integrated machine drive (IMD) has been developed based on experimental results and finite element analysis. This simulation model is used to evaluate the proposed MCL control algorithm applied to a CSI-fed IMD system for a battery-electric vehicle traction drive, and the predicted total drive system loss with MCL control is compared to predicted losses with maximum-torque-per-ampere (MTPA) and minimum dc-link current (MDCC) control. Results show that MCL control can achieve loss reductions compared to the other two control algorithms over a wide range of operating conditions, with significant loss reductions >20% in the medium-speed regime.

42 ENGINEERING↗