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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 1,549 records · Page 86
All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

An Integrated Traction Drive with a High Speed Surface Permanent Magnet External Rotor Motor for Electric Vehicles

This work presents the detailed design of an outer rotor motor and integrated drive for passenger electric vehicles. The motor uses non-heavy rare earth permanent magnets and operates at a top speed of 20,000rpm. In-slot ceramic heat exchangers are utilized for the cooling of the windings. The external rotor configuration of the motor leaves a significant amount of space in the stator bore, which is leveraged for the integration of the power electronics. A high speed external rotor motor creates a number of mechanical, thermal and assembly challenges and this work presents detailed thermal, mechanical and rotordynamics analysis.

ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2023

Development of a DC Distribution Testbed for High-Power EV Charging

This paper explores the design and implementation of a power hardware-in-the-loop (P-HIL) setup for DC distribution infrastructure integrated with high-power charging (HPC) of electric vehicles (EVs), DC loads, and sources. The utilization of DC distribution holds significant potential for enhancing the operation of a HPC station architecture. However, there are challenges establishing a DC charging hub including interoperability, commoditization, distributed energy resource integration, stability, DC protection, and lack of common system level controllers. To address these challenges, a testing setup is required that accommodates commercial off-the-shelf (COTS) products to evaluate different use cases at rated power and voltage levels. The developed P-HIL setup features a dedicated DC charging hub, DC-coupled chargers, DC loads/sources, DC protection, and a communication architecture. The integrated P-HIL system provides a versatile testing environment to address technology and interoperability gaps and implements a smart energy management system (SEMS). This platform enables comprehensive and robust testing of COTS devices, charger prototypes, SEMS controllers and protection schemes, which together will accelerate transition to EVs at scale. The setup is tested for various use-cases at full-scale, integrating 950 V DC bus voltage, 660 kW grid-tied inverter, 150 kW COTS charger, and 100 kW energy storage system within an open-source SEMS platform.

ADVANCED PROPULSION SYSTEMS,POWER TRANSMISSION AND↗
DOE OSTI2023

Cast or Additively Manufactured Coils with End Turn Enhanced Heat Transfer Surfaces for Spray or Jet Cooling

Cast or additively manufactured coils present a new opportunity for creativity in thermal management of electric machines. Improvements to the heat transfer of spray or jet cooling of coil end turns through the incorporation of pins or enhanced heat transfer surfaces in the cast end turn surfaces is explored. The thermal response of cast copper half-turns is measured for a range of spray/jet volumetric flow rates and ohmic loss heat fluxes. A significant reduction, ~30%, in the steady state temperature and increased spray cooling heat transfer coefficients was experimentally measured when the pins or enhanced heat transfer surfaces are incorporated.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2023

Design, Optimization, and Validation of GaN-Based DAB Converter for Active Cell Balancing in BTMS Applications

This paper focuses on the design of a bidirectional dual active bridge (DAB) DC/DC converter that utilizes Gallium Nitride (GaN) switches as active components. In the existing literature, MOSFET-based DAB for active cell balancing is available, but GaN-based DAB converter for active cell balancing is still new. The proposed modular isolated GaN-based DAB converter is designed as an individual module of active cell balancing for behind-the-meter storage (BTMS) applications, targeting high-power charging stations. Modular isolated converters are connected to each cell (low voltage bus), and each cell is connected in series to build up a battery module. According to the reference current command of supervisory control, each DAB converter can transfer power back and forth through the high voltage (HV) bus to balance the State of Charge (SoC) between the cells. Each module DAB converter is designed at a 50 W power rating. Switch power and transformer losses are analyzed for different switching frequencies, showing the optimum switching frequency for minimum losses. Furthermore, the procedure to select the required gate driver and the PCB layout optimization are discussed. Finally, the DAB performance analysis of GaN-based DAB and Si-based DAB is provided for a battery module operating with a LiFeMnPO4 prismatic cell with 3.2V 20Ah rated values.

active cell balancing↗
DOE OSTI2023

Effects of Encapsulant Properties on the Thermo-Mechanical Reliability of Double-Side Cooled Power Modules for Traction Inverters

Double-side cooled power modules are being developed for next-generation traction inverters due to their better heat extraction, lower profile, and lower parasitic inductances. However, due to their rigid structure, they cause reliability concerns arising from high thermo-mechanical stresses at the interconnection joints in the module. In this work, a materials-based approach using rigid encapsulants is presented for reducing thermo-mechanical fatigue. Finite-element thermo- mechanical simulations were performed to examine the effects of the elastic modulus and coefficient of thermal expansion of epoxy- based encapsulants on the bond deformation inside a double-side cooled power module. It was found that a rigid encapsulant with a high modulus of 6.0 GPa or above and a coefficient of thermal expansion around 20 ppm/oC would improve the thermo- mechanical reliability of double-side cooled power modules by decreasing the permanent bond deformation inside the modules by 50-60%.

ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2023

Multiphysics Modeling of Hydrokinetic Turbine Energy Conversion System

Hydrokinetic turbines (HKTs) hold great promise as a renewable energy source, but high maintenance costs and limited energy output hinder their widespread adoption. The lack of comprehensive research on HKT drivetrain designs creates a knowledge gap in enhancing generation efficiency and cost reduction. A model of the HKT system with a focus on electric drivetrains and power converters is required to address this knowledge gap. This paper first introduces a MATLAB-averaged model integrating electrical-mechanical-thermal domains and aging behaviors within multi-time frames. Then a PLECS model, which incorporates maximum power point tracking and dq reference framed control for AC-DC-AC power converters, is enriched by a dynamic thermal model to predict fast transients accurately. These models optimize the design at the component level, resulting in improved integrated system performance. Furthermore, the validation of the models is carried out through hardware experiments for the averaged model and hardware-in-the-loop testing for the dynamic model.

ADVANCED PROPULSION SYSTEMS,HYDRO ENERGY↗
DOE OSTI2023

Controller Hardware-in-the-Loop Modeling and Operation of a High-Power DC Charging Hub

High-power charging (HPC) concept will be a critical enabler for the wide-scale adoption and integration of electric vehicles (EVs). HPC hubs will have a significant impact on achieving this goal, particularly when considering the charging requirements of next-generation medium and heavy-duty vehicles (MD/HD) used in various vocational scenarios. This emphasizes the significance of evaluating and confirming the technical planning and multi-level operation of HPC hubs through modeling, protocol implementation, and simulation before hardware demonstration. The focus of this study is to develop the architecture, modeling, communication, and real-time controller hardware-in-the-loop (C-HIL) simulation of HPC hubs using the DC distribution system approach. Specifically, this work demonstrates the practical implementation of a custom Smart Energy Management System (SEMS) for a real-time C-HIL HPC hub simulation using the Open Charge Point Protocol (OCPP) for communication. OCPP is implemented on the Node-Red framework and the custom controller is executed in Python. We developed a rule-based controller to demonstrate the proposed approach.

ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2024

Greybox Thermal Parameter Identification of Electric Machine Stators

The parameters of electric machine thermal equivalent circuit networks are difficult to predict due to material and manufacturing uncertainties. In this paper, a Greybox system identification approach is used to identify parameters of electric machine stator lumped parameter thermal networks (LPTNs). LPTNs provide a low order, computationally efficient, dynamic model of temperatures at specific locations. Second and third order LPTN model structures are defined as state space equations with stator thermal parameters to be identified. To test the Greybox electric machine stator thermal system identification, five stator motorette prototypes were constructed with controlled variations in slot fill and slot liner thickness. The variation in the motorette thermal parameters and thermal time constants are detected using the Greybox identification. Special attention is given to the impact of sampling rate and Greybox data record length on parameter estimation accuracy.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2025

Hybrid Energy Management with Real-Time Control of a High-Power EV Charging Site

Decarbonization of transportation systems is driving higher capacity energy storage and faster charging power requirements in electric vehicles (EVs). Given the potential advantages - such as increased efficiency, reduced inverter capacity, and less total cable mass - there is a demand in the industry for more DC distribution for high-power charging (HPC) hubs. However, the cost-effective, adaptive, and robust operation of the DC-coupled HPC hub necessitates a robust site energy management system (SEMS). Validating SEMS operation using a digital twin of an HPC hub in a real-time simulator (RTS) platform is crucial before field deployment. In this study, we propose a hybrid energy management site controller designed to achieve high-level, long-term operational objectives while managing low-level power sharing control between hub assets. We develop a centralized model predictive controller (MPC) to optimize hub operating points and use these points to update the droop parameters of the site energy storage system (ESS). This approach ensures the hub follows an optimal operating point while maintaining the flexibility to respond to load surges. We tested and verified our proposed approach both offline and on a Controller Hardware-in-the-loop (C-HIL) simulation platform integrated with a SEMS framework, demonstrating real-time site operation and validating a cost-effective and robust site controller.

ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2025

Wireless Pulse-Width Modulation Control of Power Converters Using Ultra-Wideband Technology for Distributed High-Voltage Systems

In this study, we present a new approach for wireless pulse-width modulation (PWM) control of a power converter, applicable to numerous power converters within a complex electrical distribution system. This method eliminates the need for multiple physical connections of gating/PWM signals among distributed converter modules. By using ultra-wideband-based communication, the PWM control signals can be wirelessly transmitted from a central controller to multiple converters simultaneously and seamlessly. System stability is thoroughly analyzed, and experimental results validate the efficacy of the wireless control scheme for a buck converter operating at a 50-kHz switching frequency. The minimum latency obtained from this setup is 5.38 ..mu..s. This control concept offers easier implementation of distributed control in high-voltage power systems, especially in multilevel architectures, even under harsh conditions with ambient noise.

ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2024

Thermomechanical Degradation of Sintered Copper Under High-Temperature Thermal Shock

The need for reliable bonded interface materials is critical to realize the performance benefits of wide-bandgap devices in power electronics modules, especially in operating temperatures greater than 150 degrees C. In this paper, we investigate the thermomechanical performance of sintered copper (Cu) as a large-area attachment, bonded between Cu baseplates and active-metal-bonded substrates, under accelerated thermal shock (-40 degrees C to 200 degrees C) conditions. In the fabrication phase of the samples, we used different stencil patterns and found that the grid and stripe patterns resulted in a better outgassing of the residual organics during the sintering process, thereby ensuring a substantially improved bond quality compared to a full-area print. The paste consisted of Cu microflakes, and we performed sintering using a Budatec SP300 sintering press at 275 degrees C with 15 MPa of bonding pressure for 5 minutes in a nitrogen atmosphere. Under accelerated experiments, we monitored the degradation of the sintered Cu bond in the samples through C-mode scanning acoustic microscope (C-SAM) images. To quantify the defect percentage in C-SAM images, we investigated image denoising techniques to exclude the pattern prints. Finally, we cross-sectioned a sample and obtained scanning electron microscope images, which revealed adhesive fracture as the dominant failure mechanism.

ADVANCED PROPULSION SYSTEMS,INORGANIC, ORGANIC, PH↗
DOE OSTI2015

USABC Development of 12 Volt Battery for Start-Stop Application: Preprint

Global automakers are accelerating the development of fuel efficient vehicles, as a part of meeting regional regulatory CO2 emissions requirements. The micro hybrid vehicles with auto start-stop functionality are considered economical solutions for the stringent European regulations. Flooded lead acid batteries were initially considered the most economical solution for idle-stop systems. However, the dynamic charge acceptance (DCA) at lower state-of-charge (SOC) was limiting the life of the batteries. While improved lead-acid batteries with AGM and VRLA features have improved battery longevity, they do not last the life of the vehicle. The United States Advanced Battery Consortium (or USABC, a consortium of GM, Ford, and Chrysler) analyzed energy storage needs for a micro hybrid automobile with start-stop capability, and with a single power source. USABC has analyzed the start-stop behaviors of many drivers and has developed the requirements for the start-stop batteries (Table 3). The testing procedures to validate the performance and longevity were standardized and published. The guideline for the cost estimates calculations have also been provided, in order to determine the value of the newly developed modules. The analysis effort resulted in a set of requirements which will help the battery manufacturers to develop a module to meet the automotive Original Equipment Manufacturers (OEM) micro hybrid vehicle requirements. Battery developers were invited to submit development proposals and two proposals were selected for 50% cost share with USABC/DOE.

12 V START-STOP↗
DOE OSTI2014

Techno-Economic Analysis of BEVs with Fast Charging Infrastructure: Preprint

Battery electric vehicles (BEVs) offer the potential to reduce both oil imports and greenhouse gas emissions, but high upfront costs, battery-limited vehicle range, and concern over high battery replacement costs may discourage many potential purchasers. One proposed solution is to employ a subscription model under which a service provider assumes ownership of the battery while providing access to vast fast charging infrastructure. Thus, high upfront and subsequent battery replacement costs are replaced by a predictable monthly fee, and battery-limited range is replaced by a larger infrastructure-limited range. Assessing the costs and benefits of such a proposal are complicated by many factors, including customer drive patterns, the amount of required infrastructure, and battery life. Herein the National Renewable Energy Laboratory applies its Battery Ownership Model to address these challenges and compare the economics and utility of a BEV fast charging service plan to a traditional direct ownership option. In single vehicle households, where such a service is most valuable, we find that operating a BEV under a fast charge service plan can be more cost-effective than direct ownership of a BEV, but it is rarely more cost-effective than direct ownership of a conventional vehicle.

25 ENERGY STORAGE↗
DOE OSTI2021

Incorporating Residential Smart Electric Vehicle Charging in Home Energy Management Systems

Electric vehicles (EVs) are expected to drastically increase residential electricity consumption and could provide a significant source of flexible demand. Aggregating smart EV charge controllers with other smart home devices through a home energy management system can lead to more optimal outcomes that benefit homeowners, utilities, and grid operators. Control strategies should consider occupant convenience by accounting for the need for fully charged EVs near the EV departure time. In this paper, we develop an EV charging framework that accounts for occupant convenience using OCHRE, a residential energy model, and foresee, a home energy management system. We simulate a community with high EV penetration and show that integrated, smart EV charging reduces peak demand and smooths night-time energy consumption. Simulation results show that the proposed control strategy nearly eliminates peak period EV charging and reduces the daily peak demand from EVs by 23%.

ADVANCED PROPULSION SYSTEMS,ENERGY CONSERVATION, C↗
DOE OSTI2021

The Role of Mobility Data Hubs in an Integrated Decarbonized Transportation Future

The landscape for connected mobility ecosystems is evolving rapidly as information and communication technologies lower the cost and complexity of connecting people to places, integrating transportation modes and collecting data regarding such movements. These developments have been key to unlocking new business opportunities, particularly through mobility services. While the mechanisms for data collection, processing, and transfer have made significant advances in the past decade, the broader landscape of mobility data architectures and data users remains largely unresolved. It is unclear as to whether the result will converge towards a framework that resembles a coherent quilt or a disjointed patchwork of competing visions. Initial approaches to mobility data collection and provisioning have been largely siloed - by mode or software - or held for exclusive use, however several key players are quickly realizing the need and opportunities enabled through integrated mobility data eco-systems, or mobility data hubs as referred to in this paper. As the business case for hosting mobility data hubs evolves, there is great uncertainty regarding their impact to either advance or exacerbate sustainable mobility (e.g., seamless connectivity across modes, decreased energy consumption and greenhouse gas emissions, etc.). Groups such as the United Nations and World Bank have identified data platforms as a key enabler of realizing environmental and social benefits. If designed with decarbonization in mind, we hypothesize that enhanced observability provided by these ever-expanding mobility data hubs can facilitate energy and emissions reductions that are otherwise limited by transactional barriers and knowledge asymmetry that is inherent to a more siloed approach. In this sense, integration of mobility data can help to create a competitive playing field where value is not determined by exclusivity of data, but rather the quality and uniqueness of a given service. The goals of this paper are to 1) identify key players and data architectures that are emerging in a service-based mobility market, 2) explore several use cases where mobility data hubs have enabled greater sustainability outcomes, and 3) discuss key issues that will need to be resolved to fully leverage emerging mobility data hubs towards a sustainable transportation future.

ADVANCED PROPULSION SYSTEMS,MATHEMATICS AND COMPUT↗
DOE OSTI2018

Two-Layer Predictive Controller for V2G and G2V Services Using on Wireless Power Transfer Technology

This paper presents a comprehensive solution that allows electric vehicles (EV) to autonomously charge and discharge their batteries wirelessly during long term parking and/or the transient stops. A two-layer power-flow controller for bidirectional wireless power transfer system (BWPTS) in EVs applications is proposed. The proposed controller can manage the bidirectional power-flow between EV and surrounding infrastructures such as power grid, home microgrid, building micro-grid, road or another vehicle. It consists of two levels of control; the first is responsible for communicating with the surrounding infrastructures and gathering information from driver, charging station, power grid and battery management system and then, based on these information, it estimates the EV's psychological price as a function of its battery's state-of-charge (SOC) and compares it with the energy price to decide whether to charge, discharge or abstain, and how much the charging or discharging rate. The second layer receives the reference signal from the first one and generates the control parameters for two synchronized resonant converters (one is on the vehicle side and the other is on the grid side) to provide the requited power-flow. The proposed controller is adaptively estimating the system parameters to consider the misalignment conditions effects on the system performance. The parameter estimation is achieved using only one voltage sensor. The second layer control is designed based on a new analytical modeling for the power flow in the system. For verification purposes, a prototype for BWPTS was built and driven by the proposed controller, which was implemented using a field-programmable gate array (FPGA) integrated circuit. The proposed controller provides very fast and stable response during both the transient and steady state operation in comparison with the conventional PI controller.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2019

Optimum Planning for Inductively Charged On-Demand Automated Electric Shuttles at Greenville, South Carolina

Wireless charging technology presents perfect fits for autonomous electric vehicles for realizing a fully automated system (vehicle and charger). This paper presents a planning optimization analysis for a pilot project of in-route wireless charging infrastructure serving fixed-route on-demand shared automated electric shuttles (SAESs) at Greenville, South Carolina, USA. A single-objective non-linear integer planning optimization problem is formulated. A comprehensive cost function representing the inductively charged SAESs is developed, considering road construction, power electronics and materials, traction battery, and installation costs. The optimization problem is solved to determine the best combination of the system key design parameters (number and allocations of wireless chargers, charging power level, track length and on-board battery capacity) that show the most cost-effective solution and allow the SAESs realizing charge sustaining operation. The planning platform incorporates representative simulated traffic data (drive cycles and routes) for four SAESs at Greenville project using the Simulation of Urban Mobility (SUMO) tool. These data are fed to a vehicle powertrain model and a wireless charger power model to predict the battery power, energy and state-of-charge (SOC) profiles, which are provided to the search algorithm to assess the design objectives under specific constraints. The results indicated that implementing wireless charging at a few designated stops for fixed-route SAESs with proper design allows the vehicles realizing charge sustaining operation, infinite range and zero recharge downtime, with a significant reduction in the on-board battery (36 % ) and road coverage (69%), at minimum cost.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2015

Estimate of Fuel Consumption and GHG Emission Impact on an Automated Mobility District: Preprint

This study estimates the range of fuel and emissions impact of an automated-vehicle (AV) based transit system that services campus-based developments, termed an automated mobility district (AMD). The study develops a framework to quantify the fuel consumption and greenhouse gas (GHG) emission impacts of a transit system comprised of AVs, taking into consideration average vehicle fleet composition, fuel consumption/GHG emission of vehicles within specific speed bins, and the average occupancy of passenger vehicles and transit vehicles. The framework is exercised using a previous mobility analysis of a personal rapid transit (PRT) system, a system which shares many attributes with envisioned AV-based transit systems. Total fuel consumption and GHG emissions with and without an AMD are estimated, providing a range of potential system impacts on sustainability. The results of a previous case study based of a proposed implementation of PRT on the Kansas State University (KSU) campus in Manhattan, Kansas, serves as the basis to estimate personal miles traveled supplanted by an AMD at varying levels of service. The results show that an AMD has the potential to reduce total system fuel consumption and GHG emissions, but the amount is largely dependent on operating and ridership assumptions. The study points to the need to better understand ride-sharing scenarios and calls for future research on sustainability benefits of an AMD system at both vehicle and system levels.

33 ADVANCED PROPULSION SYSTEMS↗