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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 163 records · Page 9
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

Shield Design for 50 kW Three-Phase Wireless Charging System

In this paper, magnetic field emissions (MFE) from a 50 kW bipolar coil-based three-phase wireless charging system (WCS) is investigated. Then, a shield design is proposed to suppress the MFE below the safety limit identified by the International Commission of Non-Ionized Radiation Protection (ICNIRP) guidelines. Bipolar coil-based three-phase (3φ) WCSs provide extremely high power-density; therefore, the 3φ WCSs are highly promising for high-power fast-wireless-charging of the electric vehicles. For the high-power EV application, it is a critical challenge to design a shield to suppress the MFE below the safety limit. The traditional aluminum shield is found ineffective for the bipolar 3φ-WCS. The proposed shield is designed with high-permeability magnetic material, i.e. ferrite, nanocrystalline material, etc. The proposed shield is simulated in finite element analysis (FEA) and the FEA results show that the proposed magnetic shield effectively suppresses the magnetic field emission below the ICNIRP limit. The generalized design of the proposed shield can be used for even higher power bipolar coil based WCSs.

Mohammad, Mostak↗
DOE OSTI2021

The Sensitivity Analysis of Coil Misalignment for a 200-kW Dynamic Wireless Power Transfer System with an LCC-S and LCC-P Compensation

The dynamic wireless power transfer systems may reduce the battery size of electric vehicles while maintaining the travel range. Similar to the stationary wireless power transfer systems, the compensation networks are desired in dynamic wireless charging systems at the primary and secondary sides to reduce the reactive power requirement from the source and improve the efficiency. Consequently, it is essential to understand the behavior of the compensation networks, especially the sensitivity to misalignments. This paper presents a sensitivity analysis of LCC-S and LCC-P compensation networks for a 200-kW power transfer with variations in the coupling coefficient due to the electric vehicle travel and misalignments between the pads. The sensitivity study combines the electromagnetic finite element analysis and circuit analysis to determine the impact of misalignments on the wireless power transfer system characteristics. The theoretical analysis is verified by conducting circuit simulations at discrete points to verify the accuracy of the mathematical model.

Kavimandan, Utkarsh↗
DOE OSTI2020

Estimation, Minimization, and Validation of Commutation Loop Inductance for a 135-kW SiC EV Traction Inverter

With growing interests in low inductance SiC based power module packaging, it is vital to focus on system level design aspects to facilitate easy integration of the modules and reap system level benefits. To effectively utilize the low inductance modules, busbar and interconnects should also be designed with low stray inductances. A wholistic investigation of the flux path and flux cancellations in the module-busbar assembly which as differentially coupled series inductors is thus mandatory for a system level design. This work presents a busbar design which can be adopted to effectively integrate the CREE’s low inductance 1.2 kV/1.7 kV SiC power modules. The paper also proposes a novel measurement technique to measure the inductance of the modulebusbar assembly as a whole rather than deducing it from individual components. The inductance of the overall commutation loop of the inverter which encompasses the SiC power module, interconnects and PCB busbar have been estimated using finite element analysis (FEA). Furthermore, insights gained from FEA provided the guidelines to decide on the placement of the decoupling capacitors in the busbar to minimize the overall commutation loop inductance from 12.8 nH to 7.4 nH which resulted in significant reduction in the device voltage overshoot. The simulation results have been validated through measurements using an impedance analyzer with less than 5% difference between extracted loop inductance from FEA and measurements. The bus bar design study and the measurement technique discussed in this paper, can be easily extended to other power module packages. Finally, the 135 kW inverter has been compared to a similar highpower inverter utilizing a laminated busbar to highlight the performance of the former.

42 ENGINEERING↗
DOE OSTI2020

A 150-kW 99% Efficient All-Silicon-Carbide Triple-Active-Bridge Converter for Solar-Plus-Storage Systems

Solar-plus-storage systems could effectively mitigate the uncertainties of the photovoltaic (PV) generation and improve system reliability by adding an integrated battery energy storage system. As a three-port bidirectional isolated dc–dc converter with soft-switching capability, the triple-active-bridge (TAB) converter inherently matches the requirements of the solar-plus-storage system. However, challenges still remain in the TAB converter design to further improve system efficiency. In this article, the detailed design, implementation, and demonstration for a silicon carbide (SiC) 150-kW TAB converter are presented. Starting from a brief review of the TAB converter, the modulation scheme, power characteristics, and soft-switching region are analyzed. Then, the detailed design of the H-bridge converter building block is given. Here, to improve the system efficiency, a comprehensive characterization of the SiC gate driver with various external gate resistances is performed to address tradeoffs between switching loss and voltage overshoot during transients, as well as the thermal performance of the H-bridge building block. In addition, the design and characterization of the 20-kHz three-port transformer are also given. Comprehensive experimental studies are conducted on a full-power prototype to verify the proposed design. With a measured 99.1% peak efficiency, the proposed TAB converter can fulfill the requirements for solar-plus-storage applications.

14 SOLAR ENERGY↗
DOE OSTI2020

Performance and Techno-Economic Evaluation of a Three-Phase, 50-kW SiC-Based PV Inverter

The technical capabilities and benefits of silicon carbide (SiC) compared to silicon (Si) based power electronics converters as well as the premium associated with using SiC instead of Si are well understood. This work proves that the benefits provided by SiC, such as increased efficiency, would result in a lower levelized cost of energy (LCOE) compared to both commercially available, state-of-the-art inverters and the benchmark commercial system cost calculated for the U.S. Department of Energy Solar Energy Technologies Office's SunShot program. The LCOE is calculated to be same as the commercial benchmark despite the installed system cost being 8% more than the benchmark. The LCOE calculation is based on both experiential values obtained from testing the SiC photovoltaic (PV) inverter and on the bottoms-up modeled volume cost for the same 50-kW SiC-based inverter. The PV system used for the LCOE model is also explained, and the system cost breakout is presented in this paper. Furthermore, multiple scenarios with variations in the PV system are presented to show their effect on the system LCOE.

14 SOLAR ENERGY↗
DOE OSTI2022

1 kV, 10-kW SiC-Based Quadruple Active Bridge DCX Stage in a DC to Three-Phase AC Module for Medium-Voltage Grid Integration

Interfacing low voltage dc to medium voltage three-phase ac grid is often based on series-stackable modular converter architectures. To minimize energy storage requirements, it is advantageous to employ a quadruple active bridge (QAB) stage operating as a "dc transformer" in each stackable module. The QAB stage offers three isolated dc link voltages, which then allow for flexible stacking of three single-phase dc-to-ac inverter stages. Each of the module phases processes a pulsating power having a component at twice the line frequency. This presents a challenge in maintaining zero voltage switching (ZVS) on the secondary sides of the QAB during low-power portions of the line cycle. This article is focused on the design of the QAB stage. A detailed analysis of ZVS switching waveforms is presented, including effects of nonlinear device capacitances. It is shown how ZVS can be achieved at all times using a relatively small circulating current provided by the magnetizing inductance of the high-frequency transformer. Analytical expressions are given for the optimal values of the magnetizing inductance and the dead times of the QAB primary and secondary bridges. This approach is verified by experimental results on a 1 kV, 10-kW SiC-based prototype, demonstrating a relatively flat efficiency curve with a peak efficiency of 97.1% at 75% load.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2025

Characterization of a multi-kW, large-aperture gas-cooled Faraday rotator

We characterize a large-aperture gas-cooled Faraday rotator (FR) designed to mitigate stress-induced depolarization in high-energy, high-power laser systems. The rotator, based on ceramic TGG, was tested using a 150 mW probe beam at 1047 nm and a pump beam at 1070 nm. Compensating for the birefringence induced by the surrogate depolarization plate at 3.3 kW of effective pump power, the rotator reduces the spatially in-homogeneous depolarized light containing linear, circular, and elliptical polarization states to nearly linear with approximately 0.8% (or −21 dB) of residual depolarized energy. The FR demonstrated effective depolarization compensation across its 58×58 mm 2 aperture.

47 OTHER INSTRUMENTATION↗
DOE OSTI2025

Beam optics design of a prototype 20 kW conduction-cooled SRF accelerator for medical sterilization

Superconducting technology has significantly advanced the capabilities of particle accelerators, facilitating higher beam-power operations for fundamental research at a comparatively lower cost. However, the conventional implementation of superconducting technology introduces complexities in the form of cryogenic plants, cryogenic distribution systems and substantial construction and operational cost. In response to these challenges, recent research efforts at Fermilab have been dedicated to the development of a cryogen-free, conduction-cooled Nb3Sn-based superconducting technology. This paper outlines the beam optics design of a 20-kW conduction-cooled compact superconducting accelerator for medical sterilization. The paper reviews both the physics and practical constraints associated with high beam-power operation within the context of industrial applications. The focus is on providing insights into the potential of this innovative technology to overcome existing challenges and pave the way for more accessible and efficient industrial particle accelerators.

Saini, A. [Fermilab]↗
DOE OSTI2020

Little Big Horn College Health and Wellness Center 45 kilo-Watt (kW) Solar Array (Final Report)

The report summarizes the activities completed, results, and lessons learned in installing at 45 kW photovoltaic solar array on the roof and as awnings at the 25,000 square foot Health and Wellness Center on the campus of the Little Big Horn College (LBHC) in Crow Agency, Montana. The installation is expected to displace greater than 16% of the current electricity requirements at the Health and Wellness Center and save LBHC more than $6,600 in operating costs annually.

14 SOLAR ENERGY↗
DOE OSTI2020

Front shielding of the 25-kW beam absorber in Linac-to-Booster transfer line

The 25-kW beam absorber in the Linac-to-Booster transfer line is supposed to take in the beam from PIP-II 800-MeV Linac occasionally, on the average for one hour once a week. Such an operational scenario suggests that residual dose of the absorber front part can be relatively low. In order to simplify access to the front part of the absorber and beam window in case of repair or maintenance, using a slide-in shielding plug is considered as a preferred option.

43 PARTICLE ACCELERATORS↗
DOE OSTI2024

Beam Optics Design of A Prototype 20 kW Conduction-Cooled SRF Accelerator for Medical Sterilization

Superconducting technology has significantly advanced the capabilities of particle accelerators, facilitating higher beam-power operations for fundamental research at a comparatively lower cost. However, the conventional implementation of superconducting technology introduces complexities in the form of cryogenic plants, cryogenic distribution systems and substantial construction and operational cost. In response to these challenges, recent research efforts at Fermilab have been dedicated to the development of a cryogen-free, conduction-cooled Nb3Sn-based superconducting technology. This paper outlines the beam optics design of a 20-kW conduction-cooled compact superconducting accelerator for medical sterilization. The paper reviews both the physics and practical constraints associated with high beam-power operation within the context of industrial applications. The focus is on providing insights into the potential of this innovative technology to overcome existing challenges and pave the way for more accessible and efficient industrial particle accelerators.

43 PARTICLE ACCELERATORS↗
DOE OSTI2024

Development of 250 kW Ammonia and Hydrogen Industrial Burner Test Facility at the National Energy Technology Laboratory

In an effort to investigate the viability of ammonia and hydrogen as fuels in the industrial heating sector, the Department of Energy’s National Energy Technology Laboratory is developing a 250 kW burner test facility. The pursuit of a decarbonized industrial heating sector requires innovative approaches to convert existing assets to alternative fuels while maintaining adequate radiative heat transfer and limiting NOx. This new capability will leverage NETL’s experience and prior investments in ammonia and hydrogen combustion, to advance atmospheric pressure industrial combustion systems for industries such as cement kilns and glass factories. The intention in coming years is to collaborate with burner manufacturers and heavy industry partners to study, develop, and validate strategies for converting existing hardware from carbon-based fuels to next-generation clean ammonia and hydrogen technologies.

May, Kristyn Johnson↗
DOE OSTI2025

Design, Optimization, and Control of a 100 kW Electric Traction Motor Meeting or Exceeding DOE 2025 Targets

The overall objective of the electric motor portion of the Electric Drives Technology consortium is to research, develop, and test electric motors for use in electric vehicle applications capable of a peak power greater than 100 kW, power density greater than or equal to 50 kW/l, and a cost less than 3.3 $/kW. To meet the electric traction motor power density and cost targets a number of approaches were pursued simultaneously throughout the course of this project which address all of the major volumetric power density variables. The specific research thrusts at the Illinois Institute of Technology (IIT) are the following: multiphysics design for increased power density through maximum utilization of active materials, synthesis of electric machine windings and PM flux barriers with controlled space harmonics, high slot fill windings for increased current loadings or efficiency, aggressive cooling strategies, and design studies and prototype construction of candidate electric machines.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗