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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 19 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

Techno-economic-environmental impacts of industrial energy assessment: Sustainable industrial motor systems of small and medium-sized enterprises

Energy assessments can provide an effective way of identifying and implementing energy efficiency measures to save energy costs and avoid emissions throughout manufacturing facilities. Consequently, it generates significant economic and environmental benefits to localities, states, and the nation. Quantifying these benefits requires a systematic techno-economic-environmental framework for capturing the interactions. This article employs methodologies to improve the energy efficiency of small and medium-size industries through their sustainable industrial motor systems. Motor systems offer large opportunities to enhance energy efficiency through adopting advanced technologies and better-informed operations. Case studies presented illuminate the potential savings and impacts from implementing sustainable motor systems and the importance of energy assessments. Here, the integrated macro-economic analysis quantifies the regional sustainability impacts of implementing the industrial energy efficiency offered by an energy auditing program in Ohio over a ten-year period. Results show that implementing all the center’s motor recommendations have directly saved $\$702$ M in energy costs, avoided 2.7 million metric tons of carbon dioxide emissions, and created 3,445 jobs, resulting in a total annual economic impact of $\$788$ M stemming from direct, indirect, and induced regional economic impacts. It provides policy implications for encouraging sustainable industrial motor systems.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2021

U.S. Industrial and Commercial Motor System Market Assessment Report Volume 1: Characteristics of the Installed Base

Motor systems are an integral part of our industrial and commercial facilities. They provide the motive force behind the fans, pumps, compressors, chillers, and conveyors in these facilities. Given their centrality to any facility’s operations, they are a critical energy end use to understand, particularly when developing technologies and policies to meet sustainability goals, improve productivity, and enhance resilience. In the late 1990s, the U.S. Department of Energy (DOE) conducted two seminal studies to better understand the installed stock and energy savings opportunities of industrial and commercial motor systems. In the industrial sector, The United States Industrial Electric Motor Systems Market Opportunities Assessment used primary data collected through onsite assessments and led to a greater understanding of the installed base of motor systems, their characteristics, and the opportunities for energy savings (U.S. Department of Energy, 2002). Notable findings included the following: Industrial motor systems consumed 679 billion kilowatt-hours (kWh) in 1994, representing 23 percent of U.S. electricity consumption. Cost-effective energy efficiency measures could result in 62-104 billion kWh of energy savings annually. Sixty-two percent of the energy savings potential was from fan, pump, and compressor end use equipment. Nearly half of motor system electricity consumption was attributable to approximately 3,500 facilities, or 1.5 percent of U.S. manufacturing facilities. Opportunities for Energy Savings in the Residential and Commercial Sectors with High Efficiency Electric Motors provided an evaluation of the installed stock of motor driven equipment in U.S. commercial and residential buildings and opportunities for utilization of high efficiency motors and variable speed technologies (Arthur D. Little, 1999). Notable findings included the following: Commercial motor systems consumed 343 billion kWh in 1995, with refrigeration and space conditioning constituting 93 percent of the total. Cost-effective energy efficiency measures could result in 51 billion kWh of energy savings annually. Due in no small part to these seminal studies, motor system technologies and usage characteristics have changed drastically since the late 1990s. Greater awareness of cost-effective strategies for reducing motor system electricity consumption have been developed and deployed. This includes several software tools, literature, and utility and government programs promoting energy efficiency improvements in motor driven systems. Additionally, several rounds of energy efficiency standards have been enacted, resulting in improved installed motor efficiency. The cost of variable speed drives has dropped substantially, and combined with utility rebate programs, has led to their greater adoption. Further, since these results were published, the U.S. manufacturing sector has undergone a massive transformation. Due to global competition, some sectors have relocated operations overseas. Others have brought operations onshore to avail low cost and abundant natural gas. Additionally, automation and robotics have pervaded the entire sector. Consequently, these two reports likely do not represent the current state of motor driven systems in U.S. industrial and commercial facilities. As cited in recent studies, the lack of current information on motor system electricity consumption and use characteristics limits the ability to conduct analysis on energy savings potential, develop technologies to address energy and productivity gaps, and develop programs to promote energy efficiency practices and technologies for motor systems (International Energy Agency, 2007; UNIDO, 2010; McKane and Hasanbeigi, 2011; Waide and Brunner, 2011). Specifically, the lack of information affects a range of stakeholders: Governments must rely on outdated information when setting research agendas, developing policies, and designing energy efficiency programs and offerings. Utilities and energy efficiency programs cannot identify the current market needs or potential impact when designing rebate and energy efficiency programs. Electric grid planners cannot identify motor system usage characteristics when developing plans to support the resilience of the electric grid. Manufacturers of motors, motor driven equipment, and drives are hampered when developing technologies to meet the needs of their market. Motor system end users are limited in their ability to identify energy saving opportunities within their own facilities because they do not have reliable benchmark information. In response to the lack of current information and analysis on industrial and commercial motor systems, the DOE initiated an update to these two studies. Launched in 2016 and led by Lawrence Berkeley National Laboratory (LBNL), the Motor System Market Assessment (MSMA) provides an updated, more comprehensive assessment of the installed stock of motor systems in both the industrial and commercial sectors, a review of the supply chains supporting motor and drives in the U.S., and the performance improvement opportunity available from using best available technologies and maintenance and operation practices. The outcomes of the MSMA are documented in three U.S. Industrial and Commercial Motor System Market Assessment reports, with this report being the first listed: 1. Volume 1: Characteristics of the Installed Base (this report) documents the findings on the installed base of motor systems in the U.S. industrial and commercial sectors. Quantification of energy savings potential is not documented in this report but in Volume 3. 2. Volume 2: Motors and Drives Supply Chain Review reviews the state of supply chains for motors and drives installed in U.S. industrial and commercial facilities, focusing on advanced motor and drive technologies and their constituent materials. 3. Volume 3: Energy Savings Opportunity analyzes the energy performance improvement opportunity for the installed base of U.S. industrial and commercial motor systems. This report has been prepared as a reference for motor system stakeholders. It provides factual information as could be best determined by the assessment results and avoids speculating on any findings.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2022

U.S. Industrial and Commercial Motor System Market Assessment Report. Volume 3: Energy Saving Opportunity

This report seeks to inform the potential for motor systems to support decarbonization by estimating their potential energy, electricity cost, and CO 2 emissions reduction potential from adoption of proven energy efficiency actions and advanced technologies. This is the third and final report in a series of reports disseminating the findings of the U.S. Department of Energy’s (DOE’s) Motor System Market Assessment (MSMA). The MSMA and this report focus on polyphase motor systems greater than or equal to 1 horsepower (hp) in the industrial and commercial sectors. In the U.S. Industrial and Commercial Motor System Market Assessment Report Volume 1: Characteristics of the Installed Base (Volume 1 report), it was determined that these motor systems consume more than 1,000 terawatt-hours (TWh) annually. This equates to 29% of the U.S. electric grid load and results in 765 million metric tons (MMT) of CO 2 emissions and $166 billion in electricity costs. This report finds that substantial reductions to these energy, cost, and emissions impacts are possible, with three areas of significant opportunity being (1) improved load matching, (2) replacing older inefficient motors with more efficient motors, and (3) improving the condition of fluid (e.g., air, water, compressed air) distribution systems. A summary of the savings potential from these three opportunities placed within the context of the overall consumption for motor systems is illustrated in Figure ES 1 (industrial) and Figure ES 2 (commercial).

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
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↗
DOE OSTI2021

Designing the Insulation System for Motors in Electrified Aircraft: Optimization, Partial Discharge Issues and Use of Advanced Materials

Designing the insulation system for motors to be used in electrical aircraft requires efforts for maximizing specific power, but, in parallel, particular attention to achieve high reliability. As a major harm for organic insulation systems is partial discharges, design must be able to infer their likelihood during any operation stage and handle their potential inception. This paper proposes a new approach to carry out optimized or conservative insulation system designs which can provide the specified life at the chosen failure probability as well as look at the option of possibly reducing the risk of partial discharges to zero, at any altitude. Examples of designing turn, phase to ground and phase-to-phase insulation systems are reported, with cases where the design can be optimized and other cases where the optimized design does not pass IEC testing standard. Therefore, the limits for design feasibility as a function of the required level of safety and reliability are discussed, showing that the presence of partial discharges cannot be always avoided even through conservative design criteria. Therefore, the use of advanced, corona-resistant materials must be considered, in order to reach a higher, sometimes redundant, level of reliability.

Ramin, Robin (ORCID:0000000211455006)↗
DOE OSTI2024

On-Board AC Charging Topology Integrated with Electric Vehicle Motor Drive System

On-board AC charging is a convenient and widely adopted method for recharging electric vehicles (EVs) directly from standard alternating current (AC) power sources. This paper presents a novel topology for AC charging of EVs that utilizes EV 3-phase electric machine windings as the input inductors, thus eliminating the requirement for bulky grid interfacing inductors and resulting in a compact and cost-effective integrated motor drive and charger system. The proposed approach leverages the motor windings and parallel operating half-bridge inverter during the charging process by interconnecting the inverter phases with the motor windings in a mechanically interleaved and electrically paralleled manner. The implementation of this unique and innovative idea, achieved through precise control and arrangement of the motor winding as a series inductor, successfully eliminates the possibility of unintended motion of the electric machine during the charging process.

ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2022

Variational and phase response analysis for limit cycles with hard boundaries, with applications to neuromechanical control problems

Motor systems show an overall robustness, but because they are highly nonlinear, understanding how they achieve robustness is difficult. In many rhythmic systems, robustness against perturbations involves response of both the shape and the timing of the trajectory. This makes the study of robustness even more challenging. To understand how a motor system produces robust behaviors in a variable environment, we consider a neuromechanical model of motor patterns in the feeding apparatus of the marine mollusk Aplysia californica (Shaw et al. in J Comput Neurosci 38(1):25–51, 2015; Lyttle et al. in Biol Cybern 111(1):25–47, 2017). We established in (Wang et al. in SIAM J Appl Dyn Syst 20(2):701–744, 2021. https://doi.org/10.1137/20M1344974) the tools for studying combined shape and timing responses of limit cycle systems under sustained perturbations and here apply them to study robustness of the neuromechanical model against increased mechanical load during swallowing. Interestingly, we discover that nonlinear biomechanical properties confer resilience by immediately increasing resistance to applied loads. In contrast, the effect of changed sensory feedback signal is significantly delayed by the firing rates’ hard boundary properties. Our analysis suggests that sensory feedback contributes to robustness in swallowing primarily by shifting the timing of neural activation involved in the power stroke of the motor cycle (retraction). This effect enables the system to generate stronger retractor muscle forces to compensate for the increased load, and hence achieve strong robustness. The approaches that we are applying to understanding a neuromechanical model in Aplysia, and the results that we have obtained, are likely to provide insights into the function of other motor systems that encounter changing mechanical loads and hard boundaries, both due to mechanical and neuronal firing properties.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2024

Comprehensive Comparative Analysis: VSI-based vs. CSI-based Motor Drive Systems with Sinusoidal Output Voltage

The emergence of wide-bandgap (WBG) power devices opens opportunities for current source inverters (CSIs) to provide a promising alternative drive configuration for motor drive applications. The sinusoidal output voltage of CSI offers significant advantages for numerous motor drive applications, including reducing the risks associated with motor terminal overvoltages and bearing discharge currents. This paper compares the performance of CSIs and voltage source inverters (VSIs) with the same performance capabilities. More specifically, sine filters are added to the VSI output terminals to match the CSI performance, and a front-end boost converter is added to the VSI to match the CSI’s voltage-boost capability. The results show that the CSI active components require 48% less volume than the VSI, combined with other performance advantages that make it an appealing candidate for some future motor drive applications.

current source inverter, motor drive system, passi↗
DOE OSTI2024

Modelling a Motor Cooling System with Stator Lamination Fins

This work investigates the potential for cooling a radial permanent magnet motor by means of stator lamination fins. To form the fins, certain stator laminations have a larger external diameter. The optimal number of fins, as well as fm thickness, was determined to reach the maximal heat transfer between the motor stator and the coolant. Finite element and computational fluid dynamics modelling were used to calculate the thermal performance of the motor.

ENGINEERING↗
DOE OSTI2020

High-Temperature Heat Transfer Fluid Circulator for Concentrating Solar Power Systems

A high temperature Heat Transfer Fluid circulator compressor with wide turn down ratio aerodynamic performance was designed, fabricated and tested for application with high pressure super Critical CO2 fluid capable of temperatures and pressures to >750°C and 25 MPa respectively. The modular system decoupled the drive motor system from an independent compressor shaft to provide thermal isolation between the high temperature compressor shaft and the lower temperature capable motor elements. While the thermal management approach appears to be viable there are potential losses in the secondary cooling flows that need to be taken into account and fine-tuned during operation in order to achieve desired overall system efficiencies. The system was also shown to be viable and dynamically stable throughout the entire operating speed range, thereby validating the overall system configuration and structural design approach used. Finally, while it was not possible to achieve specific PTC-10 test points, the compressor performance tests provide sufficient data to indicate that the compressor has the ability to achieve the required performance in practice. The two key factors affecting compressor design and cost are the maximum expected temperature and pressure. The maximum allowable temperatures for current state-of-the-art (SOA) motor driven compressor technology is limited to of approximately 150-200°C, but inlet temperatures >750 °C may be encountered. While the optimal efficiency of compression is in the transcritical region, some concepts require inlet pressures to 225 bar.

14 SOLAR ENERGY↗
DOE OSTI2021

High-Temperature Heat Transfer Fluid Circulator for Concentrating Solar Power Systems How Mohawk and Velo3Dare Printing the Future of Energy

A high temperature Heat Transfer Fluid circulator compressor with wide turn down ratio aerodynamic performance was designed, fabricated and tested for application with high pressure super Critical CO2 fluid capable of temperatures and pressures to >750°C and 25 MPa respectively. The modular system decoupled the drive motor system from an independent compressor shaft to provide thermal isolation between the high temperature compressor shaft and the lower temperature capable motor elements. While the thermal management approach appears to be viable there are potential losses in the secondary cooling flows that need to be taken into account and fine-tuned during operation in order to achieve desired overall system efficiencies. The system was also shown to be viable and dynamically stable throughout the entire operating speed range, thereby validating the overall system configuration and structural design approach used. Finally, while it was not possible to achieve specific PTC-10 test points, the compressor performance tests provide sufficient data to indicate that the compressor has the ability to achieve the required performance in practice. The two key factors affecting compressor design and cost are the maximum expected temperature and pressure. The maximum allowable temperatures for current state-of-the-art (SOA) motor driven compressor technology is limited to of approximately 150-200°C, but inlet temperatures >750 °C may be encountered. While the optimal efficiency of compression is in the transcritical region, some concepts require inlet pressures to 225 bar.

14 SOLAR ENERGY↗
DOE OSTI2024

Aircraft electric motor with integrated cooling system

Aircraft electric motors include a motor unit having a rotor and a stator. The stator includes a plurality of windings and cooling channels arranged to provide cooling thereto. A drive unit is configured to drive operation of the motor unit. A cooling system includes a working fluid arranged within a cooling fluid flow path, wherein the cooling fluid flow path includes a liquid cooling path configured to direct flow of the working fluid through, at least, the cooling channels of the motor unit and a vapor cooling path configured to direct flow of the working fluid through the drive unit and a separator arranged upstream of each of the liquid cooling path and the vapor cooling path and configured to direct a liquid portion of the working fluid into the liquid cooling path and configured to direct a vapor portion of the working fluid into the vapor cooling path.

Alahyari, Abbas A.↗
DOE OSTI2023

High-bandwidth image-based predictive laser stabilization via optimized Fourier filters

Controlling the delivery of kHz-class pulsed lasers is of interest in a variety of industrial and scientific applications, from next-generation laser-plasma acceleration to laser-based x-ray emission and high-precision manufacturing. The transverse position of the laser pulse train on the application target is often subject to fluctuations by external drivers (e.g., room cooling and heating systems, motorized optics stages and mounts, vacuum systems, chillers, and/or ground vibrations). For typical situations where the disturbance spectrum exhibits discrete peaks on top of a broad-bandwidth lower-frequency background, traditional PID (proportional-integral-derivative) controllers may struggle, since as a general rule PID controllers can be used to suppress vibrations up to only about 5%–10% of the sampling frequency. Here, a predictive feed-forward algorithm is presented that significantly enhances the stabilization bandwidth in such laser systems (up to the Nyquist limit at half the sampling frequency) by online identification and filtering of one or a few discrete frequencies using optimized Fourier filters. Furthermore, the system architecture demonstrated here uses off-the-shelf CMOS cameras and piezo-electric actuated mirrors connected to a standard PC to process the alignment images and implement the algorithm. To avoid high-end, high-cost components, a machine-learning-based model of the piezo mirror’s dynamics was integrated into the system, which enables high-precision positioning by compensating for hysteresis and other hardware-induced effects. A successful demonstration of the method was performed on a 1 kHz laser pulse train, where externally-induced vibrations of up to 400 Hz were attenuated by a factor of five, far exceeding what could be done with a standard PID scheme.

Natal, Joseph↗
DOE OSTI2024

System for multiple burns from a rocket motor

A system for multiple burns from a solid fuel rocket motor may extinguish rocket fuel after the rocket has been ignited. The motor may be extinguished via rapid decompression of the combustion chamber. The fuel may then be reignited by a suitable igniter, and the process of extinguishing and reigniting may be repeated, enabling multi-burn maneuvers. A decompressive extinguishing plug nozzle may extinguish solid rocket fuel after the rocket has been ignited and/or keep a rocket in a disarmed (zero thrust) state until the rocket is to be armed. The nozzle may include a plug that mostly impedes the opening of the nozzle and an outer cowl that is movable to rapidly decompress the combustion chamber. This rapid decompression extinguishes the solid rocket fuel. In some aspects, the fuel can be reignited and extinguished multiple times.

Dallmann, Nicholas↗
DOE OSTI2024

Development of High Temperature (>700°C) Molten Salt Pump Technology for Generation 3 Solar Power Tower Systems

Bearings are required for long-shafted pumps historically used in concentrating solar thermal power applications. For molten chloride salts, bearings for such service conditions are not commercially available, nor has a design been demonstrated to work. Therefore, a project was sponsored by the Department of Energy’s Solar Energy Technologies Office for the development and demonstration of a submerged bearing for use in chloride salt pumps. This project’s tasks covered the tribological testing of candidate materials and the design, fabrication, testing, and post-test analysis of full-scale salt-compatible bearings. This work expands upon previous work. The effects of potential particulate in the salt were investigated through tribological bench testing. Through 11 tests, the MgO particulate size and concentration in a molten chloride salt were varied, and the effects on friction, wear rate, and wear characteristics were recorded. Novel journal bearings for chloride salt service were designed and fabricated based on these results. The bearings were of a relevant scale (i.e., for a 1.5 in. pump shaft) to demonstrate the technology with respect to further scale-up. The bearings were made of Haynes 244 and Yttria Partially Stabilized Zirconia. A custom bearing test rig, salt tanks, and associated infrastructure (e.g., heaters, tanks, transfer lines, gas flow control) were designed, procured, and installed. A few issues were encountered in the system fabrication process, resulting in delay of the project schedule. The system was successfully fabricated and assembled. Heating, cover gas, and pump motor systems were integrated into the control logic. This progress of the bearing test system represents a significant step forward towards demonstrating this promising technology. Nevertheless, the project ended before testing of the full-scale bearings could be performed.

14 SOLAR ENERGY↗
DOE OSTI2021

Primary Frequency Control Using Motor Drives for Short Term Grid Disturbances

Industrial motor systems make up a quarter of all electric sales in the United States. Variable speed drives (VSDs) can provide energy efficiency savings to the customer by regulating motor speed based on specific and varying needs. In addition to the benefits provided to the customer, VSDs can provide support to the grid through ancillary services. The Center for Ultra-Wide-Area Resilient Electric Energy Transmission Networks (CURENT) developed a power electronics converter-based grid emulator to allow testing of various power system architectures and demonstration of key technologies in monitoring, control, actuation, and visualization. This paper proposes using an active front-end VSD's connected motor load to provide frequency regulation to a large scale power grid. Each part of the emulator is described including motor and power electronics model and control. The proposed frequency regulation is implemented in VSDs and modeled in both a transmission system in EMTDC/PSCAD and verified on CURENT's hardware testbed.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2020

Pulse-train drive system for electrostatic generators and motors

A novel motor drive system has been described for use in electrostatic generator/motor systems based on the time variation of capacity of a rotating condenser comprised of segmented rotor and stator elements. It takes advantage of the fact that the motor action of such a system depends only on the rms value of the drive pulses, which therefore can be formed simply by periodically interrupting a high-frequency ac wave train. This new circuitry simplifies the drive system and takes advantage of recent developments of devices used in the art of inversion of dc voltages to high-frequency (tens of kiloHz) ac.

42 ENGINEERING↗