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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 OSTI2020

A High-Speed High-Power-Density Non-Heavy Rare-Earth Permanent Magnet Traction Motor

There has been a global push for higher torque density and lower cost traction motors. The use of non-heavy rare-earth (non-HRE) permanent magnet materials in traction motors are being investigated for the sustainability, profitability and affordability of electric vehicles and to broaden their adoption. A 20,000-rpm permanent magnet traction motor using non-HRE magnet materials is proposed. A dual three-phase winding configuration driven by a segmented dual three-phase drive is proposed to reduce the current ripple, and as a result, the DC Link capacitor, as well as to ease the voltage constraint at high speed and eliminate any risk of uncontrolled regeneration. Furthermore, the dual winding configuration enables a fault tolerant design which is useful for reliability. The paper presents comprehensive electromagnetic, thermal and mechanical designs and analyses using an integrated approach. The results have shown that the design is robust against demagnetization and confirmed its thermal and mechanical viability.

47 OTHER INSTRUMENTATION↗
DOE OSTI2014

Synchronous motor with soft start element formed between the motor rotor and motor output shaft to successfully synchronize loads that have high inertia and/or high torque

A line-start synchronous motor has a housing, a rotor shaft, and an output shaft. A soft-start coupling portion is operatively coupled to the output shaft and the rotor shaft. The soft-start coupling portion is configurable to enable the synchronous motor to obtain synchronous operation and to drive, at least near synchronous speed during normal steady state operation of the motor, a load having characteristics sufficient to prevent obtaining normal synchronous operation of the motor when the motor is operatively connected to the load in the absence of the soft-start coupling. The synchronous motor is sufficiently rated to obtain synchronous operation and to drive, at least near synchronous speed during normal steady state operation of the motor, a load having characteristics sufficient to prevent obtaining normal synchronous operation of the motor when the motor is operatively connected to the load in the absence of the soft-start coupling.

42 ENGINEERING↗
DOE OSTI2021

Cortical proteins may provide motor resilience in older adults

Motor resilience proteins may be a high value therapeutic target that offset the negative effects of pathologies on motor function. This study sought to identify cortical proteins associated with motor decline unexplained by brain pathologies that provide motor resilience. We studied 1226 older decedents with annual motor testing, postmortem brain pathologies and quantified 226 proteotypic peptides in prefrontal cortex. Twenty peptides remained associated with motor decline in models controlling for ten brain pathologies (FDR < 0.05). Higher levels of nine peptides and lower levels of eleven peptides were related to slower decline. A higher motor resilience protein score based on averaging the levels of all 20 peptides was related to slower motor decline, less severe parkinsonism and lower odds of mobility disability before death. Cortical proteins may provide motor resilience. Targeting these proteins in further drug discovery may yield novel interventions to maintain motor function in old age.

Buchman, Aron↗
DOE OSTI2025

Sorting rare earth magnets motors for recycling without opening the motors

Abstract A novel approach for sorting electric motors without dismantling them is reported in this article. This approach increases the likelihood that a motor selected from a mixture for recycling would contain rare earth elements (REEs), which are pivotal for numerous advanced green technologies. The challenge of inadvertently dismantling motors without REEs during recycling is addressed by this proposed innovative method. It relies on cogging interactions and power density for sorting motors with REEs. The process uses an algorithm introduced in this work to sort motors in two steps by (a) distinguishing induction motors from permanent magnet motors, and (b) distinguishing motors with critical REEs (e.g., Nd, Pr, Dy, Tb) from ferrite-based motors, all without opening the motors. The former was accomplished with 100% accuracy while the latter was accomplished with ~ 78% accuracy. Such high accuracy improves the recycling efficiency of critical REEs from motors, alleviating concern about supply disruption and supporting resource conservation and sustainability.

36 MATERIALS SCIENCE↗
DOE OSTI2018

RESULTS OF ACCELERATED LIFE TESTING OF LCLS-II CAVITY TUNER MOTOR

An Accelerated Life Test (ALT) of the Phytron stepper motor used in the LCLS-II cavity tuner has been conducted at JLab. Since the motor will reside inside the cryomodule, any failure would lead to a very costly and arduous repair. As such, the motor was tested for the equivalent of 30 lifetimes before being approved for use in the production cryomodules. The 9-cell LCLS-II cavity is simulated by disc springs with an equivalent spring constant. Plots of the motor position vs. tuner position ' measured via an installed linear variable differential transformer (LVDT) ' are used to measure motor motion. The titanium spindle was inspected for loss of lubrication. The motor passed the ALT, and is set to be installed in the LCLS-II cryomodules.

Huque, Naeem↗
DOE OSTI2017

Coupling with concentric contact around motor shaft for line start synchronous motor

A method comprises providing a line-start synchronous motor. The motor has a stator, a rotor core disposed within the stator, and a motor shaft. In accordance with a step of the method, a coupling for coupling a load to the motor is provided. The coupling has a motor shaft attachment portion configured to provide substantially concentric contact around the shaft at the end of the motor shaft. The coupling has a load attachment portion configured to operatively connect to a load. In accordance with a step of the method, a load is coupled to the motor with the coupling, and driven from start to at least near synchronous speed during steady state operation of the motor with a load coupled thereto. The motor shaft attachment portion may comprise a bushing assembly with matching and opposed tapered surfaces that cooperate to secure the motor shaft attachment portion around the motor shaft.

42 ENGINEERING↗
DOE OSTI2020

A Nonlinear Regression Method for Composite Protection Modeling of Induction Motor Loads

Protection equipment are used to prevent damages to induction motor loads by isolating those from the power network in the event of severe faults. Modeling the response of induction motor loads and their protection is vital for power system planning and operation, especially in understanding system's response moments after a fault has occurred. This article proposes an optimization based framework to generate composite protection models for commercial building motor loads. Introducing a mathematical abstraction, the task of finding a suitable (simplified) model of the composite protection scheme is formulated as a nonlinear regression problem. Numerical examples are provided to illustrate the application of the framework.

Kundu, Soumya↗
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

Traction Motor Design Trade-Offs with Additively Manufactured Anisotropic Bonded Magnets

Extrusion based big area additive manufacturing (BAAM) has been previously demonstrated for the fabrication of dense anisotropic bonded magnets. This paper reports on design trade-offs when such magnets are employed in a motor designed for electric vehicle applications. An external rotor fractional slot permanent magnet synchronous machine designed with sintered dysprosium free magnets rated for 100kW peak and 50kW continuous power is used as the baseline. The impact of using the bonded BAAM magnets on the motor and inverter volumes, motor loss and cooling systems as well as demagnetization margins is evaluated. It is found that although the motor power density reduces due to the lower energy product of the BAAM magnets, there are other system level benefits including reductions in the cooling system requirement, lower inverter rating and volume, decrease in short circuit current and improved demagnetization marains.

additive manufacturing↗
DOE OSTI2020

Machine learning model to project the impact of COVID-19 on U.S. motor gasoline demand

Owing to the global lockdowns that resulted from the COVID-19 pandemic, fuel demand plummeted and the price of oil futures went negative in April 2020. Robust fuel demand projections are crucial to economic and energy planning and policy discussions. Here we incorporate pandemic projections and people's resulting travel and trip activities and fuel usage in a machine-learning-based model to project the US medium-term gasoline demand and study the impact of government intervention. We found that under the reference infection scenario, the US gasoline demand grows slowly after a quick rebound in May, and is unlikely to fully recover prior to October 2020. Under the reference and pessimistic scenario, continual lockdown (no reopening) could worsen the motor gasoline demand temporarily, but it helps the demand recover to a normal level quicker. Under the optimistic infection scenario, gasoline demand will recover close to the non-pandemic level by October 2020. The COVID 19 pandemic and consequent lockdown has had a substantial impact on mobility and therefore fuel demand and it is not clear when demand will recover. Ou et al. use a machine learning model that integrates health recovery scenarios to project the near-term future of gasoline demand.

COVID-19 pandemic↗
DOE OSTI2020

Multi-Scale Thermal Analysis for Design of SiC-Based Medium Voltage Motor Drive: Preprint

This paper describes a multi-scale thermal analysis approach for the design of an air-cooled 1.7-kV SiC MOSFET-based medium-voltage variable-speed motor drive. The National Renewable Energy Laboratory supported the project objectives by providing thermal management design support to the project partner The Ohio State University (OSU). The scope of the models and limited resources required efficient and flexible thermal models to be developed. Two modeling techniques are described that significantly reduced model run time and enabled more complex models to be run faster while retaining needed accuracy. The first technique uses the effectiveness-NTU method to extract convection boundary conditions from a computational fluid dynamics (CFD) model that can be applied to a fast-running finite element analysis model. The second is a porous media technique that enables system-level CFD simulations that incorporate effects from heat exchangers (e.g., pin fin heat sinks) that run in a fraction of the time required for fully resolved CFD simulations. The multi-scale approach to the thermal analysis enabled fast and accurate simulation for the converter design ranging from the die level up to the full system with 36 submodules. The modeling results were validated against experimental data from system tests performed by OSU.

DIRECT ENERGY CONVERSION↗
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 OSTI2018

Permanent Magnet Synchronous Motors for Commercial Refrigeration (Final Report)

This report provides background information on various fractional-horsepower electric motor technologies used for evaporator fan applications in commercial refrigeration and summarizes data from a DOE-sponsored evaporator fan motor laboratory and field demonstration project. This report also extrapolates that data to project the potential economic and environmental benefits resulting from upgrading the current installed base of commercial refrigeration evaporator fan motors to permanent magnet synchronous (PMS) motors.Evaporator fan motors used in commercial refrigeration applications are fractional horsepower in size, responsible for moving air across the evaporator coil, and typically run at one speed. Historically, shaded-pole induction motors have been the most commonly used evaporator fan motors in commercial refrigeration equipment and beverage vending machines. These are the simplest and least expensive type of fractional-horsepower motor, with an efficiency of approximately 20%. Electronically commutated (EC) permanent magnet motors, also known as brushless DC motors, were initially commercialized in the late 1980s, and their use in commercial refrigeration applications has increased within the last 10 to 15 years because of economic incentives and regulatory requirements. State-of-the-art EC motors are approximately 66% efficient. Another induction motor type, the permanent split capacitor (PSC) motor, offers a mid-point between shaded-pole and EC motor price and efficiency levels. PSC motors are typically about 29% efficient.A permanent magnet synchronous (PMS) AC motor that can directly use grid-supplied AC current without the need to rectify to DC has recently been commercialized. This new motor exhibits a peak efficiency of 75% and has the potential to significantly reduce the energy consumption of evaporator fan motors in commercial refrigeration equipment. Laboratory evaluation of evaporator fan motor technologies was performed to quantify and compare the performance of shaded-pole, PSC, EC, and PMS evaporator fan motors in a controlled environment, so as to minimize the influence of external factors and anomalies. The laboratory evaluation included dynamometer testing of the fan motors and airflow testing of the motor/fan assemblies. It was found that the 6–12 W PMS motor exhibited a peak efficiency of 75% with a power factor of approximately 0.9 at a power output of 11 W. It was also found that a 38–50 W PMS motor exhibited a peak efficiency of 82% with a power factor of approximately 0.9 at a power output of 35 W.Airflow testing of shaded-pole, PSC, EC, and PMS motor/fan assemblies was performed using an airflow test chamber, which was designed in accordance with ANSI/AMCA Standard 210-16/ASHRAE Standard 51-16, to measure the performance of the subject motor/fan assembly and to determine the incumbent display case system impedance (AMCA 2016). A family of fan curves (static pressure vs airflow rate and electrical power input vs airflow rate) was generated for the 6–12 W PMS motor/fan assemblies with 8-inch fan blades pitched from 17 to 32 degrees. A similar set of curves was generated for the 38–50 W motors paired with 10 and 12-inch blades. Various incumbent motor/fan assemblies were also tested in the laboratory airflow test chamber and their fan curves were generated.Field evaluation of refrigerated display case evaporator fan motors was accomplished by performing side-by-side comparisons of 6–12 W PMS motors to 6–12 W shaded-pole and EC evaporator fan motors. It was found that, on average, a PMS motor consumes 79% less power and draws 82% less current than a shaded pole motor, and on average, 34% less power and 49% less current than an EC motor. In addition, the PMS motor exhibits an average power factor of approximately 0.82, which is on average 40% greater than that of existing evaporator fan motors.Two field test sites were selected to evaluate the performance of the larger 38 to 50 W PMS evaporator fan motors in walk-in cooler/freezer applications. At each supermarket, two walk-in units were selected for investigation: one walk-in dairy cooler and one walk-in freezer. A 61% decrease in fan motor power was measured when retrofitting existing evaporator fan motors with PMS motors in the walk-in cooler. In addition, a 48% decrease in fan motor power was measured when retrofitting existing evaporator fan motors with PMS motors in the walk-in freezer.The culmination of the field evaluation of fan motor technologies was a whole-store retrofit conducted at a supermarket. Pre- and post-retrofit measurement of evaporator fan motor power in medium- and low-temperature refrigerated display cases and walk-in coolers/freezers was performed. Overall for the whole-store retrofit, the current supplied to all monitored evaporator fan motors was reduced by 52%, the real power was reduced by 46% and the apparent power was reduced by 51% following the retrofit of the 262 evaporator fan motors that w

42 ENGINEERING↗