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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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13 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Postfault Operation of Three-Level Inverter Driven Six-Phase PMSM With Enhanced Torque–Speed Region

This article presents an open-switch postfault operational technique with enhanced torque–speed region for three-level (3L) active neutral point clamped (ANPC) inverter-driven symmetrical six-phase (SSP) permanent magnet synchronous machines (PMSMs). Maximum torque (MT), minimum loss (ML), and single three-phase (STP) operations are commonly used for the postfault operations of six-phase drives. The maximum possible torque and speed in these operations are generally limited by voltage, current ratings, and the neutral point configuration of the motor. To enhance the postfault torque and speed operating region, the torque and speed limits in different postfault operational techniques are determined based on the voltage, current constraints, and neutral point configuration of the SSP-PMSM. In this work, a unified postfault operation is proposed that increases the postfault operational limits by combining MT, ML, and STP operations and modifying the neutral point configuration of the SSP-PMSM. In addition, a technique is also presented that modifies the pulsewidth modulation technique to enable full torque operation below 0.5 p.u. speed. The proposed postfault operational technique enables full-speed (1 p.u.) operation by operating in STP mode and full torque operation (1 p.u.) below 0.5 p.u. speed. Furthermore, the postfault operational technique is experimentally validated using a Gallium Nitride (GaN) device-based3L-ANPC inverter-driven SSP-PMSM.

42 ENGINEERING↗
DOE OSTI2023

A Voltage Injection-Based Current Harmonics Suppression Strategy for Six-Phase PMSM With Nonsinusoidal Back EMF

This article presents a voltage injection-based current harmonic minimization method for wide bandgap device-based six-phase permanent magnet synchronous machine (PMSM) drives. The presence of low-order harmonics is common in the back EMF of PMSMs with low slot and high pole numbers. The back EMF harmonics generate low-order harmonic currents that increase torque ripples. Furthermore, zero-sequence current (ZSC) is also observed if all six phases are connected to a common neutral point. ZSC does not affect the torque ripple but reduces the system efficiency. A special technique is required to reduce ZSC for variable speed drives as direct ac component to synchronous reference frame (SRF) dc transformation is not possible for ZSC. In this article, a voltage injection-based current harmonics reduction method is proposed. The injected harmonic voltage coefficients are calculated from the harmonic estimations of back EMF and updated using closed-loop harmonic compensators to improve steady-state performance. For ZSC reduction, third harmonics power controller, and for 6n ± 1 (n = 1, 2,...) order harmonic current reduction, SRF current controllers are presented in this article. Furthermore, the current harmonics minimization method is experimentally verified using a GaN-based three-level active neutral point clamped inverter-driven six-phase PMSM.

42 ENGINEERING↗
DOE OSTI2020

Materials Data on PmSm by Materials Project

SmPm is Magnesium-derived structured and crystallizes in the hexagonal P-6m2 space group. The structure is three-dimensional. Sm is bonded to six equivalent Sm and six equivalent Pm atoms to form SmPm6Sm6 cuboctahedra that share corners with eighteen equivalent SmPm6Sm6 cuboctahedra, edges with six equivalent SmPm6Sm6 cuboctahedra, edges with twelve equivalent PmPm6Sm6 cuboctahedra, faces with eight equivalent SmPm6Sm6 cuboctahedra, and faces with twelve equivalent PmPm6Sm6 cuboctahedra. All Sm–Sm bond lengths are 3.65 Å. All Sm–Pm bond lengths are 3.66 Å. Pm is bonded to six equivalent Sm and six equivalent Pm atoms to form PmPm6Sm6 cuboctahedra that share corners with eighteen equivalent PmPm6Sm6 cuboctahedra, edges with six equivalent PmPm6Sm6 cuboctahedra, edges with twelve equivalent SmPm6Sm6 cuboctahedra, faces with eight equivalent PmPm6Sm6 cuboctahedra, and faces with twelve equivalent SmPm6Sm6 cuboctahedra. All Pm–Pm bond lengths are 3.65 Å.

36 MATERIALS SCIENCE↗
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↗
DOE OSTI2020

Coupled Electro-Thermal Analysis of Permanent Magnet Synchronous Motor for Electric Vehicles

Permanent magnet synchronous motors (PMSM) are extensively used in electric vehicles. However, high internal heat generation and inefficient heat dissipation often limit the operational reliability, and longevity of the PMSM. Therefore, proper quantification of heat generation in electric motor and advanced embedded motor cooling techniques remain topics of immense interest. In order to accurately predict electro-magnetic performance, i.e., efficiency, component-wise heat losses and the corresponding temperature distribution of a jacket cooled machine, this paper presents a two-way iteratively coupled electro-thermal modeling framework. Finite element based software Motor-CAD has been utilized for electro-magnetic performance calculation of BMW i3 PMSM. Finite volume based computational fluid dynamics/heat transfer (CFD/HT) software ANSYS® FLUENT® has been employed to simulate the temperature distribution of the PMSM, using the electro-magnetic losses as heat input. Computed heat losses, stator, winding, rotor, and magnet temperatures are utilized as coupling parameters between the electro-magnetic and thermal models. A conventional one-way coupling algorithm has also been developed and compared to the newly proposed two-way coupling algorithm. Numerical results confirm that at high current density, one-way coupling algorithm significantly over-predicts the motor temperature compared to the two-way algorithm. A comprehensive analysis has been carried out to characterize the influences of current density, speed, and forced convection heat transfer coefficient on the heat losses, overall efficiency, and maximum temperature of the PMSM. Lastly, an efficiency map has been interpreted from the coupled electro-magnetic simulation.

42 ENGINEERING↗
DOE OSTI2025

Extended State Observer-Based Robust Model Predictive Velocity Control for Permanent Magnet Synchronous Motor

This article proposes an extended state observer based robust model predictive velocity control to decrease system prediction error under parameter uncertainties for permanent magnet synchronous motor (PMSM). We develop a new PMSM model that consists of velocity and acceleration to lump the system information and an external disturbance into a disturbance. The extended state observer (ESO) is designed to estimate the velocity, acceleration, and disturbance. By estimating the state variables and disturbance using the ESO, the model predictive control (MPC) finds the optimal control input by predicting future system behavior. Additionally, the direct current controller is designed so that the direct current converges to zero. Because the proposed method is not designed based on the cascade structure from the viewpoint of velocity control, the optimization control for the velocity and currents can be defined. Thus, the proposed method is robust against external disturbances and parameter uncertainties owing to feedback linearization, state feedback, and ESO-based MPC using the acceleration PMSM model. The proposed control algorithm was experimentally verified and it showed improved velocity tracking performance compared with ESO-based MPC using the conventional PMSM model.

42 ENGINEERING↗
DOE OSTI2021

Multi-Core Microcontroller Hardware In the Loop System for Electric Machine Control

Hardware in the Loop (HIL) is a simulation technique used to reduce the software development cycle and test control systems in a non-destructive environment. This work describes a cost effective HIL simulator on a dual core microcontroller in which one core acts as a controller and the other emulates the system under control. The emulator runs one step per Pulse Width Modulation (PWM) period in real time. To handle the computational burden and prioritize execution of simulation and control tasks, an interrupt-based software architecture with task prioritization has been developed. As a demonstration, the HIL has been implemented on a Texas Instruments TMS320F28379D dual core microcontroller, which emulates a Permanent Magnet Synchronous Machine (PMSM) with resolver feedback. Hardware peripherals are developed and tested concurrently with the control system, providing higher confidence in the software. By using the peripherals in the HIL development, the controller exercises either the HIL emulation or a pin compatible PMSM testbench. To quantify performance and validate the processor based emulator, the HIL results are compared to the preexisting testbench for accuracy benchmarking at no-load and under load for a range of operating points.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2023

Reliable, High Power Density Inverters for Heavy Equipment Applications

With this final report, the combined team of the University of Arkansas (UA), University of Illinois, Urbana-Champaign (UIUC), Wolfspeed, Caterpillar, and Ampaire have successfully met all of their project objectives. Noteworthy for the heavy equipment portion of the project with Caterpillar is that the team made its project milestones two years into the project by designing a power dense motor drive for a permanent magnet synchronous machine. Upon finding out that Caterpillar had pivoted to switched-reluctance machines (SRMs), the team subsequently redesigned and implemented the SRM drive with a coolant temperature of 105°C! The other major task that the UA, UIUC, and Wolfspeed teams took on was the design of a PMSM drive for a hybrid aircraft that was flown on Feb. 20, 2023 by Ampaire after extensive testing and evaluation. While there were also technical objectives in thermal management, integrated gate drivers, reliability studies, and high temperature capacitors with integrated bussing, each of these have been fully reported on in quarterly reports. In brief, advances in thermal management and high temperature capacitors were utilized in order to achieve a 105°C motor drive. The integrated gate driver work resulted in a higher density drive with no loss of efficiency. Most of the last year, during a no-cost extension, was spent waiting for the Ampaire motor drive to be tested (outside of our project). Many months passed with the device just sitting in California while the company dealt with battery-related issues. This delayed the integration and testing activities until Fall 2022. Once those began, then the process took about 4-5 months to complete culminating in the test flight in Feb. 2023. By providing technical advances and integration into final platforms, the barrier to economic impact has been lowered. This project benefits the public by overcoming key technical barriers to electrified and hybrid electric heavy equipment and aircraft. This, in turn, leads to lower greenhouse gas emissions and a cleaner environment. This final report summarizes the integrated gate driver work and the Ampaire hybrid electric aircraft integration and test flight efforts. All other information has been previously reported in quarterly reports. A summary of the motor drives created during this project is provided along with a listing of publications.

42 ENGINEERING↗
DOE OSTI2024

A Real-Time Testbed for Smart Inverter Cyber Security Studies

Distributed energy resources (DER) have become a popular solution to modern-day issues surrounding the efficiency and reliability of power generation, as well as climate change concerns. Energy centers are shifting towards incorporating smart inverters with embedded functionalities such as high voltage ride through (HVRT), low voltage ride through (LVRT), active and reactive power compensation. However, the integration of smart inverters leave DER systems highly vulnerable to cybersecurity threats. The distributed network protocol 3 (DNP3) is a common method of communication between grid-tied hardware. Despite its popularity, the level of security leaves all hardware connected to the grid at risk of severe cyber-attacks. Thus, it is important to study any potential cybersecurity threats towards grid-tied smart inverters to mitigate cybersecurity vulnerabilities and refine existing cyber-security protections. This report describes the proposed testbed design to study cybersecurity threats to smart inverters. The testbed utilizes a real-time simulation case in RSCAD that includes a grid-tied wind turbine (WT) topology featuring two back-to-back two-level voltage source converters (BTB,2L-VSCs) and a permanent magnet synchronous machine (PMSM). The simulated case runs within the NovaCor real time digital simulator (RTDS). This report focuses on the design and implementation of a single module of the GTNETx2 card as a distributed network protocol and the configuration of an IEEE 1518 DNP database file that includes input and output variables mapped to different connection points in the grid that transmit and receive discrete, analog, and binary signals on command. This allows realistic emulation of the communication between the smart inverter and the grid for cybersecurity studies.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2020

Comparison of electro-thermal performance of advanced cooling techniques for electric vehicle motors

Permanent magnet synchronous motors are commonly used in the powertrain of electric vehicles because of their high power and torque densities. Attempts to increase power and torque densities beyond the state-of-the-art often suffer from thermal limitations of the adopted winding-wire insulation class. In this paper, overall effectiveness of four different cooling technologies, namely conventional stator jacket cooling, embedded circular and rectangular cooling channels within stator core, and direct winding heat exchangers have been studied numerically. Here, by realizing temperature dependent magnetic and material properties, winding and core losses, a two-way coupling algorithm has been utilized to study the detailed electro-magnetic and thermal performance of BMW i3 motor with aforementioned cooling techniques. The numerical results illustrated that the direct winding heat exchangers approach provides better electro-thermal performance in comparison to the other cooling techniques analyzed. On the contrary, embedded rectangular and circular channel in stator core adversely affect the electro-magnetic performance and overall efficiency of the motor, despite their superior thermal performance compared to the jacket cooling

42 ENGINEERING↗
DOE OSTI2025

Implementation of Advanced Grid Support Functionalities by Smart Operation of Residential Loads with low Cost Converter Interface

This paper investigates a grid-supportive load concept for small-scale residential appliances, focusing on a residential refrigerator. Power consumption is adjusted based on grid conditions to achieve IEEE-1547 grid support functions. Two key aspects are presented: a low-cost refrigerator converter with Lyapunov energy function-based local controllers for speed control, and the impact on a standard microgrid system, demonstrating advanced grid support from the load side. This method enhances grid resilience and reliability and can be extended to other residential loads. The study contributes to efficient and robust grid-supportive load management systems, showing promising performance. This approach has the potential to improve overall grid stability and can be adapted for various types of residential appliances. The modeling and simulations in MATLAB/Simulink and PLECS confirm the feasibility and effectiveness of the proposed solution. Future work will explore real-world implementation and scalability of this concept for broader applications.

grid supportive loads (GSL)↗
DOE OSTI2021

Flow Assisted Evaporative Cooling for Electric Motor

This paper examines a novel concept of flow assisted latent heat driven two-phase evaporative cooling (EC) confined in-between slot liner and active-winding of electric motor. Wicking micro-structure enhanced PDMS liner axially sucks coolant in the form of thin film between the PDMS liner and active-winding and eventually enables thin film evaporation on the outer surface of the active-winding. Therefore, EC based thermal management eliminates contact resistance between the winding and slot-liner and, enhances the heat extraction from the winding without compromising the electro-magnetic performance. Two-way coupled electro-magnetic (EM) – computational fluid dynamics/heat transfer (CFD/HT) and EM - lumped parameter thermal network (LPTN) models have been developed to assess the electro-thermal performance of the EC under steady and transient conditions. Taking a case study of a 125 kW jacket cooled BMW i3 motor and dielectric coolant FC-84, EC is shown to be capable of handling a maximum steady state rms current density of 26 A/mm2 at a evaporative heat transfer coefficient of 5,000 W/m2.K, which is about 78.7% higher compared to the traditional jacket cooling (JC). In case of EC, a maximum steady state and transient rms current density of 30 A/mm2 (106.2% higher compared to the JC), and 40.8 A/mm2 have been realized by using high thermal conductivity epoxy (1.9 W/m.K) impregnation material. Thermal performance of the EC is also assessed and compared with JC over a dynamic drive cycle. Lastly, a motorette testing has been performed to demonstrate the applicability of the proposed EC method and to validate the developed modeling framework.

42 ENGINEERING↗