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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
NASA NTRS2023

Design Studies on Mechanically Geared, Magnetically Geared, and Direct Drive Drivetrains for UAM Applications

Urban air mobility vehicles require high reliability and high performance electric motor drive trains. In this paper, a design optimization study is carried out to compare mechanically geared, magnetically geared, and direct drive motor drivetrain topology achievable performance in a 100 kW hover power quad rotor propulsor application. Design studies are carried out accounting for a nominal mission profile. Studies are carried out assuming constant propulsor rotor RPMs of 400, 1000, 2000, and 3000 RPM. Results show that mechanically geared drives are the lightest at all RPMs but their weight benefit over direct drive and magnetically geared decays with increased rotor RPM. Direct drive is shown to always achieve the highest efficiency due to its lower motor speed resulting in low electrical frequencies. Magnetically geared drivetrains are shown to need some requirement refinement or technology improvement to provide significant benefit over direct drive drivetrains.

Thomas Tallerico↗
NASA NTRS2023

Design Studies on Mechanically Geared, Magnetically Geared, and Direct Drive Drivetrains for UAM Applications

Urban air mobility vehicles require high reliability and high performance electric motor drive trains. In this paper, a design optimization study is carried out to compare mechanically geared, magnetically geared, and direct drive motor drivetrain topology achievable performance in a 100 kW hover power quad rotor propulsor application. Design studies are carried out accounting for a nominal mission profile. Studies are carried out assuming constant propulsor rotor RPMs of 400, 1000, 2000, and 3000 RPM. Results show that mechanically geared drives are the lightest at all RPMs but their weight benefit over direct drive and magnetically geared decays with increased rotor RPM. Direct drive is shown to always achieve the highest efficiency due to its lower motor speed resulting in low electrical frequencies. Magnetically geared drivetrains are shown to need some requirement refinement or technology improvement to provide significant benefit over direct drive drivetrains.

Thomas Tallerico↗
NASA NTRS2019

Lessons Learned in Fabrication of a High-Specific-Torque Concentric Magnetic Gear

Magnetic gearing is being investigated at NASA as a replacement to conventional mechanical gearing in aerospace applications. Some potential benefits of magnetic gears over mechanical gearing are torque transmission without mechanical contact, decreased transmission noise, and no required lubrication. However, in order to be a viable alternative for aerospace applications, magnetic gearing must be shown to provide high enough specific torque (torque per unit mass). NASA's second magnetic gearing prototype (PT-2) was able to achieve promising specific torque on par with low torque mechanical gearboxes. This work will briefly review the electromagnetic and structural design of PT-2, provide detailed information on fabrication and assembly, examine build errors, walk through rebuild efforts to improve operation, and conclude with remarks on build difficulties and opportunities for improvement in future prototypes.

Magnetic Gearing↗
NASA NTRS2019

Lessons Learned in Fabrication of a High-Specific-Torque Concentric Magnetic Gear

Magnetic gearing is being investigated at NASA as a replacement to conventional mechanical gearing in aerospace applications. Some key benefits of magnetic gears over mechanical gearing are torque transmission without mechanical contact, decreased transmission noise, less frequent maintenance, and lack of lubrication. In order to take advantage of these benefits in aerospace applications, magnetic gearing must be shown to provide high enough specific torque (torque per unit mass). Prototype 2 (PT-2), developed to maximize specific torque, and fabricated at NASA Glenn Research Center, has shown promising specific torque comparable to low torque mechanical gears. This work will briefly review the electromagnetic and structural design of PT-2, provide detailed information on fabrication and assembly, examine build errors, walk through rebuild efforts to improve operation, and conclude with remarks on build difficulties and opportunities for improvement in future prototypes.

Electrified Vertical Take Off and Landing↗
NASA NTRS2019

Results of NASA's Magnetic Gear Program to Date

In rotorcraft, one of the main sources of mechanical failure is the gearbox, because of the many wear and failure modes associated with tooth contact in traditional mechanical gear boxes. Magnetic gears transmit torque without mechanical tooth contact between gear bodies and therefore they have none of the tooth contact related failure modes associated with mechanical gearing. As a result, magnetic gears have the potential to enable more reliable rotorcraft gearboxes. However, magnetic gears have not been demonstrated to match the performance of mechanical gearboxes at a high enough technology readiness level (TRL) to be used on an aircraft to date. To that end, NASA's Revolutionary Vertical Lift Technologies project has made an investment in developing magnetic gearboxes specifically for electrified vertical lift vehicles (EVTOL). In this presentation, the results of that investment to date will be discussed.

Tallerico, Thomas↗
NASA NTRS1982

Magnetic-Gear Concept for Special Applications

Proposed gear has magnetic instead of mechanical teeth. Magnetic gears consists of permanent magnets resembling mechanical gears but with smooth faces and alternating magnetic poles in place of mechanical teeth. Low torque, noncontacting gears useful in special environments.

Chandler, J. A.↗
NASA NTRS2019

Electromagnetic Mass and Efficiency of Magnetic Gears for Electrified Aircraft

Magnetic gears are currently being developed for use in a variety of industries such as wind and automotive, because of their higher reliability and lower maintenance cost than their mechanical counterparts. The bulk of magnetic gear development to date has focused on maximizing the technology's volumetric torque density. In contrast, the primary performance metrics for an aircraft's gear box are its mass and efficiency. To that end this paper presents a study of the achievable electromagnetic specific torque and efficiency of concentric magnetic gears. NASA's second magnetic gear prototype is used as the baseline for this study. Achievable electromagnetic specific torque and efficiency trends are presented with respect to higher level design variables such as gear ratio and radius.

Tallerico, Thomas F.↗
NASA NTRSDate not supplied

Progress in Magnetic Gearing for Aeronautics and Space Applications

Magnetic gears harness the magnetic force between non-contacting sets of permanent magnets. They achieve a gear ratio through the geometry and constrained motion of the magnets or the transformation of the magnetic fields by carefully shaped soft magnetic material. Their non-contact nature eliminates the need for gear lubrication and the wear mechanisms associated with mechanical contact. Magnetic gears have the potential to reduce the strong, tonal vibration and noise that is inherent to mechanical gears. Magnetic gears are also easily integrated into electric machines because they rely on the same physics and utilize the same materials and many of the same components. For these reasons and the invention of higher performing magnetic gear configurations over the past 20 years, magnetic gears have received growing attention for aerospace applications. This presentation summarizes the motivation for studying magnetic gears and the progress made in developing the technology to meet the demanding requirements of aerospace applications. The focus is on the development completed and ongoing at NASA, but SBIR projects in the field are summarized. The discussion focuses on the application of magnetic gears and magnetically-geared motors in electrified aircraft propulsion systems and actuation systems for space mechanisms. The NASA work includes the design, optimization, and testing of magnetic gears and magnetically-geared motors for electrified vertical takeoff and landing aircraft and the design and ambient environment testing of a magnetically-geared actuator for use in extremely cold and dusty space environments. The presentation concludes with thoughts on the technical barriers to adoption and potentially fruitful topics for future research.

Justin J. Scheidler↗
NASA NTRS2019

Magnetic Gears and Their Structural Limitations

Magnetic gears present significant structural design challenges, because metallic/electrically conductive structures are highly undesirable as they would lead to significant efficiency reductions. Additionally, most non-electrically conductive structural materials have low thermal conductivity, which makes cooling the gear difficult. These limitations are of particular significant in magnetic gear's modulator structures. NASA Glenn has shown that pole pieces on the order of 1 to 2 mm thick optimize magnetic gears specific torque. These thin pole pieces however see very large magnetic forces and modulator structural limitations prevent the use of magnetically optimum pole pieces. The best solution to this issue to date has been the use of carbon fiber retaining rings on the external surface of the modulator, however this solution increases ring modulator airgap, resulting in a torque reduction from the optimum design. The pole pieces are also the largest sources of losses in magnetic gears. Because the modulator is nestled between the ring and sun gear extraction of this heat is a difficult problem and the modulator structure has to be designed to dissipate this heat load. In the presentation I will present the design of NASA Glenn's 4th magnetic gear's modulator in detail that uses a combination of 3D fiber reinforced nylon, IM7 carbon fiber, and pitch base cn80 fiber to close both structurally and thermally.

Tallerico, Thomas↗
NASA NTRS2019

Electromagnetic Efficiency and Mass of Magnetic Gears for Electrified Aircraft

Magnetic gears are currently being explored to replace mechanical gears in various industries such as wind and automotive due to their higher reliability and lower maintenance requirements. In these applications volume minimization has been the goal of magnetic gear development. In contrast, the primary performance metrics for electrified aircraft drives are mass and efficiency. This paper presents the first ever study of design tradeoffs between electromagnetic mass and efficiency of concentric magnetic gears and the feasibility of achieving the low mass and high efficiency required for electrified aircraft applications. Higher level design variables are considered, including gear ratio, number of magnetic pole pairs, and number of magnets per pole pair.

Tallerico, Thomas↗
NASA NTRS2019

Design of a Magnetic Gear for NASA's Vertical Lift Quadrotor Concept Vehicle

Magnetic gears are an attractive alternative to mechanical gears for electrified aircraft drive systems due to their ability to transmit torque without mechanical tooth contact. Consequently, magnetic gears enable electrified aircraft to take advantage of the benefits of gearing without introducing most of the contact-related reliability concerns associated with mechanical gearing. Magnetic gears however, have not been shown to match the specific torque (torque/mass) and efficiency of their mechanical counterparts in an aerospace application to date. In this paper, the design of a concentric magnetic gear for a personal air transport NASA reference vehicle is presented to demonstrate the feasibility of a magnetic gear for aerospace applications.

Tallerico, Thomas F.↗
NASA NTRS2019

Design of a Magnetic Gear for NASA's Vertical Lift Quadrotor Reference Vehicle

Magnetic gears are an attractive alternative to mechanical gears for electrified aircraft drive systems due to their ability to transmit torque without mechanical tooth contact. Consequently, magnetic gears enable electrified aircraft to take advantage of the benefits of gearing without introducing most of the contact-related reliability concerns associated with mechanical gearing. Magnetic gears however, have not been shown to match the specific torque (torque/mass) and efficiency of their mechanical counterparts in an aerospace application to date. In this paper, the design of a concentric magnetic gear for a personal air transport NASA reference vehicle is presented to demonstrate the feasibility of a magnetic gear for aerospace applications.

Tallerico, Thomas↗
NASA NTRSDate not supplied

Design Study of Double-Sided Axial-Flux Magnetically Geared Motors for Electric Aircraft Applications

Electric aircraft require advances in electric motor drivetrain efficiency, specific power, and reliability. In terms of mass and efficiency, mechanically geared electric motor drivetrains will significantly outperform direct drive electric motor drive trains in most applications. Mechanical gears however have numerous wear and failure modes that can result in increased maintenance and reliability penalties for an aircraft. Magnetic gears are being explored by NASA as a potential alternative to mechanical gears for electric aircraft applications. Magnetic gears have none of the surface contact related wear and failure modes of mechanical gears. Therefore, they potentially pose a high reliability alternative to mechanical gears. Magnetic gears can also share magnetic components with an electric motor in a magnetically geared drivetrain to achieve significant weight savings. In this paper, one possible topology of magnetically geared motor, the double-sided axial flux magnetically geared motor, is studied to quantify its achievable performance. Design study results suggest that the topology can achieve greater than 20 Nm/kg and 97% efficiency at a 100 kW output power.

Magnetic gears↗
NASA NTRSDate not supplied

Design Study of Double-Sided Axial-Flux Magnetically Geared Motors for Electric Aircraft Applications

Electric aircraft require advances in electric motor drivetrain efficiency, specific power, and reliability. In terms of mass and efficiency, mechanically geared electric motor drivetrains will significantly outperform direct drive electric motor drive trains in most applications. Mechanical gears however have numerous wear and failure modes that can result in increased maintenance and reliability penalties for an aircraft. Magnetic gears are being explored by NASA as a potential alternative to mechanical gears for electric aircraft applications. Magnetic gears have none of the surface contact related wear and failure modes of mechanical gears. Therefore, they potentially pose a high reliability alternative to mechanical gears. Magnetic gears can also share magnetic components with an electric motor in a magnetically geared drivetrain to achieve significant weight savings. In this paper, one possible topology of magnetically geared motor, the double-sided axial flux magnetically geared motor, is studied to quantify its achievable performance. Design study results suggest that the topology can achieve greater than 20 Nm/kg and 97% efficiency at a 100 kW output power.

Thomas F Tallerico↗
NASA NTRS2018

Magnetic Gearing Research at NASA

Magnetic gearing is an alternative to mechanical gearing, where torque is transferred through magnetic force as opposed to contact force. The technology has the potential to be used in aircraft applications, without the lubrication, noise, and maintenance issues that can exist with mechanical gearing. Initial design and prototype development work was done at NASA to create a foundational understanding of the technology and the factors that influence its specific torque. The specific torque achieved through design optimization was found to be less than that of high-torque mechanical aircraft transmissions, but may be comparable to that of lower torque mechanical transmissions for electrified vertical takeoff and landing aircraft. The lessons learned from NASA's initial technology development and the direction of NASA's future work in field are discussed.

propulsion systems↗
DOE OSTI2022

Sub-Scale Stage 1 Magnetic Gear for a Marine Hydrokinetic Generator

The goal of this project is to design, fabricate, and test a hermetically sealed 50 kilowatt (kW) multistage magnetically geared generator (MGG). In order to reduce risk, a sub-scale 5kW multistage MGG was first built. This project will benefit MHK device developers by providing an MHK PTO that overcomes the reliability concerns of the mechanical gears and the sizing constraints of the direct-drive generators. Measurement data for a 9.5:1 gear ratio magnetic gear with a measured peak torque of 227 N-m as well as the dual stage magnetic gear with a 63:1 gear ratio.

16 TIDAL AND WAVE POWER↗
DOE OSTI2021

Stage 2 Sub-Scale Magnetic Gear

The goal of this project is to design, fabricate, and test a hermetically sealed 50 kilowatt (kW) multistage magnetically geared generator (MGG). In order to reduce risk, a sub-scale 5kW multistage MGG was first built. This project will benefit MHK device developers by providing an MHK PTO that overcomes the reliability concerns of the mechanical gears and the sizing constraints of the direct-drive generators. 7.67:1 gear ratio magnetic gear with a measured peak torque of 1796 N-m

16 TIDAL AND WAVE POWER↗
NASA NTRS2018

Magnetic Gearing Research at NASA

Magnetic gearing is an alternative to mechanical gearing, where torque is transferred through magnetic force as opposed to contact force. The technology has the potential to be used in aircraft applications, without the lubrication, noise, and maintenance issues that can exist with mechanical gearing. Initial design and prototype development work was done at NASA to create a foundational understanding of the technology and the factors that influence its specific torque. The specific torque achieved through design optimization was found to be less than that of high-torque mechanical aircraft transmissions, but may be comparable to that of lower torque mechanical transmissions for electrified vertical takeoff and landing aircraft. The lessons learned from NASA's initial technology development and the direction of NASA's future work in field are discussed.

electric aircraft propulsion↗