Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “motors”

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.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 19 records

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↗

New principles of self‐organization created through the interplay of DNA condensates, microtubules, and motors

Bioinspired design—which holds great promise for a new generation of materials that are robust to defects, scalable under green manufacture, environmentally responsive, and programmably reconfigurable—requires mastery over molecular self-organization. Yet, from its specific mechanisms to most general architectures, the principles governing self-organization remain poorly understood and not even fully enumerated. For living systems, one obvious architectural principle is the modular reuse of a few simple molecular components in myriad combinations to achieve more complex phenomena. For example, the mechanical tasks of a cell are driven by the nonequilibrium dynamics of cytoskeletal filaments and molecular motors—the same filaments and motors, reprogrammed by a variety of modulators, perform tasks ranging from cell movement to division. Similarly, many compartmentalization tasks are performed by liquid-like condensates of simple components, which act as membraneless organelles to localize particular molecules in space and time (e.g. for gene regulation or RNA processing). In a few cases, condensates combine and interact with the cytoskeleton to create still more complex phenomena, e.g. the nucleation of microtubule asters from the centrosome (a protein condensate) to form the mitotic spindle during cell division. Very little is known about the fundamental mechanisms of such filament-plus-condensate phenomena. Despite few examples, the landscape of behaviors that can be achieved through the combination of condensates, filaments, and motors appears vast. However, exploration has been hindered by a lack of systems that have sufficiently programmable and dynamically tunable interactions between component condensates, filaments, and motors. We proposed to combine programmable DNA condensates, filamentous microtubules, and light-controlled motors into self-organizing systems whose principles go beyond those that have been observed in nature. In one limit, our systems will use microtubules and motors to create the molecular analog of a network of roads, which will organize droplets of DNA condensates capable of carrying molecular cargo. DNA condensates coupled to motors will flow from one microtubule aster hub to another, with their direction and timing controlled by DNA circuits. In another limit, microtubules will swim through bulk DNA condensates and exhibit strong interactions with boundaries between different types of condensates. Microtubule swimmers will reflect, get trapped, or refract at boundaries, under a mechanical analog of the classical optical index of refraction. DNA condensates having different mechanical indexes of refraction will be used to construct the analog of optical lenses, so that microtubule swimmers can be manipulated like light—collimated, diffracted, focused, and sorted based on properties analogous to wavelength. These two limits define two new architectures, within which multiple new mechanistic principles for self-organization will be discovered and explored. To explore these architectures, the motor-based coupling between DNA condensates and filaments will be controlled in time and space through the use of opto-proteins that create reversible links between DNA condensates and motors upon illumination. For each principle of interest, patterns of light will create virtual experiments by defining patterns of activity where DNA condensates walk along filaments, or filaments swim through condensates, and patterns of inactivity which will serve either as controls, or as boundary conditions vital to create the desired phenomena. This research serves the goals of Basic Energy Sciences Biomolecular Material Program by elucidating the principles by which the emergent, nonequilibrium behavior of collections of DNA condensates, motors, and microtubules can be programmed by environmental light patterns to create complex motion and materials transport. Because DNA condensates can be readily coupled to virtually any high performance nanomaterial, from carbon nanotubes, to metal nanoparticles, to light harvesting systems, this work provides a path to the construction, self-maintenance and reconfiguration of materials relevant to the Department of Energy.

60 APPLIED LIFE SCIENCES↗

A new tubular ironless linear induction motor using non-interrupted winding method

The ironless linear induction motor device can be used for any application which requires a large motion span or rotation restrictedly by the ironless feature due to the strong magnetic field environment. One of the possible applications is ITER diagnostics shutters. The tokamak reactor systems have a severe radiation issue during the operation. The traditional Kapton-insulated wires have significantly lower radiation resistance than an expected large radiation dose at ITER Motion Stark Effect (MSE) shutter location. Furthermore, the traditional single-sided linear induction motor winds the wire to make the N-turn pitch coils independently and then connect them in series to make a one-phase winding. Therefore, it is a big challenge to make so many radiation-protection connectors in such a limited space as inside the vacuum vessel of fusion reactors. The approved mineral-insulated kinds of cables need a large bend radius for the end turns, so the traditional single-sided linear motor with two-layer three-phase windings need to be upgraded to the tubular linear motors. The new proposed tubular ironless linear induction motor can not only overcome the large bend radius issue with the mineral-insulated cables but also allow the motor coils wound continuously around the tubular-shaped stator, forward and backward N times to make a N-turn winding for each phase, in order to resolve the radiation protection issue with the winding connection. The 3D transient Maxwell electromagnetic model with a tubular three-phase linear induction motor has been analyzed. Furthermore, this paper will present the detailed design and winding method of ironless linear induction motor actuators, and results of the 3D transient numerical simulation of the actuator performance.

Ironless↗

Preliminary Design of Ironless Linear Induction Motors for ITER MSE Shutter Actuators

In this article, the shutters need to be closed or opened during the operation and calibration period time for the fusion diagnostic systems, such as the International Thermonuclear Experimental Reactor (ITER) motional stark effect (MSE). Standard electric motors and actuators will not work in a strong magnetic field environment due to the presence of the magnetic field of fusion reactors. The innovative linear induction motor (LIM) with an ironless feature overcomes this kind of challenge and can be used for any application that requires controlled motion with a large stroke in the magnetic field environment. It consists of a high-electrical conductivity plate like copper and three-phase motor windings with nonferrous or stainless-steel stators. The conductor plate attached with the shutter is simply driven by the underneath three-phase linear windings to achieve linear motion. The motor drive can be controlled remotely by a controller using the electrical connection, so no sensitive electronic components are located in the harsh environment where the motor itself is located. The design requirements and test facility have been described. Several 3-D transient Maxwell electromagnetic (EM) models with different locations of three-phase linear motor windings and shutter stators have been analyzed and evolved to meet any applications allowed in the harsh environment inside the vacuum vessel of fusion reactors. The preliminary design results are presented in this article.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

High-Torque Heavy-Rare-Earth-Free Electric Motor Thermal Management

This project is part of a multi-lab Next-Generation Reliable Electric Drive Systems for Medium and Heavy-Duty Vehicles (NEXT-DRIVE) project led by Oak Ridge National Laboratory (ORNL), and including NREL, Sandia National Laboratories (SNL), and Ames Laboratory that leverages research expertise and facilities of these national labs to develop tools and approaches for reducing the design and development time of new electric drive technologies for medium and heavy-duty vehicles (MHDVs) and their associated costs while increasing reliability and asset utilization. The Next-Drive project aligns with the DOE's goals by introducing high-fidelity multi-physics and AI/ML-based modeling to design low-cost, highly reliable, and longer-lifetime drivetrains, aiming to achieve 25 years of progress in 5 years. The efforts of this project will focus on NEXT-DRIVE Task 4 (led by ORNL, NREL, and AMES) - developing high-fidelity modeling framework and identifying technologies enabling heavy-rare-earth-free electric motors for medium- and heavy-duty vehicles to achieve 1 million miles of operation. Contrary to conventional approaches that optimize the motor for power density, the focus will be to identify motor designs that achieve the best trade-off between motor power density and durable operation. NREL tasks include development of high-fidelity motor thermal models incorporating rotor windage losses and identification, evaluation and measurement of motor interface materials in key thermal pathways. The poster summarizes NREL's accomplishments for the first half of FY 2025 and outlines future plans.

33 ADVANCED PROPULSION SYSTEMS↗

Optimizing Grid Regulation With Gravity Storage Systems: A Comparative Analysis With Different Motor Inertias

The integration of renewable energy sources into power grids necessitates solutions for grid support and stability during fluctuations in electricity generation and demand. Gravity energy storage systems (GESS) are emerging as a promising technology for managing the balance between energy supply and demand. However, their capacity to optimize energy flow and offer voltage and frequency regulation amid imbalances in generation and demand is less reported. This paper investigates the control of GESS for optimizing energy flow during voltage and frequency regulation. The study evaluates the regulation capabilities of GESS with different motor inertias during a Texas grid event: one with a high-speed, low-inertia motor and another with a low-speed, high-inertia motor. Results indicate that both GESS scenarios provide fast frequency response by converting potential energy into kinetic energy and vice versa, with a response time of 1.5 s from the frequency variation. This aligns with grid requirements for primary frequency response from traditional synchronous generators and motors with large inertia. Furthermore, a GESS based on a high-inertia motor may be able to operate over a broader range of frequency variations, whereas a low-inertia system may be limited by thermal constraints of the motor.

frequency regulation↗

Wearable Technology and Its Influence on Motor Development and Biomechanical Analysis

The convergence among biomechanics, motor development, and wearable technology redefines our understanding of human movement. These technologies allow for the continuous monitoring of motor development and the state of motor abilities from infancy to old age, enabling early and personalized interventions to promote healthy motor skills. For athletes, they offer valuable insights to optimize technique and prevent injuries, while in old age, they help maintain mobility and prevent falls. Integration with artificial intelligence further extends these capabilities, enabling sophisticated data analysis. Wearable technology is transforming the way we approach motor development and maintenance of motor skills, offering unprecedented possibilities for improving health, performance, and quality of life at every stage of life. The promising future of these technologies paves the way for an era of more personalized and effective healthcare, driven by innovation and interdisciplinary collaboration.

Morouço, Pedro (ORCID:0000000259569790)↗

Optimizing Grid Regulation With Gravity Storage Systems: A Comparative Analysis With Different Motor Inertias: Preprint

The integration of renewable energy sources into power grids necessitates solutions for grid support and stability during fluctuations in electricity generation and demand. Gravity energy storage systems (GESS) are emerging as a promising technology for managing the balance between the energy supply and demand. However, their capacity to optimize energy flow and offer voltage and frequency regulation amid generation-demand imbalances is less reported. This paper investigates the control of GESS for optimizing energy flow during voltage and frequency regulation. The study evaluates the regulation capabilities of GESS with different motor inertias during a Texas grid event: one with a high-speed, low-inertia motor and another with a low-speed, high-inertia motor. Results indicate that both GESS systems provide fast frequency response by converting potential energy into kinetic energy and vice versa, with a response time of 1.5 seconds from the frequency variation. This aligns with grid requirements for primary frequency response from traditional synchronous generators and motors with large inertia. Furthermore, a GESS with a high-inertia motor may be able operate over a broader range of frequency variations whereas a low-inertia system may be limited by thermal constraints of the motor.

frequency regulation↗

Optimizing Grid Regulation with Gravity Energy Storage Systems: A Comparative Analysis with Different Motor Inertias

The integration of renewable energy sources into power grids necessitates solutions for grid support and stability during fluctuations in electricity generation and demand. Gravity energy storage systems (GESS) are emerging as a promising technology for managing the balance between energy supply and demand. However, their capacity to optimize energy flow and offer voltage and frequency regulation amid imbalances in generation and demand is less reported. This paper investigates the control of GESS for optimizing energy flow during voltage and frequency regulation. The study evaluates the regulation capabilities of GESS with different motor inertias during a Texas grid event: one with a high-speed, low-inertia motor and another with a low-speed, high-inertia motor. Results indicate that both GESS scenarios provide fast frequency response by converting potential energy into kinetic energy and vice versa, with a response time of 1.5 s from the frequency variation. This aligns with grid requirements for primary frequency response from traditional synchronous generators and motors with large inertia. Furthermore, a GESS based on a highinertia motor may be able to operate over a broader range of frequency variations, whereas a low-inertia system may be limited by thermal constraints of the motor.

ENERGY STORAGE,POWER TRANSMISSION AND DISTRIBUTION↗

Experiments in 3D Printing Electric Motors

This paper catalogues a series of experiments we conducted to explore how to 3D print a DC electric motor. The individual parts of the electric motor were 3D printed but assembled by hand. First, we focused on a rotor with soft magnetic properties, for which we adopted ProtoPasta TM , which is a commercial off-the-shelf PLA filament incorporating iron particles. Second, we focused on the stator permanent magnets, which were 3D printed through binder jetting. Third, we focused on the wire coils, for which we adopted a form of laminated object manufacture of copper wire. The chief challenge was in 3D printing the coils, because the winding density is crucial to the performance of the motor. We have demonstrated that DC electric motors can be 3D printed and assembled into a functional system. Although the performance was poor due to the wiring problem, we showed that the other 3D printing processes were consistent with high performance. Nevertheless, we demonstrated the principle of 3D printing electric motors.

3D printed motor↗

Enhancing EV Motor Design Through Knowledge-Based AI and Hierarchical Fuzzy Logic Model

This work presents a novel approach to optimizing electric vehicle motor design through the integration of Knowledge-Based Artificial Intelligence (KB-AI) and Hierarchical Fuzzy Logic. Traditional motor design processes are time-intensive, relying heavily on iterative simulations and domain-specific expertise. These processes are further complicated by the nonlinear relationships between key design parameters. The proposed framework addresses these challenges by systematically encoding expert knowledge from scientific literature into a fuzzy logic system, allowing for the efficient handling of complex design variables. The hierarchical fuzzy logic model reduces computational complexity by decomposing the nonlinear relationships into manageable rule sets while maintaining design accuracy. The proposed methodology was applied to the design of a 100 kW motor, yielding optimal values for key parameters. This resulted in a compact motor design with a volume of 2.2 liters, showcasing the framework’s ability to deliver high-performance, application-specific motor configurations.

Kumar, Praveen [ORNL] (ORCID:0000000291877857)↗

Next-Generation Electric Motors and Electromagnetic Devices (CRADA Final Report)

As part of the Cyclotron Road program, the Foli Research team investigated electric motors and other electromagnetic devices additively manufactured by depositing fine conducting wire onto a substrate. By leveraging modern motion control and efficient upstream manufacturing processes, the team explored using geometric control and turnkey production comparable to printed circuit board manufacturing, aiming at ten-fold improvements in signal density, while eliminating the material use, cost, and complexity overheads of subtractive processes at large scales. Owing to the achievable density and additive scaling, disparate components became monolithic, and disparate processes were combined with the aim of reducing development costs, uncertainties, and timelines. When applied to electric motors, this technology may enable agile manufacturing of next-generation designs, with dramatic increases in achievable power density and material utilization. Electric motors represent the single largest user of electricity in the U.S. and a critical component of decarbonized infrastructure. Despite this significance, the manufacturing of motors and other electromagnetic devices remains capital-intensive, labor-intensive, and performance-limiting. Advanced manufacturing processes were required to produce high-performance, low-cost, application-specific electric motors and electromagnetic devices to support an electrified future.

42 ENGINEERING↗

Thermal Management Solution for an Integrated Outer-Rotor Motor Drive: Opportunities and Challenges

This work highlights an integrated thermal management solution for the outer-rotor motor (ORM) drive. The integrated ORM drive utilizes water-ethylene glycol coolant for power electronics and stator cooling. Air cooling is used for rotor laminations, magnets and outer-rotor structures, and the rotor shaft. To fully understand the performance of the integrated ORM drive and thermal management coupling effects, a full drive conjugate heat transfer model has been developed to investigate coupled cooling performance of various components of the ORM drive. Various motor rotational speeds, power output scenarios, and cooling options for the integrated ORM drive have been investigated. The model estimates the operating window for the ORM drive while keeping component operating temperatures below prescribed limits. The model also highlights the importance of windage losses at higher rotational speeds for this ORM design, which involves higher rotor surface area per unit width of the rotor. Different designs are also investigated, particularly focusing on rotor cooling with air either naturally induced by rotor spin or forced airflow with the help of a blower, to circumvent challenges imposed by higher windage losses. The work highlights motor rotational speed limitations and the need for potential liquid cooling options for desired rotor performance at higher rotational speeds. Liquid cooling for the rotor may even become more critical for nonuniform rotor-stator gaps, leading to even higher and uneven windage losses across the full circumference of the motor, consequentially, more heating for the rotor.

30 DIRECT ENERGY CONVERSION↗

An Additively Manufactured Fe-3Si Stator for a High-Performance Electrical Motor

Additive manufacturing (AM) has the potential to produce novel high-performance electrical machines, enabling the direct printing of complex shapes and the simultaneous processing of multiple feedstocks in a single build. We examined the properties and functional performance of Fe-3 wt.% Si materials that were printed via selective laser melting, machined down to thin laminates, and stacked to form a stator core of a prototype brushless permanent-magnet electrical motor. Big Area Additive Manufacturing of Nd2Fe14B (NdFeB)–polyphenylene sulfide (PPS) bonded magnets was performed, with them then being magnetized and used for the rotor. The magnetic, mechanical, and electrical properties of the as-printed and various heat-treated thin laminates and the back electromotive force (EMF) of the electrical motors at different rotational speeds were measured. The thin laminates exhibit a maximum relative permeability of 7494 at an applied field of 0.8 Oe and a core loss of about 20 W/lb at 60 Hz with the maximum induction of 15 kg. In addition to the demonstration of AM printing, motor assembly, and complete characterization of printed Fe-3 wt.% Si, this report highlights the areas of improvement needed in printing technologies to achieve AM built electrical motors and the need for isotropic microstructure refinements to make the laminates appropriate for high-mechanical-strength and low-loss rotational electrical devices.

36 MATERIALS SCIENCE↗

Electric Motor Thermal Management

The poster reports the accomplishments of EDT-Electric Motor Thermal Management consortium project for 2024 VTO Annual Merit Review (AMR). The overall aims of the project are to support research enabling compact, reliable, low-cost, and efficient electric machines aligned with roadmap research areas; to collaborate with ORNL, Ames, and SNL to provide motor thermal analysis support, reliability evaluation, and material measurements on related motor research at national laboratories; and collaborate with university partners including Georgia Institute of Technology and University of Wisconsin Madison to support university-led motor thermal management research efforts.

ADVANCED PROPULSION SYSTEMS↗

Quantum Computing for AI-based Design and Optimization of Electric Motors

Knowledge-based artificial intelligence and hierarchical fuzzy logic offer an interpretable framework for electricvehicle motor preliminary design, but their computational burden grows with linguistic granularity and coupled design-space size. This paper presents a reduced quantum reformulation of the hierarchical fuzzy inference of air-gap flux density, a representative level-one motor-design parameter. Starting from the published electric-vehicle motor-design framework, a three-term fuzzy prototype is constructed from the original inference structure. The reduced model is then reformulated as a modular quantum register-oracle system, in which each hierarchical subrelation is encoded as a block oracle and evaluated through superpositionbased candidate-label testing. The proposed modular quantum formulation reproduces the reduced classical prototype after block fusion. A resource analysis shows that the reduced modular system requires seven qubits per block and twenty-two qubits in a straightforward four-block implementation. Finally, a crossovercomplexity model is derived to identify the regime in which quantum candidate search may become favorable relative to hierarchical fuzzy inference. The results show that no quantum advantage should be claimed for the present one-output reduced benchmark, but that a plausible crossover emerges for larger joint candidate spaces and higher linguistic granularity. The work therefore establishes a technically consistent starting point for future quantum-assisted electric-vehicle motor-design optimization.

Kumar, Praveen [ORNL] (ORCID:0000000291877857)↗

Thermal Management System of an Outer-Rotor-Motor-Based Traction Drive With Integrated Power Electronics in its Central Cavity

Increasing power densities of electric vehicle traction drive systems necessitates combining the electric motor and the power electronics into one unit. A compact, integrated traction drive unit with fewer components also drives production costs down, enabling wider adoption of electric vehicles. However, the integration of power electronics in the electric machine is associated with challenges of designing an effective thermal management solution for the combined traction drive system. This paper focuses on the thermal management approach selected for Oak Ridge National Laboratory’s outer-rotor-motor-based integrated traction drive and evaluates its potential performance. The outer-rotor-motor configuration provided an opportunity for integration of the six-phase inverter in the available space in the central cavity of the internal stator. A cylindrical inverter enclosure with integrated coolant (water-ethylene glycol) channels in its walls was designed to enable heat removal from the power electronics. Numerical thermal-fluid modeling and initial channel/fin optimization results for the cylindrical heat sink are presented here. As permanent magnets are integrated in a high-speed (20 000 RPM) outer rotor, forced air convection provides cooling for the magnets. The magnets were segmented axially to mitigate the eddy current losses. Heat generated in the stator windings and laminations is removed by water-ethylene glycol coolant circulating in interpolar T-shape ceramic heat exchangers inserted between windings. General design concepts and numerical thermal-fluid simulations illustrating the electric motor thermal management solution are also presented.

Kekelia, Bidzina↗