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Matthew Granger

Publications and source records attributed to Matthew Granger.

At least 19 records

X-57 Electromagnetic Interference Design, Integration, and Test Consideration

X-57 is NASA’s first all electric aircraft that utilizes existing airframe of Tecnam 2006P GA aircraft integrated with new all electric power train. The objective of the project was to deliver high performing distributed electric propulsion system while developing US industry in the area of EAP. The project was divided into three distinct flight mods, each serving as a risk reduction efforts to final mod where full distributed power train with highly modified wing structure would be tested in flight. Flight weight, efficient power electronics are enablers for distributed, electric aircraft propulsion systems, and GRC team has developed high power and highly efficient SiC based converters for both cruise and high lift systems on the aircraft. Both controller’s development efforts demonstrate a means to achieve an in-the-nacelle controller with purely passive cooling while maintaining high efficiency. This paper describes the lessons learned on design, integration, and testing challenges that X-57 faced while developing these novel technologies.

Power Train↗

Combined Analysis of NASA's High Efficiency Megawatt Motor and Its Converter

NASA’s High Efficiency Megawatt Motor (HEMM) is being developed to achieve the performance needed by single aisle class electrified aircraft. It is a 1.4 MW electric machine designed as a generator for NASA’s STARC-ABL concept vehicle. It has performance objectives of greater than 16 kW/kg electromagnetic specific power and efficiency of greater than 98%. The key enabling technology for HEMM’s high performance metrics is a superconducting rotor cooled by an integrated cryocooler. HEMM’s integrated cryocooler is being designed to only lift 50 W of heat at its target 50 K cold tip operating temperature. HEMM’s superconducting rotor therefore needs to have essentially zero electromagnetic losses in order to stay below the 50 W heat rejection limit of the cryocooler. This paper presents the combined analysis of HEMM and a preliminarily designed HEMM converter to analyze the rotor loss impact of several potential converter filter topologies. The analysis results point to interleaving and series inductance filters not being sufficient to suppress switching harmonic caused rotor loss. Paths forward to develop a converter to eliminate rotor loss are discussed.

Matthew Granger↗

Combined Analysis of NASA's High Efficiency Megawatt Motor and Its Converter

NASA’s High Efficiency Megawatt Motor (HEMM) is being developed to achieve the performance needed by single aisle class electrified aircraft. It is a 1.4 MW electric machine designed as a generator for NASA’s STARC-ABL concept vehicle. It has performance objectives of greater than 16 kW/kg electromagnetic specific power and efficiency of greater than 98%. The key enabling technology for HEMM’s high performance metrics is a superconducting rotor cooled by an integrated cryocooler. HEMM’s integrated cryocooler is being designed to only lift 50 W of heat at its target 50 K cold tip operating temperature. HEMM’s superconducting rotor therefore needs to have essentially zero electromagnetic losses in order to stay below the 50 W heat rejection limit of the cryocooler. This paper presents the combined analysis of HEMM and a preliminarily designed HEMM converter to analyze the rotor loss impact of several potential converter filter topologies. The analysis results point to interleaving and series inductance filters not being sufficient to suppress switching harmonic caused rotor loss. Paths forward to develop a converter to eliminate rotor loss are discussed.

Matthew Granger↗

Design of a High Power Density, High Efficiency, Low THD 250kW Converter for Electric Aircraft

A high efficiency, high power density, low distortion 250kW motor controller is being developed at NASA Glenn Research Center. Future electric aircraft require motor controllers which achieve the needed key performance parameters required to show benefit in increasing overall aircraft efficiency. Through a combination of carefully considered electrical topological choices and through the use of recent advancements in power switches and magnetic materials, a converter is designed which meets these requirements. A multilevel and interleaved converter architecture is chosen to meet the voltage, current, and THD requirements. The enclosure and thermal designs meet their weight targets and enable high altitude operation.

Matthew Granger↗

Powering the Moon: From Artemis Technology Demonstrations to a Lunar Economy

The National Aeronautics and Space Administration (NASA) is working towards developing and demonstrating new technologies, capabilities, and business approaches that are needed for future human deep space exploration missions. This includes collaborating with commercial and international partners to establish the first long-term presence on the Moon under the Artemis mission. Artemis lunar surface operations begin with robotically exploring the lunar south polar region for locations suitable for harvesting lunar surface resources. Over time, activities will expand beyond robotic operations, increasing the need for highly reliable and available electrical power. Beyond Artemis, there are interests in full commercial lunar surface activities. A lunar microgrid is being proposed to deliver highly reliable and available electrical power on the lunar surface and meet the power needs. Microgrids are of interest in terrestrial applications due to their ability to integrate a variety of renewable power sources. A similar approach can be taken for the lunar surface. A lunar microgrid would offer the ability to integrate various power sources to maximize power availability, including nuclear, solar arrays, batteries, and regenerative fuel cells. Microgrids are flexible and can be designed to allow for islanded operation, where power is utilized near the loads to minimize power distribution losses, or in a power sharing mode where power is transmitted longer distances. This capability is crucial during failures where overall power availability is reduced. Microgrids will also allow for the power system to grow and evolve over time, meeting the need to expand beyond initial lunar surface activities.

Jeffrey Csank↗

Design Techniques for Lightweight Aircraft Motor Drives

Electric aircraft require a propulsion system with a high specific power. Designing electric motor drives for aeronautics applications is a multidisciplinary effort which requires complex design and construction techniques to achieve the desired performance metrics. This presentation explains some of the electrical, mechanical, thermal, and magnetics design techniques used in these motor drives. The presentation also shows how the techniques are used in two ongoing NASA EAP projects.

Aircraft Motor Drive↗

Establishing a Lunar Surface Power Grid

The National Aeronautics and Space Administration (NASA) is seeking to develop a lunar surface power system for its Artemis missions as well as for planned future commercial lunar surface activities. This power system is composed of a number of assets which contain electrical loads and many of these contain energy resources. These assets can be connected to form a grid, which allows power to be shared between the system’s distributed energy resources. This grid can provide backup power to existing assets as well as primary power to future assets. A trade study was conducted for an Artemis scale grid, which has identified 3 kV AC as an ideal transmission voltage. Development work has also begun for a universal modular interface converter (UMIC) which connects assets and microgrids operating at 120 V DC space power to the grid. Products from this grid definition and UMIC development work will enable highly reliable and available power for Artemis and future planetary surface missions, which is key to achieving NASA’s long term vision of space exploration.

Planetary surface power↗

Design and Testing of a Hard-Fault Protection Circuit for a 1 kV SiC MOSFET Inverter

Due to increasingly high DC link voltages and further advancements in the current density of silicon carbide (SiC) MOSFETs, it has become evident that conventional IGBT protection methods are not sufficient to prevent exceeding the current rating of these devices during low-inductance fault events. This paper explores the use of an air core Rogowski coil topology to mitigate these hard fault events. The design of this circuit resulted in safe shutdown of a low impedance phase-to-phase fault in under one microsecond, tested up to DC link voltages of 1 kV. This paper details the theory, design, simulation, and successful test results of this method.

hard fault protection↗

Lunar Microgrid Trade Studies to Define Interface Converter Requirements

The National Aeronautics and Space Administration (NASA) is interested in developing an incremental lunar power grid to support continuous human/robotic operations under the Artemis missions and can scale to global power utilization and industrial power levels. The initial lunar surface power system will be composed primarily of assets that contain their own power generation and energy storage. These assets can be connected to form a grid, which allows power to be shared between the system’s distributed energy resources. This grid can provide backup power to existing assets as well as primary power to future assets. A trade study was conducted for an Artemis scale grid, which has identified 3 kVAC as an ideal transmission voltage. This paper documents the analysis and findings from these trade studies. These studies were used to define the operating voltage and develop a common interface for connecting lunar surface assets to the power grid. The Universal Modular Interface Converter (UMIC) connects lunar surface assets to the high voltage grid. Products from this grid definition and UMIC development work will enable highly reliable and available power for Artemis and future planetary surface missions, which is key to achieving NASA’s long-term vision of space exploration.

Planetary surface power↗

A Modular AC to DC Interface Converter to Enable Lunar Surface Power Transmission

NASA is developing technology to enable sustained operations on extraterrestrial planetary bodies such as the Moon and Mars. One fundamentally enabling technology is long-distance electrical power transmission. This paper describes the Universal Modular Interface Converter (UMIC), which connects 120 VDC space power equipment to a 3 kVAC grid, and is intended to enable kilometer-distance transmission of 1s to 10s of kW of electrical power to support Artemis and future lunar missions. Specifically, this paper describes the technology within the UMIC product, its electrical power interfaces, and the state of its development. It also describes initial hardware and simulation test results of the UMIC.

Planetary surface power↗

Hard Fault Protection for a Silicon Carbide-Based Aerospace Motor Drive

Due to increasingly high DC link voltages and further advancements in the current density of silicon carbide (SiC) MOSFETs, it has become evident that conventional IGBT protection methods are not sufficient to protect these devices from overcurrent during low-inductance fault events. The use of an air core Rogowski coil topology was explored to see if it could mitigate these hard fault events. The design of this circuit resulted in safe shutdown of a low impedance phase-tophase fault, tested up to DC link voltages of 1 kV.

High Voltage↗

NASA's X-57 High Lift Motor Controller: Detailed Design, Test Results, and Outcomes

NASA's X-57 all-electric aircraft was a research project aimed at investigating lightweight and efficient electric propulsion components. The general approach was to utilize a distributed electric propulsion (DEP) design. An essential component of this design was the High Lift Motor Controller (HLMC), a motor drive which provided power to the High Lift Motors (HLMs) and High Lift Propellers (HLPs) responsible for providing additional thrust for take-off and landing. This paper presents the detailed design, test results, and outcomes from the development of the HLMC, a 14 kW, 1kg, 98.3% efficient, outer mold line (OML) cooled, silicon carbide (SiC) MOSFET-based inverter and controller.

Electric Aircraft↗

Design and Development of a Fluid Immersion Cooled, SiC MOSFET, 37.5 kW, Bi-Directional Motor Converter

NASA's SUb-sonic Single Aft eNgine (SUSAN) aircraft is a concept aircraft whose architecture is that of a subsonic regional jet transport aircraft. SUSAN contains a single turbofan engine coupled to an electrified aircraft propulsion (EAP) system. To provide a path towards this goal, a 25% scale version of the SUSAN aircraft is being researched. A main component of the 25% power train is the Motor And Generator Intelligent Converter (MAGIC). This paper presents the design, development, and initial test results from MAGIC, a 37.5 kW, fluid immersion cooled, silicon carbide (SiC) MOSFET-based, bi-directional converter and controller.

PAO↗

Design and Development of a Fluid Immersion Cooled, SiC MOSFET, 37.5 kW, Bi-Directional Motor Converter

NASA's SUb-sonic Single Aft eNgine (SUSAN) aircraft is a concept aircraft whose architecture is that of a subsonic regional jet transport aircraft. SUSAN contains a single turbofan engine coupled to an electrified aircraft propulsion (EAP) system. To provide a path towards this goal, a 25% scale version of the SUSAN aircraft is being researched. A main component of the 25% power train is the Motor And Generator Intelligent Converter (MAGIC). This paper presents the design, development, and initial test results from MAGIC, a 37.5 kW, fluid immersion cooled, silicon carbide (SiC) MOSFET-based, bi-directional converter and controller.

Immersion↗

Leveraging High-Level Synthesis to Migrate Motor Control Algorithms From Microcontroller to FPGA

As motor control algorithms become increasingly complex, traditional microcontroller-based implementations are reaching computational limits that prevent the controller from operating at the required speed. This paper presents a novel workflow leveraging High-Level Synthesis (HLS) to migrate motor control algorithms from a microcontroller implementation to a Field-Programmable Gate Array (FPGA) implementation. The proposed approach utilizes the free Vitis HLS software to automatically convert Embedded Coder-generated C code from a Simulink model into Hardware Description Language (HDL) code suitable for FPGA deployment.

FPGA↗