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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 37 records · Page 2
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

Performance Evaluation of Three RTU Energy Efficiency Technologies

This project was part of an effort by CLEAResult and ComEd to evaluate the energy saving potential of emerging technologies in the Chicago area. This project focused on evaluating emerging technologies related to rooftop units (RTUs). An RTU with a single-stage compressor and a constant-speed fan with an induction motor was selected as the baseline for technology comparison. Three retrofit strategies were investigated. The first two involved replacing the single-stage compressor of an RTU by either a two-stage or variable-speed compressor and adding a variable frequency drive (VFD) to the constant speed fan. The use of a multi-/variable-stage compressor improves the part-load efficiency of the compressor which will ultimately result in annual energy savings as well as peak demand shaving in some cases where the design capacity of the RTU is larger than the maximum cooling load of the building space that it is serving. The third technology was the use of a high rotor pole switched reluctance motor (SRM) as a replacement for the constant-speed supply fan. The SRM was applied in single-speed, two-stage and variable-speed compressor RTUs. SRM motors run via reluctance torque. Their stator poles are driven by direct current (DC) power and require an inverter as well as active control when using alternating current (AC) power. This inherent property results in high efficiency over a range of operating conditions. It also exhibits higher efficiency compared to variable frequency drives (VFDs) since its switching frequency is much slower (SCE, 2018).The three technologies investigated are summarized below: 1) Replacing the single-speed compressor with a two-stage compressor and adding a VFD to the supply fan. 2)Replacing the single-speed compressor with a variable-speed compressor and adding a VFD to the supply fan. 3) Replacing the constant-speed induction motor of the supply fan with a high rotor pole SRM. DOE’s building simulation platform EnergyPlus and its graphical user interface OpenStudio were used to evaluate the energy-saving potential of upgrading RTUs, by leveraging experimental data from previous research.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2024

FIDVR Capability of Hybrid Grid-Forming PV Power Plants During Feeder Restoration

Grid-forming inverters must optimally transfer power from dc-coupled photovoltaic arrays and batteries into an ac grid. Further, they must be able to restore single-phase induction motors (SPIMs) and withstand fault-induced delayed voltage-recovery (FIDVR) events. These resilience and reliability challenges are addressed here by: (i) engineering a controller to optimally operate dc-coupled hybrid resources; (ii) modeling residential air-conditioning compressors for restoration/FIDVR studies; and (iii) analyzing SPIM thermal-relay performance under limited inverter currents and designing an electronic protection for stalled SPIMs. Furthermore, these contributions are demonstrated via electromagnetic-transient simulations and can be helpful to understand recommendations by the North American Electric Reliability Corporation.

14 SOLAR ENERGY↗
DOE OSTI2020

Toroidal Field Reversing Switch

A motor-driven, high-current switch is being designed by Stäubli Electrical Connectors in collaboration with Princeton Plasma Physics Laboratory to reverse the DIII-D Toroidal field coil current. The existing field reversing procedure requires approximately 4 h of labor performed between run days to reconfigure the bus work, thus requiring a separate run day to complete experimental scans with both field directions. This typically results in different wall conditions which complicate the results or make them invalid. The proposed switch will complete the reversal process in approximately 4-5 min, between shots, so that wall conditions are not a factor, and easily fits within the 10-12 min DIII-D shot cycle. The switch is a compact design fitting into a 157.5 × 41 cm envelope. The switch uses two copper pins that slide between Stäubli MULTILAM contacts. The switch is rated for total current of 180-kA dc for 10 s with a 12-min repetition rate; the maximum operating coil current is 124-kA dc. The switch diagnostics include: voltage drop, current monitor, thermal monitors, position sensors, and motor torque. Here, the switch is rated for 300 cycles per year, and 3000 cycles overall before contact replacement, with contact inspection yearly. The design details and operation of the switch are covered in this article.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2026

A High Power Density and High Efficiency Traction Drive Based on a Segmented Inverter and an Axial and Radial Flux Hybrid Machine

Eaton Corporation and Oak Ridge National Laboratory (ORNL) collaborated to develop a high performance traction drive system aimed at increasing power density and overall efficiency. The system integrates Eaton’s hybrid flux motor—combining radial and axial flux paths to convert end-winding and structural elements into torque-producing components—with ORNL’s high-power-density segmented inverter. This motor design achieves higher torque density within the same footprint as traditional radial flux machines by effectively utilizing end turns. ORNL’s segmented inverter reduces the DC bus capacitor requirement by over 50% compared to standard voltage source inverters (VSIs), achieving power densities exceeding 100 kVA/L. The dual-module architecture also enables six-phase operation, aligning with Eaton’s motor design. Together, the motor and inverter offer a compact, efficient traction drive system with the potential for significant reductions in system weight and improvements in powertrain efficiency.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2020

Validation and Parametric Investigations Using a Lumped Thermal Parameter Model of an Internal Permanent Magnet Motor

One of the key challenges for the electric vehicle industry is to develop high-power-density electric motors. Achieving higher power density requires efficient heat removal from inside the motor. In order to improve thermal management, a multi-physics modeling framework that is able to accurately predict the behavior of the motor, while being computationally efficient, is essential. This paper first presents a detailed validation of a Lumped Parameter Thermal Network (LPTN) model of an Internal Permanent Magnet (IPM) synchronous motor within the commercially available Motor-CAD® modeling environment. The IPM motor’s stator is studied at steady state, and winding losses are generated by a constant DC current. The validation is based on temperature comparison with experimental data and with more detailed Finite Element Analysis (FEA). All critical input parameters of the LPTN are considered in detail for each layer of the stator, especially the contact resistances between the impregnation, liner, laminations and housing. Finally, a sensitivity analysis for each of the critical input parameters is provided. A maximum difference of 4% — for the highest temperature in the slot windings and the end windings — was found between the LPTN and the experimental data. Comparing the results from the LPTN and the FEA model, the maximum difference was 2% for the highest temperature in the slot windings and end windings. As for the LTPN sensitivity analysis, the thermal parameter with the highest sensitivity was found to be the liner-to-lamination contact resistance. The latter is often ignored in the literature, whereas its impact on temperature rise was found to be more significant than any other contact resistance within the stator.

47 OTHER INSTRUMENTATION↗
DOE OSTI2020

Validation and Parametric Investigations Using a Lumped Thermal Parameter Model of an Internal Permanent Magnet Motor: Preprint

One of the key challenges for the electric vehicle industry is to develop high-power-density electric motors. Achieving higher power density requires efficient heat removal from inside the motor. In order to improve thermal management, a multi-physics modeling framework that is able to accurately predict the behavior of the motor, while being computationally efficient, is essential. This paper first presents a detailed validation of a Lumped Parameter Thermal Network (LPTN) model of an Internal Permanent Magnet (IPM) synchronous motor within the commercially available Motor-CAD® modeling environment. The IPM motor’s stator is studied at steady state, and winding losses are generated by a constant DC current. The validation is based on temperature comparison with experimental data and with more detailed Finite Element Analysis (FEA). All critical input parameters of the LPTN are considered in detail for each layer of the stator, especially the contact resistances between the impregnation, liner, laminations and housing. Finally, a sensitivity analysis for each of the critical input parameters is provided. A maximum difference of 4% - for the highest temperature in the slot windings and the end windings - was found between the LPTN and the experimental data. Comparing the results from the LPTN and the FEA model, the maximum difference was 2% for the highest temperature in the slot windings and end windings. As for the LTPN sensitivity analysis, the thermal parameter with the highest sensitivity was found to be the liner-to-lamination contact resistance. The latter is often ignored in the literature, whereas its impact on temperature rise was found to be more significant than any other contact resistance within the stator.

ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2025

DC-Link Capacitor Design for a Neutral-Point-Less Three-Level Dual-Phase Inverter for Traction Application

Conventional multilevel inverters, such as neutral￾point-clamped and T-type inverters, have gained popularity in electric vehicle applications due to their advantages, including high voltage range, high power capability, low switching losses, low total harmonic distortion, and low electromagnetic interference. However, these traditional multilevel inverters require a neutral point connection to generate a zero-voltage vector. The neutral point current oscillates at three times the fundamental frequency, leading to voltage imbalance and overvoltage stress on the power modules. Additionally, the use of two stacked DC-link capacitors increases the volume required for the same overall capacitance and complicates packaging due to ripple current and heat dissipation from separate components. This is a significant concern for traction drive units, where space is limited. In this paper, a neutral-point-less multilevel dual three￾phase inverter topology is investigated for traction inverter applications. Simulation results demonstrate that the proposed topology effectively retains the benefits of multilevel operation while utilizing a single DC-link capacitor. The inverter model was simulated in conjunction with an industry-standard battery model to evaluate the potential for capacitor size reduction compared to a conventional three-level inverter.

33 ADVANCED PROPULSION SYSTEMS↗
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 OSTI2025

Multi-objective automatic discovery of optimized metamaterials for varying velocity impact protection

Mechanical metamaterials have demonstrated exceptional impact performance while remaining lightweight. Impact resistance has traditionally been investigated using quasi-static simulations, often with the assumption that performance will translate to high-velocity impact scenarios. However, critical crash protection parameters—such as peak stress and absorbed energy—are highly sensitive to impact velocity, leading to inconsistent performance under dynamic loading. To address this, we introduce a strain-rate-aware, active deep learning framework that enables multi-objective optimization of impact protection metrics across a wide range of impact velocities. Our framework captures the strain-rate sensitivity of architected lattices by learning to control spatial gradation in cellular metamaterials, resulting in over 200 % enhancement in impact protection relative to state-of-the-art designs such as Voronoi and re-entrant lattices. We demonstrate its practical utility by designing next-generation lattice structures for automotive bumper systems that satisfy multiple, velocity-specific safety criteria—capabilities beyond those of conventional designs. More than just a predictive tool, this framework marks the first step towards enabling adaptable impact-resistant structures across dynamic regimes.

Deep learning↗
DOE OSTI2022

Wound Field and Hybrid Synchronous Machines for EV Traction with Brushless Capacitive Rotor Field Excitation (Final Report)

This project focused on the development of wound field synchronous machines (WFSMs) and hybrid excitation synchronous machines (HESMs) with brushless capacitive power transfer for the field excitation. The target application for the machines developed is the main traction motor in electric vehicles. The magnetization in these types of machines is provided by a field winding on the rotor which is excited with DC current. The magnetization level in the machine can be varied by changing the magnitude of the field current. The variable magnetization or field is one of the key features of WFSMs. WFSMs are commonly used as generators however they have several attractive features for automotive traction applications. 1) No use of permanent magnet: Rare earth permanent magnets are primarily mined and processed in China. They have been subject to large price and supply variations and their export may be restricted during times of geopolitical tension. 2) Easy field weakening: Wound field synchronous machines have complete control of their field excitation. With proper design, this type of machine can electromagnetically have an infinite constant power speed range. 3) High power factor: With proper choice of the field excitation, WFSMs may be operated with high or even unity power factor. This potentially allows for the inverter connected to the stator winding to be downsized. In comparison induction machines and interior permanent magnet synchronous machines must supply reactive power to the stator increasing the kVA rating and cost of the inverter. 4) Reduced iron losses at high speed: By reducing the field excitation, the iron loss in the stator can be reduced. This is in comparison to interior permanent magnet synchronous machines which must use stator current to buck or reduce the flux produced by the permanent magnets. Generally, WFSMs have their highest efficiency at high speed. 5) Torque output at high temperatures: The magnetization provided by the field winding only depends on the field current and not on the field winding temperature. This is in contrast to permanent magnet machines where the permanent magnet flux decreases as the magnet temperature increases. Historically a number of approaches have been developed to provide DC current to the rotating field winding in WFSM’s including brushes and slip rings, low frequency brushless exciters, and high frequency rotary transformers and rectifiers. In this project, a different approach was used: brushless capacitive power transfer. Brushless capacitive power transfer uses two sets of rotating capacitors or electrodes in which an AC electric field is established by a high frequency inverter. A displacement current can flow through the airgap in the rotating capacitors which is rectified on the rotor using a diode bridge. The potential advantage of capacitive power transfer is that there is no need for heavy iron to guide magnetic flux. The electric flux lines terminate on the charges on the rotary capacitor surfaces. This should also limit the electric field outside the rotary capacitor airgaps. The main challenge with capacitive power transfer is that the capacitance and surface area of the rotating capacitors is small. Because capacitive power transfer systems are essentially a dual of a magnetic system, an Ampere per Hertz relationship is characteristic versus a Volts per Hertz relationship. A very high frequency power inverter must be used to provide sufficient excitation to the field winding. The concept of using capacitive power transfer to excite a high performance WFSM was initially developed in a previous U.S.A. Dept. of Energy project, DE-EE0006829. This project focused on increasing the power density of the WFSMs and reducing the cost and manufacturing complexity of the capacitive power transfer system. This project has demonstrated that WFSMs with brushless capacitive field power transfer can provide a high-power density and low-cost automotive powertrain technology.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2025

Property optimized energy absorber for automotive bumpers utilizing multi-material and structural design strategies

This study proposes a novel design for automotive bumper using optimized lattice structures and multi-materials to balance low-speed collision and high-speed pedestrian impact performance. Different blends of 20 % carbon fiber-reinforced acrylonitrile butadiene styrene with thermoplastic polyurethane were used to tailor material properties. The energy absorber features lattice structures with customized mechanical responses, created by varying the incline angle θ from 0 to 180°. We conducted 576 finite element simulations on a half-scale model to optimize energy absorption and stiffness, leading to 66 optimized designs that met both low-speed and high-speed impact criteria. Two sub-scale optimized energy absorbers with different peak forces—both meeting low-speed impact requirements—were 3D printed and validated through drop-weight testing. The one with lower peak stress demonstrated a more compliant response, exhibiting approximately 90 % lower initial peak force and an increase in energy absorption of around 33 % (from 24 J to 32 J). Compared to the baseline triangular lattice, the optimized absorber increased energy absorption by 68 % from (19 J to 32 J) and reduced peak stress by 70 %. It also showed near-complete recovery with minimal fractures, making it suitable for repeated use. This design improves safety while offering a lightweight, durable, and cost-effective bumper system.

36 MATERIALS SCIENCE↗
DOE OSTI2020

FAST: Continuing the Focus on Data Quality

This presentation provides an overview of fiscal year 2019 federal motor vehicle fleet data, collected at the individual vehicle level during the fall of 2019, how the the collecting project has reviewed that information for potential quality issues, how the quality of this year's data submission compare to the prior year, and recommendations for federal agencies in their efforts to continue to improve the quality of their submissions. This presentation will be given at the January 2020 FedFleet training event, hosted by the US General Services Administration in Washington, DC. The information is collected through the Federal Automotive Statistical Tool (FAST) project. FAST is a Web-based information system managed by the US Department of Energy, the US General Services Administration, and the Energy Information Administration. FAST is used to collect information about the fleet of motor vehicles used and managed by the Federal government. FAST is developed and maintained by DOE's Idaho National Laboratory (INL).

99 GENERAL AND MISCELLANEOUS↗
DOE OSTI2023

Electrification: 2023 Final Progress Report

This project proposes to develop a high-power density, high speed traction motor architecture called QMag, driven by a high-power density motor drive inverter using silicon carbide semiconductor devices. This new architecture will achieve the efficiency and power density targets by means of innovative winding and rotor structures, high bandwidth controls, and advanced thermal management solutions. The project team will pursue the goals of the project systematically, through Finite Element Analysis for machine design, through simulation and co-simulation techniques for power electronics and controls evaluation, and finally system design, fabrication, testing and evaluation. If this project successfully achieves and demonstrates the DOE targets for power density, cost, and reliability, the technology has the potential to become a core enabler of the flagship higher power product portfolio in commercial traction businesses, which has so far been confined to DC, induction, Brush Less DC (BLDC), Permanent Magnet AC (PMAC), and reluctance machines.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2024

Integrated Motor and Drive (IMD) for Traction Applications Project (Final Technical Report)

This paper proposes the concept of the topological equivalence between the commutation cells of a voltage source inverter (VSI) and a current source inverter (CSI) using duality and equivalent circuit transformation techniques. A switching resonance of CSI is analyzed and an effective three-phase RC damper is derived from the dc-link RC damper of VSIs based on the topological equivalence of the VSI and CSI commutation cells. Furthermore, a new three-phase RC damper design framework utilizing the topological equivalence is proposed. Experimental results verify that the proposed three-phase RC damper design for CSI significantly reduces the switching resonance and improves the CSI’s output waveform total harmonics distortions (THDs).

42 ENGINEERING↗
DOE OSTI2020

Pulse-train drive system for electrostatic generators and motors

A novel motor drive system has been described for use in electrostatic generator/motor systems based on the time variation of capacity of a rotating condenser comprised of segmented rotor and stator elements. It takes advantage of the fact that the motor action of such a system depends only on the rms value of the drive pulses, which therefore can be formed simply by periodically interrupting a high-frequency ac wave train. This new circuitry simplifies the drive system and takes advantage of recent developments of devices used in the art of inversion of dc voltages to high-frequency (tens of kiloHz) ac.

42 ENGINEERING↗
DOE OSTI2023

A Data-Driven Passive Islanding Detection Scheme

This paper proposes a novel statistical parameters based data driven approach for passive islanding detection. The proposed scheme relies in the voltage data, measured at the point of common coupling, and is comprised of three stages. The Stage-1 quickly detects what is termed as coarse islanding, Stage-2 computes the decaying DC detector (DDCD), and 3) finally, the digital relay logic (DRL) is devised in Stage-3. The proposed scheme is tested as per the IEEE-1547, UL 1741 and IEC-62116 standards. Various tests are investigated on the modified IEEE-13 bus system, modeled in PSCAD/EMTDC, under stringent test scenarios such as power mismatch, induction motor starting effect, capacitor bank switching and various level of loads changes, considered for both single and multiple DG systems. The test results reveal that the proposed scheme can detect islanding in less than 2 cycles, and results in nearly zero non detection zone (NDZ). Also, the scheme can very well be used for single-phase microgrids too as it relies only on the single phase voltage information.

anti-islanding protection↗
DOE OSTI2025

Inverse Segmented Motor Drive Using Dual ANPC Inverters for Common-Mode Voltage and Neutral-Point Current Cancellation

This article proposes an inverse segmented motor drive (SgMD) utilizing dual active neutral point clamped (ANPC) inverters. In the proposed configuration, the neutral point current and common-mode (CM) voltage is topologically canceled, achieving zero total neutral point current and CM voltage under ideal conditions. Also, the zero total neutral point current minimizes the neutral point voltage imbalance in ANPC inverters. The mechanisms behind neutral point current and CM voltage cancellation in the proposed inverse SgMD are first introduced. The modifications to the motor windings for implementing the inverse SgMD are explained, showing that a standard motor can be readily adapted for the proposed configuration. A space vector modulation (SVM) scheme tailored for the proposed topology is presented, along with a carrier-based implementation. Simulation results validate that the proposed topology can achieve zero total CM voltage and neutral point current. It is also shown that the proposed inverse SgMD can reduce neutral point voltage fluctuation by about 90% and RMS current stress in the dc-link capacitors by about 43% compared to the conventional SgMD.

Lee, Sangwhee [ORNL] (ORCID:0000000335490057)↗
DOE OSTI2022

A Universal Converter for DC, Single-phase AC, and Multi-phase AC Systems (Final Report)

The goal of this project was to develop a new class of universal power converters that utilize the unique properties of WBG switches, including high reverse voltage blocking and fast switching, to achieve superior performance in universal converters. Some of the features of the proposed converter are as follows: 1) Significantly longer lifetime, higher power density, lower costs associated with bill of materials, and lower shipping, installation, and repair costs compared to the existing WBG-based solutions, 2) Very flexible operation for transferring power between any type of source (dc, single-phase ac, or multi-phase ac) and any type of load (dc, single-phase ac, or multi-phase ac) without using large passive components or additional stages/components, even when the instantaneous values of input and output power are not the same, and 3) High performance operation at all power levels. Considering its advantages and wide range of applications, the proposed converter has the potential to create a new paradigm in power electronics. Among numerous applications of this converter are electric vehicles, wind energy systems, PV systems, industrial motor drives, residential variable frequency drive systems, and nanogrid applications. This project focused on the application of this converter for residential PV, residential motor drive, and industrial motor drive applications, and evaluated the performance of this converter for these applications.

42 ENGINEERING↗