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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
NASA NTRS2024

Preliminary Measurements of Partial Discharge Inception Voltage Degradation with Constant Temperature Aging of Magnet Wire Twisted Pairs for Electric Aircraft Motors

Electric aircraft require high reliability electric motors to meet the stringent safety standards of the aviation industry. Motor winding insulation lifetime and reliability models for electric aircraft applications are needed to enable design of high reliability and high-performance electric motors for aviation applications. Three primary stresses effect the lifetime of motor winding insulation: thermochemical, mechanical, and electrical. This paper presents preliminary experiments on twisted pairs of magnet wire targeting understanding the thermo-chemical degradation of motor winding insulation through constant temperature thermal aging. Three types of magnet wire twisted pairs where tested: polyimide insulated magnet wire, epoxy coated polyimide insulated magnet wire, and epoxy potted polyimide magnet wire. The degradation of the samples over time at temperature was tracked using partial discharge inception voltage measurements. These initial experiments were used for development of procedures and expertise in partial discharge testing and thermo-chemical aging to inform future testing. The preliminary nature of these experiments should be noted when viewing the results. Lessons learned from the experiments are documented.

Thomas Tallerico↗
NASA NTRS2018

Electric Motor Noise from Small Quadcopters: Part 1 - Acoustic Measurements

There is increased interest in using electric motors to drive propulsors across a range of small air vehicle classes. Applications include both vertical lift and conventional takeoff and landing systems for Small Unmanned Aircraft Systems. Mission profiles call for integrating these systems into urban airspaces exposing populated areas to new noise sources. In addition to the propulsor noise from rotors and propellers, electric motors are expected to contribute to the overall sound levels and possibly human annoyance. This work presents acoustic measurements of electric motors used for small quadcopters to characterize the sound and identify sources with and without a propeller. Free field microphone measurements were used to determine directivity and a phased microphone array was used to identify sound sources. A companion paper (Part II - Source Characteristics and Prediction) compares the far field results with current probe measurements of the signal driving the motor, the structural response of the motor case, and describes prediction methods of electric motor noise.

Electric Propulsion↗
NASA NTRS2018

Electric Motor Noise for Small Quadcopters: Part I - Acoustic Measurements

There is increased interest in using electric motors to drive propulsors across a range of small air vehicle classes. Applications include both vertical lift and conventional takeoff and landing systems for Small Unmanned Aircraft Systems. Mission profiles call for integrating these systems into urban airspaces exposing populated areas to new noise sources. In addition to the propulsor noise from rotors and propellers, electric motors are expected to contribute to the overall sound levels and possibly human annoyance. This work presents acoustic measurements of electric motors used for small quadcopters to characterize the sound and identify sources with and without a propeller. Free field microphone measurements were used to determine directivity and a phased microphone array was used to identify sound sources. A companion paper (Part II – Source Characteristics and Prediction) compares the far field results with current probe measurements of the signal driving the motor, the structural response of the motor case, and describes prediction methods of electric motor noise.

Aircraft Noise↗
DOE OSTI2024

Aircraft electric motor having a stator heat pipe cooling scheme

Aircraft electric motors are described. The aircraft electric motors include a motor unit having a rotor and a stator, wherein the stator includes a plurality of windings and cooling channels arranged to provide cooling to the plurality of windings, a drive unit configured to drive operation of the motor unit, and a cooling system. The cooling system includes an oscillating heat pipe containing a first working fluid, wherein the oscillating heat pipe is arranged to pick up heat from at least one winding, the oscillating heat pipe having an evaporator section arranged in thermal contact with the at least one winding and a condenser section arranged away from the evaporator section and a heat pickup portion arranged to receive a second working fluid to remove heat from the condenser section of the oscillating heat pipe.

Saviers, Kimberly Rae↗
DOE OSTI2025

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↗
NASA NTRSDate not supplied

An Initial Vibro-Acoustic Model for Predicting Electric Motor Noise

A system-level tool to predict electric motor noise, suitable for trade studies of eVTOL and UAM aircraft, does not exist. This work describes the ongoing effort to develop such a tool. It utilizes a 3 phase prediction routine that models the electro-magnetic interactions of the electric motor, the resulting structural vibrations of the motor rotor, and finally the acoustic propagation generated by those structural vibrations.

Electric Motor Noise↗
NASA NTRSDate not supplied

An Initial Electric Motor Rotor Vibration Model

Ongoing integration of outrunner brushless electric motors into drones and Advanced Air Mobility aircraft presents a need for accurate acoustic predictions derived from prediction of the motor rotor vibrations. In outrunner motors, the external rotor vibrates and drives the acoustic field. At resonant frequencies of the rotor, the rotor displacements will be the largest. The vibrations can lead to acoustic tones that are relevant to the overall acoustic design of these types of vehicles. This study performs a finite element analysis to assess the modes in two electric motor rotors. This model is then refined into a simple parameterized geometry that can make the same predictions for motors of the same class. A parametric sweep and least-squares-curve fit to the finite element analysis data results in a series of simple curves that can predict the mode shapes and frequencies that are likely to appear in this class of motors without the need for any simulation. The simulations are validated by comparison to acoustic and experimental modal-analysis data.

Electric Motor Noise↗
NASA NTRSDate not supplied

An Initial Electric Motor Rotor Vibration Model

Ongoing integration of outrunner brushless electric motors into drones and Advanced Air Mobility aircraft presents a need for accurate acoustic predictions derived from prediction of the motor rotor vibrations. In outrunner motors, the external rotor vibrates and drives the acoustic field. At resonant frequencies of the rotor, the rotor displacements will be the largest. The vibrations can lead to acoustic tones that are relevant to the overall acoustic design of these types of vehicles. This study performs a finite element analysis to assess the modes in two electric motor rotors. This model is then refined into a simple parameterized geometry that can make the same predictions for motors of the same class. A parametric sweep and least-squares-curve fit to the finite element analysis data results in a series of simple curves that can predict the mode shapes and frequencies that are likely to appear in this class of motors without the need for any simulation. The simulations are validated by comparison to acoustic and experimental modal-analysis data.

Electric Motor Noise↗
DOE OSTI2025

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↗
NASA NTRS2019

CAMIEM: Compact Additively Manufactured Innovative Electric Motor

New manufacturing methods are needed to obtain innovative electric motor designs that have much higher power densities and/or efficiencies compared to the current state-of-the-art. Additive manufacturing offers the potential to radically change motor designs so that they have compact designs, multi-material components, innovative cooling, and optimally designed and manufactured components. New component designs enabled by additive manufacturing technologies have been designed and were fabricated to include the housing, rotors, stator cooling ring, a direct printed stator, and a wire embedded stator. The new components were integrated into the motor and tested evaluate the performance gains in comparison to the baseline electric motor configuration. Partners on the sub-project include NASA GRC, NASA LaRC, NASA AFRC, LaunchPoint Technologies, and the University of Texas El Paso.

Halbig, Michael C.↗
NASA NTRS1980

Torque control for electric motors

Method for adjusting electric-motor torque output to accomodate various loads utilizes phase-lock loop to control relay connected to starting circuit. As load is imposed, motor slows down, and phase lock is lost. Phase-lock signal triggers relay to power starting coil and generate additional torque. Once phase lock is recoverd, relay restores starting circuit to its normal operating mode.

Bernard, C. A.↗
NASA NTRSDate not supplied

Current Status and Future Plans for Electric Motors and Drives at NASA

Current Status and Future Plans for Electric Motors and Drives at NASA: Our work advances propulsion for aircraft while reducing energy consumption, noise, emissions and the cost of air travel. We are committed to investigating the use of alternative energy sources and improving the safety and expediency of flight. Electrified Aircraft Propulsion (EAP) is the use of propulsors (propellers or fans) driven by electric motors to propel aircraft ranging from air taxis to subsonic transports. NASA is developing technology, aircraft concepts, test aircraft, and ground test facilities to turn this idea from science fiction to reality. Specifically, motors and/or generators (Electric machines) are needed on all electrified aircraft. And NASA is sponsoring or performing work to achieve power densities 2-3 times the state of the art for machines in the MW or larger class. Three major machine types are being developed: permanent magnet, induction, and wound field. Power converters are also an essential component in most EAP aircraft concepts, as they are used to convert from ac to dc power, or vice versa. Silicon carbide and gallium nitride convertors are being developed with conventional cooling as well as a cryogenically cooled converter. Future plans include demonstrating integrated flight-ready systems in both ground and flight tests; collaborating with and leveraging ARPA-E EAP programs; and supporting FAA standards development for market acceptance and safety.

Powertrain↗
NASA NTRSDate not supplied

Preliminary Electric Motor Drivetrain Optimization Studies for Urban Air Mobility Vehicles

Electric and hybrid electric aircraft require high performance and reliable electric motor drivetrains. These drivetrains, consisting of a motor, an inverter, a gearbox, and a thermal management system, are highly coupled systems where the design of individual components in the drivetrain will significantly affect the sizing and performance of the other components in the system. In this paper, a preliminary co-optimization tool for electric motor drivetrains for Urban Air Mobility vehicles is presented. An example study with the tool is completed for NASA’s RVLT quadrotor concept vehicle.

Thomas Tallerico↗
NASA NTRS2005

Liquid-Hydrogen-Cooled 450-hp Electric Motor Test Stand Being Developed

With growing concerns about global warming, there is a need to develop pollution-free aircraft. One approach is to use hydrogen-fueled aircraft that use fuel cells or turbogenerators to produce electric power to drive the electric motors that turn the aircraft s propulsive fans. Hydrogen fuel would be carried as a liquid, stored at its boiling point of 20.5 K (-422.5 F). Conventional electric motors, however, are too heavy for aircraft propulsion. We need to develop high-power, lightweight electric motors (highpower- density motors). One approach is to increase the conductivity of the wires by cooling them with liquid hydrogen (LH2). This would allow superconducting rotors with an ironless core. In addition, the motor could use very pure aluminum or copper, substances that have low resistances at cryogenic temperatures. A preliminary design of a 450-hp LH2-cooled electric motor was completed and is being manufactured by a contractor. This motor will be tested at the NASA Glenn Research Center and will be used to test different superconducting materials such as magnesium diboride (MgB2). The motor will be able to operate at speeds of up to 6000 rpm.

Albert F. Kascak↗
NASA NTRSDate not supplied

Surface Vibration Measurement and Analysis for UAM/UAS Electric Motor Noise

Urban Air Mobility vehicles are an emerging class of vertical lift vehicles using electric motors to drive multiple rotors for lift. The outrunner electric motors that are commonly used, may be capable of generating noise that could contribute to the vehicle’s overall noise profile and could generate cabin noise. Understanding and predicting the noise requires more knowledge of the rotor vibrations and eventually a model to predict the frequencies of those vibrations. This work presents a measurement of the rotor vibrations of two different small-scale motors. Two techniques to measure the surface vibration were used. The displacement spectra are compared with acoustic measurements. A finite element analysis model is used to predict the rotor resonance frequencies. The predicted frequencies are in fair agreement with the experimentally observed vibration frequencies, but requires further work to understand discrepancies.

Electric Motor Noise↗
DOE OSTI2024

Tutorial - Electric Motor and Integrated Traction Drive Thermal Management

The share of vehicles with fully electric propulsion systems is constantly increasing, and so is their traction drive power. The continuous push to increase power of electric vehicle (EV) traction drives necessitates their efficient cooling to prevent damage to temperature sensitive components of the drive system and achieving higher power outputs in a smaller footprint. With increasing power and power density of electric traction drives, their thermal management is becoming increasingly challenging. This tutorial will provide an overview of thermal management approaches for electric motors and power electronics in EV applications. It will review examples of current industry solutions for power-dense electric motor cooling, power electronics (inverter) cooling, their integration concepts and thermal management system solutions. We'll look at the advantages and challenges of power electronics integration into a single traction drive unit and respective thermal management system concepts. We'll talk about barriers to implementation of a unified thermal management system. The tutorial will also review key aspects of thermal management system design: modeling and simulation using FEA and CFD tools, experimental characterization, and general workflow for thermal management system evaluation.

ADVANCED PROPULSION SYSTEMS,DIRECT ENERGY CONVERSI↗
NASA NTRS2018

Update on Electric Motor Noise Measurements and Predictions

Results from recent acoustic and vibration experiments with small electric motors are presented. The results are compared with finite element analysis and analytical predictions. The relevance of electric motor noise to the overall noise produced by small quadcopters is highlighted. Progress toward quiet loading approaches is discussed.

Electric Motor Noise↗