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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 OSTI2026

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)↗
DOE OSTI2024

Electric Motor Thermal Management

During FY 2022, NREL efforts focused on supporting collaborations with external research partners within the Electric Drive Technologies research consortium. The poster highlights collaborations with SNL, ORNL, and Georgia Tech. The collaboration with SNL utilized NREL's experimental capabilities to mechanically characterize SNL-provided material samples for motor applications. The collaboration with ORNL supported efforts to refine the design of a high-speed, non-heavy-rare-earth outer-rotor motor. The collaboration with Georgia Tech focused on a novel cooling technique for electric machines. NREL supported the effort by leading the thermal analysis and design of advanced machines.

ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2023

Mechanical Analysis of Carbon Fiber Retaining Sleeve for A High-speed Outer Rotor SPM Electric Motor Design

Outer rotor motors can be designed with a larger airgap diameter than inner rotor motors for the same overall diameter and therefore provide higher torque which makes them ideal for high torque space constrained applications. This advantage fits well with the increasing demand of high-speed electric machines in many applications due to their inherent high-power density. However, increasing the motor speed results in significant centrifugal loads for the outer rotor motor design. Layers of carbon fiber sleeve winding on the rotor outer surface is necessary to guarantee its structural integrity without introducing too much weight on the motor itself. In this paper, we studied the mechanical stress of a carbon fiber retaining sleeve in a surface permanent magnet outer rotor motor that spins up to 20,000 RPM. Analytical results from finite element method (FEM) confirmed that the maximum stress experienced by the carbon fiber sleeve was under the material’s yield strength. The proposed sleeve will allow this outer rotor motor to operate at high speeds.

Lin, Lianshan↗
DOE OSTI2024

Enhanced Second Generation (2G) High Temperature Superconducting (HTS) wire for Electric Motor Applications

This project focused on the development of a revolutionary Second Generation (2G) high temperature superconducting (HTS) wire engineered specifically to meet the requirements for a new generation of high temperature superconducting electric machines. This novel design combined a roll-to-roll irradiation process to enhance the performance of the HTS wire in the presence of strong magnetic fields (improved flux pinning) with an innovative process to incorporate multiple HTS layers within a single 2G wire.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2023

Motorette Thermal Performance Testing and Modeling for an Electric Motor with Additively Manufactured Hollow Conductors with Integrated Heat Pipes

This paper discusses the design, build and test of a motorette to characterize the thermal performance of an additively manufactured coil integrated with heat pipes. The motorette is powered using a variable frequency AC power supply and cooled through two independent cooling systems. The first cooling system cools the stator core using forced convection of air flowing over a finned heat sink mounted on the stator outer diameter. The second cooling system cools the heat pipes using forced convection of 50-50 water ethylene glycol (WEG) mixture flowing through condenser chambers. A 3D thermal FEA model of the setup is built and heat transfer coefficients (HTC) of convective boundaries are computed using coolant flow rates from test data and empirical equations. Temperature at locations on the coil and heat sink are recorded and compared to thermal model predicted values. A maximum temperature error of 22.7% occurs at 180ARMS and 800 Hz operating point for the AM dual coil. The thermal model provides higher temperatures compared to test results and hence it is on the conservative side but in general, there is good correlation between test and model results. Lastly, opportunities for improvement to both test data measurement and 3D thermal FEA modeling are discussed.

additive manufacturing↗
DOE OSTI2023

Electric motor cooling with oscillating heat pipes

A stator and a motor including a stator. The stator includes a stator hub, a plurality of stator teeth extending from the stator hub that define a stator slot having a stator slot base, at least one winding disposed in the stator slot, and one or more oscillating heat pipes disposed at least partially in the at least one winding. The at least one winding is held apart from the stator slot base so that a cooling channel is defined between an inner winding portion of the at least one winding and a portion of the one or more oscillating heat pipes is disposed in the channel so cooling fluid can be passed between the stator slot base and the inner winding portion to cool the inner winding portion via at least operation of the one or more oscillating heat pipes.

Alahyari, Abbas A.↗
DOE OSTI2023

Compressor system with heat recovery

A system includes a first working fluid compressor configured to pressurize a working fluid, and a prime mover coupled to the first working fluid compressor and configured to provide a mechanical input into the first working fluid compressor. An exhaust assembly is coupled to the prime mover and is configured to receive exhaust heat from the prime mover, the exhaust assembly including a generator configured to generate electric current based on the exhaust heat received by the exhaust assembly. A second working fluid compressor includes an electric motor electrically and synchronously coupled to the generator and configured to pressurize the working fluid.

Torrey, David Allan↗
DOE OSTI2025

Design, Optimization, and Control of a 100 kW Electric Traction Motor Meeting or Exceeding DOE 2025 Targets

The overall objective of the electric motor portion of the Electric Drives Technology consortium is to research, develop, and test electric motors for use in electric vehicle applications capable of a peak power greater than 100 kW, power density greater than or equal to 50 kW/l, and a cost less than 3.3 $/kW. To meet the electric traction motor power density and cost targets a number of approaches were pursued simultaneously throughout the course of this project which address all of the major volumetric power density variables. The specific research thrusts at the Illinois Institute of Technology (IIT) are the following: multiphysics design for increased power density through maximum utilization of active materials, synthesis of electric machine windings and PM flux barriers with controlled space harmonics, high slot fill windings for increased current loadings or efficiency, aggressive cooling strategies, and design studies and prototype construction of candidate electric machines.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2023

An Integrated Traction Drive with a High Speed Surface Permanent Magnet External Rotor Motor for Electric Vehicles

This work presents the detailed design of an outer rotor motor and integrated drive for passenger electric vehicles. The motor uses non-heavy rare earth permanent magnets and operates at a top speed of 20,000rpm. In-slot ceramic heat exchangers are utilized for the cooling of the windings. The external rotor configuration of the motor leaves a significant amount of space in the stator bore, which is leveraged for the integration of the power electronics. A high speed external rotor motor creates a number of mechanical, thermal and assembly challenges and this work presents detailed thermal, mechanical and rotordynamics analysis.

ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2020

Coupled Electro-Thermal Analysis of Permanent Magnet Synchronous Motor for Electric Vehicles

Permanent magnet synchronous motors (PMSM) are extensively used in electric vehicles. However, high internal heat generation and inefficient heat dissipation often limit the operational reliability, and longevity of the PMSM. Therefore, proper quantification of heat generation in electric motor and advanced embedded motor cooling techniques remain topics of immense interest. In order to accurately predict electro-magnetic performance, i.e., efficiency, component-wise heat losses and the corresponding temperature distribution of a jacket cooled machine, this paper presents a two-way iteratively coupled electro-thermal modeling framework. Finite element based software Motor-CAD has been utilized for electro-magnetic performance calculation of BMW i3 PMSM. Finite volume based computational fluid dynamics/heat transfer (CFD/HT) software ANSYS® FLUENT® has been employed to simulate the temperature distribution of the PMSM, using the electro-magnetic losses as heat input. Computed heat losses, stator, winding, rotor, and magnet temperatures are utilized as coupling parameters between the electro-magnetic and thermal models. A conventional one-way coupling algorithm has also been developed and compared to the newly proposed two-way coupling algorithm. Numerical results confirm that at high current density, one-way coupling algorithm significantly over-predicts the motor temperature compared to the two-way algorithm. A comprehensive analysis has been carried out to characterize the influences of current density, speed, and forced convection heat transfer coefficient on the heat losses, overall efficiency, and maximum temperature of the PMSM. Lastly, an efficiency map has been interpreted from the coupled electro-magnetic simulation.

42 ENGINEERING↗
DOE OSTI2021

Comparison of Candidate Designs and Performance Optimization for an Electric Traction Motor Targeting 50 kW/L Power Density

The continued expansion of the global electric vehicle fleet is accompanied by an unprecedented demand for high power density electric traction motors. With the ambitious U.S. DRIVE 2025 target of 50 kW/L power density and an equally aggressive cost reduction goal, innovative approaches have to be utilized in terms of both the design and manufacturing of electric traction motors. In this paper, six motor options are compared and the best design is picked for each option to investigate the drive and excitation requirements and the weighted power efficiency over multiple load points, with necessary mechanical stress and demagnetization checks. State-of-the-art winding technologies, including high slot fill die compressed windings and hairpin windings, and rotors both with permanent magnet (PM) and PM-free are incorporated. The design of high flux density and low harmonic content magnetic field is also demonstrated.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2023

Electric and Hydraulic Propel Torque Modulation for a Compact Track Loader With the Hybrid Hydraulic Electric Architecture (HHEA)

Abstract The Hybrid Hydraulic Electric Architecture (HHEA) has previously been proposed for off-highway vehicles to reap the efficiency and controllability benefits of electrification without needing very large electric motors. This is achieved with the use of a set of selectable common pressure rails to transmit the majority of power and small electric motors to modulate that power. Previous work has shown significant energy savings for the work circuits of a variety of machines. In this paper, the energy saving potential of HHEA for the propel circuit of a compact track loader is studied. The ports of the track hydraulic motors are selectably connected to the common pressure rails, and instead of using the electric assist motors to buck/boost pressure, as in HHEA for linear actuators, small electric assist motors are used to add/subtract torque directly. The interplay between the torque limits of the electric motors and the ability of the hydraulic motor to vary displacements is studied, along with the effect these factors have on energy saving potential. It is found that the ability to vary the displacement of the hydraulic motor allows for: more efficient electric motor operating conditions, reduced electric torque requirement, and reduced pressure rail switching events. All three of these advantages can be achieved at once using variable displacements; but trade-offs exist between these advantages (i.e. improved efficiency can be achieved at the expense of a larger electric torque requirement). Overall, the HHEA can reduce energy consumption by ∼ 36% compared to the stock machine, depending on the hydraulic motor’s ability to vary displacements, and assuming the electric motor torque is limited to 20% of that required in a direct electrification scheme.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2020

Dual Phase Soft Magnetic Laminates for Low-cost, Non/Reduced-Rare-Earth Containing Electrical Machines

To accelerate the mass market adoption of electric drive vehicles, the key technology barriers in electric motors are (1) magnet cost and rare-earth element price volatility; (2) non-rare-earth electric motor performance; and (3) materials property optimization. The goal of this project was to address these barriers by advancing a unique and innovative dual phase soft magnetic material technology and demonstrating the material in a 30-kW synchronous reluctance motor without using any permanent magnet for electric vehicles. Dual phase magnetic materials offer the electric motor designer the ability to locally control the magnetic saturation level in a motor laminate, while at the same time enhancing the mechanical strength of the laminate material, resulting in an enhancement in motor performance and efficiency. Scalable dual phase soft magnetic laminates manufacturing technologies were developed in collaboration with multiple US manufacturers. 1000 lbs of alloy sheet with a thickness of 0.25mm and width of 280 mm was manufactured within the specifications. Batch sizes of up to 240 laminates per run were produced from the alloy sheet. Two prototype motors with dual phase soft magnetic laminates were designed, built, and tested. The major goal of building the subscale prototype as a pathway to develop scalable manufacturing technologies for the dual phase soft magnetic laminates was met. The additional goal of building and testing the subscale prototype in order to validate the calculated performance with the tested motor performance was also met. For the full-scale 30kW continuous power synchronous reluctance motor prototype, the tested performance met the targets in terms of continuous power at the operating speeds up to 8000 rpm. Post-test studies were conducted and the root causes for the discrepancy between the predicted and tested peak power, continuous power at high speed range, and efficiency were identified. Further modeling study showed that the dual phase rotor machine has a 27% higher torque to active weight ratio than an equivalent performance silicon steel rotor machine. Application space and multiple discussions with traction motor and electric vehicle manufacturers for commercialization of the dual phase soft magnetic material technology were identified and conducted. An initial cost model was established based on the developed manufacturing technologies with the US manufacturers. Future paths for further cost reduction were identified, including increasing the market volume by broadening the applications of the dual phase soft magnetic laminate technology for electric machines in other energy sections such as oil & gas, heating, ventilation, and air conditioning (HVAC), and power generation.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2021

U.S. Industrial and Commercial Motor System Market Assessment Report Volume 2: Advanced Motors and Drives Supply Chain Review

Electric motors in commercial and industrial applications account for almost a third of total electric grid load in the United States. With these applications representing such a significant level of energy use, increasing efficiency in these applications can help substantially increase resilience and lower total energy costs. This report examines stationary high-efficiency electric motor technologies and their supply chains.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2025

Power Electronics and Electric Machines for Advanced Aircraft

Power electronics and electric machines are critical components of efficient, high-performance aircraft - from fixed-wing turbine to electric vertical takeoff and landing aircraft and beyond. Improvements to these components create enormous energy efficiencies, enable cost savings, and ensure fail-safe operations. National Renewable Energy Laboratory researchers are developing innovative power electronics, electric motors, integrated electric traction drives, and thermal management systems to build highly efficient, lightweight, ultrareliable powertrains for aircraft.

42 ENGINEERING↗
DOE OSTI2025

Integrated On-Board Charger for Dual Motor Based Electric Vehicle Power Train

This paper presents an integrated on-board charger for dual motor based electric vehicle (EV) power train with silicon carbide semiconductor switch-based traction inverters. The proposed charger architecture reconfigures the traction inverters to be used in the battery charging mode, thereby eliminating several high frequency switches and their accessories. The motor windings are reused as line inductors for the power factor correction (PFC) rectifier stage in the charging mode thereby reducing the requirements of magnetic components. The architectures reduce the cost, weight, and volume of the EV power train. Simulation results are presented to demonstrate the working principle of the proposed architecture.

Mukherjee, Subho [ORNL] (ORCID:0009000672297925)↗
DOE OSTI2022

Electric machines as motors and power generators

Devices, methods, and systems for electrostatic machines which can act as both an electric motor, converting electrical energy to mechanical energy, and an electric generator, converting mechanical energy to electrical energy, are described. In some embodiments, a spring positioned between two oppositely charged plates may be used as an electric motor and/or electric generator.

Datskos, Panagiotis G.↗