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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

Development and Demonstration of a Class 6 Range-Extended Electric Vehicle for Commercial Pickup and Delivery Operation: Preprint

Range-extended hybrids are an attractive option for medium- and heavy-duty commercial vehicle fleets because they offer the efficiency of an electrified powertrain with the driving range of a conventional diesel powertrain. The vehicle essentially operates as if it was purely electric for most trips, while ensuring that all commercial routes can be completed in any weather conditions or geographic terrain. Fuel use and point-source emissions can be significantly reduced, and in some cases eliminated, as many shorter routes can be fully electrified with this architecture. Under a U.S. Department of Energy (DOE)-funded project for Medium- and Heavy-Duty Vehicle Powertrain Electrification, Cummins has developed a plug-in hybrid electric Class 6 truck with a range-extending engine designed for pickup and delivery application. The National Renewable Energy Laboratory (NREL) assisted by developing representative workday drive cycles for Class 6 operation and an adapted cycle to enable vehicle track testing. A novel, automated driving system was utilized by Southwest Research Institute (SwRI) to improve the repeatability of the track testing conducted to quantify vehicle energy consumption. Cummins used a drivetrain model to design the hybrid control system for increased fuel savings. The control system functionality and fuel savings objective of 50% or more were confirmed by track testing described in this paper.

ADVANCED PROPULSION SYSTEMS↗

Motor Configuration Selection for A New Technical Challenge to Develop A 5 MW Cryogenic Motor and Drive

Due to aviation’s appreciable and growing share of humanity’s impact on our environment and estimates that CO2emissions only account for 34% of aviation’s total effective radiative forcing [1], there is a need to reach beyond climate goals that focus only on CO2emissions, such as the US Aviation Climate Action Plan’s [3] goal to reach net-zero carbon emissions by 2050.There is motivation to develop technology that pushes toward future large transport aircraft with net zero climate impact that are highly electrified (i.e., have higher power electrical propulsion system components). This paper describes a new, 6-year technical challenge to address this need by developing a 5 MW superconducting motor and cryogenic drive. Section 1 will detail the motivation for this work. Section 2 will describe the technical challenge and the selected specifications for the motor. Section 3 will present the results of a motor configuration trade study and the down selection of one configuration to develop a detailed design for. The technical challenge focuses on the design of a5 MW superconducting motor and cryogenic drive and demonstration of it at a 2+ MW scale to achieve TRL 3. Both fully superconducting (superconducting stator and rotor) and fully cryogenic (superconducting rotor and cryogenic stator) machine configurations will be explored. An emphasis will be placed on addressing the key tall poles for high power superconducting machines. Further details will be included in the full paper. The requirements and goals of the motor will be detailed. The rated speed (2,000 to 3,000 rpm) is defined to be appropriate for directly driving multi-MW fans or propellers. A range of rated speed is permitted because the motor is not designed for a specific aircraft and to provide design flexibility if AC losses in the stator winding are found to be a significant constraint (i.e., a lower speed can be selected to reduce electrical frequency). Relatively conservative requirements for efficiency (99%) and specific power (20 kW/kg) are defined, because TRL advancement and pushing toward flight readiness is emphasized over performance optimization. However, more aggressive efficiency and specific power goals are specified (99.9% and 40 kW/kg). The 3rd section will present the results of a motor configuration trade study. The study started with a qualitative assessment of sixteen motor configurations based on geometric, mechanical, thermal, and electromagnetic criteria. This assessment has been completed with three evaluators scoring all nine criteria. A configuration down select was made by prioritizing the sixteen configurations into four tiers based on each configuration’s total score and consideration of manufacturability, complexity, and support hardware (e.g., rotary vacuum seals, bearings). Configurations in priority A and B will be further evaluated through quantitative assessments, whereas those in priority C will only be further evaluated if time permits and priority D will not be further evaluated. Eight of the sixteen configurations were down selected for quantitative assessment, which will include analytical calculations and low-to moderate-fidelity finite element analysis to produce a preliminary Pareto front of efficiency versus specific power for each configuration. This assessment emphasizes the calculation of AC losses in the stator winding and an exploration of thermal management approaches to remove that heat and maintain cryogenic temperature. The final paper will include a description of each motor configuration that was considered. The quantitative assessments are underway, and an assessment of one configuration is complete for multiple stator conductor options. The remaining assessments are scheduled to be completed by late March so that the final down select to one configuration can be included in this paper.

Net Zero↗

Impedance Measurements of Motor Drives and Supplies in NASA NEAT Facility

Many electrified aircraft configurations consist of a number of power components operating on the same shared electrical bus. Understanding the impedance performance of electrical loads and sources is key to understanding, and designing for, acceptable overall vehicle power quality and power system stability. This paper discusses impedance measurements made on the NASA Electric Aircraft Testbed (NEAT) Electrical Power System (EPS) at NASA Glenn Research Center. First, an overall discussion of the NEAT facility configuration during testing is presented; then details of the impedance measurement approach and the various testing configurations are discussed. Next, input impedance measurements at NEAT, including sources (DC supplies) and loads (multiple motor drives, electric machines, and resistive load banks, with long interconnecting cable leads), are performed under a number of conditions, and results, including load model comparisons and stability analysis, are presented and discussed.

electrified aircraft propulsion↗

Impedance Measurements of Motor Drives and Supplies in NASA NEAT Facility

Many electrified aircraft configurations consist of a number of power components operating on the same shared electrical bus. Understanding the impedance performance of electrical loads and sources is key to understanding, and designing for, acceptable overall vehicle power quality and power system stability. This paper discusses impedance measurements made on the NASA Electric Aircraft Testbed (NEAT) Electrical Power System (EPS) at NASA Glenn Research Center. First, an overall discussion of the NEAT facility configuration during testing is presented. Then, details of the impedance measurement approach and the various testing configurations are discussed. Next, input impedance measurements at NEAT, including sources (DC supplies) and loads (multiple motor drives, electric machines, and resistive load banks, with long interconnecting cable leads), are performed under a number of conditions, and results, including load model comparisons and stability analysis, are presented and discussed.

electrified aircraft propulsion↗

Of Actors, Cities and Energy Systems: Advancing the Transformative Potential of Urban Electrification

The electrification of transportation and the integration of electric vehicles (EVs) with buildings connected to clean grids has been touted as one of the key solutions to the global decarbonization challenge. Cities are on the frontlines of current and future electrification, as they depend on and drive electricity generation, distribution, and use. City actors also occupy a central role in the actions to enable electrification to support energy transitions in efficient, equitable, environmentally sound, and resilient ways. Currently, however, research and development on the interactions between actors, cities and energy systems is predominantly conducted in disciplinary siloes. This topical review analyzes the transformational potential of urban electrification. It focuses on efforts to electrify transportation and integrate EVs with buildings connected to a clean grid. We find that actions in these area are driving change; they are adopted by wealthier populations and on an experimental basis by specific communities. Their larger-scale growth is constrained by institutional, behavioral, and infrastructural factors. We also find that existing siloed disciplinary approaches are often incompatible with advancing holistic research. To achieve that, divergent communities of scholars need to come together to integrate their research and create broader perspectives. Through incorporation of the social sciences, these perspectives need to consider the societal limits and potentials brought to bear by human behavior and decision making. Only then can urban electrification be understood as the empirically rich and socially complex topic that it is. And only with this understanding will innovations and smart policy actions be able to tap into the transformational potential of urban electrification.

cities↗

Subscale Hardware-In-The-Loop Results for Hybrid Electric Turbofan Controls Use Cases

NASA is investigating hybrid electric turbine engine systems for commercial transport aircraft due to the potentially significant improvements hybrid electric technology offers in performance, fuel consumption, and operational and design flexibility. Recently, the technology has been tested at full scale in partnership with industry and advanced to Technology Readiness Level 4. This presentation will focus on a recent subscale hardware-in-the-loop test of an open source turbofan engine model developed by NASA. The Advanced Geared Turbofan 30,000 lbf – electrified (AGTF30-e) engine is used as a reference model to demonstrate control system design and use cases for an example mild hybrid electric system with no large-scale energy storage. This model is run in real-time in NASA’s Hybrid Propulsion Emulation Rig (HyPER) and is used to drive an emulation of the turbomachinery system using subscale electric machines. This dynamic scaled shaft emulation interacts with a subscale (<100 kW) hybrid system consisting of electric machines, motor controllers, and a programmable electronic load. Specific use cases demonstrated include the use of Turbine Electrified Energy Management to improve operation during transients, megawatt-scale power extraction from the AGTF30-e, and power transfer between engine spools. Results related to the effectiveness of hybrid systems are qualitatively compared to results from industry testing.

Hybrid↗

Modular Design of Receiver Side Power Electronics for 200 kW High Power Dynamic Wireless Charging System

Dynamic wireless power transfer (DWPT) can provide energy to EVs in motion and extend the drive range. By upscaling the charging power to 200 kW (High Power DWPT), the percentage of electrified roadway reduces and the solution becomes cost-effective. However, coil coupling-coefficient variation during vehicle movement fluctuates the transferred power which is unfavorable for vehicle battery. Secondary regulation design can smooth the power but the converter design becomes very challenging due to requirement in high power, high efficiency, fast control, as well as high power density since the unit will be onboard. This paper provides the modular design approach of a 200 kW secondary side unit to achieve high performance and scalability. The DC/DC converter using SiC devices demonstrated 98.3% efficiency.

Xue, Lincoln↗

Electrical Propulsive Fuselage Concept for Transonic Transport Aircraft

NASA is broadly engaged in Electrified Aircraft Propulsion (EAP) efforts across air vehicle sizes and electric aircraft propulsion approaches. EAP enables a wide range of propulsion airframe integration options as well as the use of rechargeable energy storage in an aircraft. This paper is limited to a discussion of boundary layer ingestion (BLI) systems which are located on the fuselage of the aircraft and use electrical drive systems. We term that combination an "electrical propulsive fuselage". The benefits, challenges, and design parameters of an electrically driven fuselage BLI system are considered. Five existing types of fuselage BLI implementation approaches which can be implemented using either electrical or mechanical drive systems are reviewed. An overview of boundary layer types, fan response to boundary layer, and electrical system for aircraft propulsion is presented. An idea distributed electric propulsive fuselage is proposed.

Electrified Aircraft Propulsion↗

A Summary of NASA Rotary Wing Research: Circa 2008–2018

The general public may not know that the first “A” in NASA stands for Aeronautics. If they do know, they will very likely be surprised that in addition to airplanes, the “A” includes research in helicopters, tiltrotors, and other vehicles adorned with rotors. There is, arguably, no subsonic air vehicle more difficult to accurately analyze than a vehicle with lift-producing rotors. No wonder that NASA has conducted rotary wing research since the days of the NACA and has partnered, since 1965, with the U.S. Army in order to overcome some of the most challenging obstacles to understanding the behavior of these vehicles. Since 2006, NASA rotary wing research has been performed under several different project names [Gorton et al., 2015]: Subsonic Rotary Wing (SRW) (2006–2012), Rotary Wing (RW) (2012–2014), and Revolutionary Vertical Lift Technology (RVLT) (2014–present). In 2009, the SRW Project published a report that assessed the status of NASA rotorcraft research; in particular, the predictive capability of NASA rotorcraft tools was addressed for a number of technical disciplines. A brief history of NASA rotorcraft research through 2009 was also provided [Yamauchi and Young, 2009]. Gorton et al. [2015] describes the system studies during 2009–2011 that informed the SRW/RW/RVLT project investment prioritization and organization. The authors also provided the status of research in the RW Project in engines, drive systems, aeromechanics, and impact dynamics as related to structural dynamics of vertical lift vehicles. Since 2009, the focus of research has shifted from large civil VTOL transports, to environmentally clean aircraft, to electrified VTOL aircraft for the urban air mobility (UAM) market. The changing focus of rotorcraft research has been a reflection of the evolving strategic direction of the NASA Aeronautics Research Mission Directorate (ARMD). By 2014, the project had been renamed the Revolutionary Vertical Lift Technology Project. In response to the 2014 NASA Strategic Plan, ARMD developed six Strategic Thrusts. Strategic Thrust 3B was defined as the “Ultra-Efficient Commercial Vehicles—Vertical Lift Aircraft.” Hochstetler et al. [2017] uses Thrust 3B as an example for developing metrics usable by ARMD to measure the effectiveness of each of the Strategic Thrusts. The authors provide near-, mid-, and long-term outcomes for Thrust 3B with corresponding benefits and capabilities. The importance of VTOL research, especially with the rapidly expanding UAM market, eventually resulted in a new Strategic Thrust (to begin in 2020): Thrust 4—Safe, Quiet, and Affordable Vertical Lift Air Vehicles. The underlying rotary wing analysis tools used by NASA are still applicable to traditional rotorcraft and have been expanded in capability to accommodate the growing number of VTOL configurations designed for UAM. The top-level goal of the RVLT Project remains unchanged since 2006: Develop and validate tools, technologies and concepts to overcome key barriers for vertical lift vehicles. In 2019, NASA rotary wing/VTOL research has never been more important for supporting new aircraft and advancements in technology. 2 A decade is a reasonable interval to pause and take stock of progress and accomplishments. In 10 years, digital technology has propelled progress in computational efficiency by orders of magnitude and expanded capabilities in measurement techniques. The purpose of this report is to provide a compilation of the NASA rotary wing research from ~2008 to ~2018. Brief summaries of publications from NASA, NASA-funded, and NASA-supported research are provided in 12 chapters: Acoustics, Aeromechanics, Computational Fluid Dynamics (External Flow), Experimental Methods, Flight Dynamics and Control, Drive Systems, Engines, Crashworthiness, Icing, Structures and Materials, Conceptual Design and System Analysis, and Mars Helicopter. We hope this report serves as a useful reference for future NASA vertical lift researchers.

Yamauchi, Gloria K.↗

Reversionary Control Modes for the Mitigation of Failures in a Partially Turboelectric Aircraft Propulsion System

In support of emission and fuel burn reduction goals, the aviation industry is actively pursuing the advancement of electrified aircraft propulsion (EAP) technology. This includes turboelectric and hybrid electric propulsion designs that combine gas turbine engine and electrical system hardware. Such architectures exhibit a high degree of coupling between subsystems. This drives the need for system-level control strategies to ensure the safe, coordinated, and efficient operation of all subsystems. The design and certification of any aircraft propulsion system requires that all potential subsystem failures are identified, and the hazards posed by these failures are appropriately mitigated. This requirement is particularly challenging for EAP systems due to their integrated nature. One approach to assist in EAP failure mitigation is the inclusion of automated reconfiguration capabilities within the propulsion control system. Such control modes, referred to as reversionary control modes, are designed to automatically detect failures and activate backup control modes upon failure detection. This paper covers the design and evaluation of reversionary control mode logic developed for a partially turboelectric propulsion concept. Test results from a real-time hardware-in-the-loop evaluation of the concept are also presented and discussed. The results show that the developed reversionary control logic can successfully detect and mitigate subsystem failures in a representative environment that includes actual electrical system hardware.

Electrified Aircraft Propulsion↗

Reversionary Control Modes for the Mitigation of Failures in a Partially Turboelectric Aircraft Propulsion System

In support of emission and fuel burn reduction goals, the aviation industry is actively pursuing the advancement of electrified aircraft propulsion (EAP) technology. This includes turboelectric and hybrid electric propulsion designs that combine gas turbine engine and electrical system hardware. Such architectures exhibit a high degree of coupling between subsystems. This drives the need for system-level control strategies to ensure the safe, coordinated, and efficient operation of all subsystems. The design and certification of any aircraft propulsion system requires that all potential subsystem failures are identified, and the hazards posed by these failures are appropriately mitigated. This requirement is particularly challenging for EAP systems due to their integrated nature. One approach to assist in EAP failure mitigation is the inclusion of automated reconfiguration capabilities within the propulsion control system. Such control modes, referred to as reversionary control modes, are designed to automatically detect failures and activate backup control modes upon failure detection. This paper covers the design and evaluation of reversionary control mode logic developed for a partially turboelectric propulsion concept. Test results from a real-time hardware-in-the-loop evaluation of the concept are also presented and discussed. The results show that the developed reversionary control logic can successfully detect and mitigate subsystem failures in a representative environment that includes actual electrical system hardware.

Electrified Aircraft Propulsion↗

Reversionary Control Modes for the Mitigation of Failures in a Partially Turboelectric Aircraft Propulsion System

In support of emission and fuel burn reduction goals, the aviation industry is actively pursuing the advancement of electrified aircraft propulsion (EAP) technology. This includes turboelectric and hybrid electric propulsion designs that combine gas turbine engine and electrical system hardware. Such architectures exhibit a high degree of coupling between subsystems. This drives the need for system-level control strategies to ensure the safe, coordinated, and efficient operation of all subsystems. The design and certification of any aircraft propulsion system requires that all potential subsystem failures are identified, and the hazards posed by these failures are appropriately mitigated. This requirement is particularly challenging for EAP systems due to their integrated nature. One approach to assist in EAP failure mitigation is the inclusion of automated reconfiguration capabilities within the propulsion control system. Such control modes, referred to as reversionary control modes, are designed to automatically detect failures and activate backup control modes upon failure detection. This paper covers the design and evaluation of reversionary control mode logic developed for a partially turboelectric propulsion concept. Test results from a real-time hardware-in-the-loop evaluation of the concept are also presented and discussed. The results show that the developed reversionary control logic can successfully detect and mitigate subsystem failures in a representative environment that includes actual electrical system hardware.

Electrified Aircraft Propulsion↗

RouteE: A Vehicle Energy Consumption Prediction Engine

The emergence of connected and automated vehicles and smart cities technologies create the opportunity for new mobility modes and routing decision tools, among many others. To achieve maximum mobility and minimum energy consumption, it is critical to understand the energy cost of decisions and optimize accordingly. The Route Energy prediction model (RouteE) enables accurate estimation of energy consumption for a variety of vehicle types over trips or sub-trips where detailed drive cycle data are unavailable. Applications include vehicle route selection, energy accounting and optimization in transportation simulation, and corridor energy analyses, among others. The software is a Python package that includes a variety of pre-trained models from the National Renewable Energy Laboratory (NREL). However, RouteE also enables users to train custom models using their own data sets, making it a robust and valuable tool for both fast calculations and rigorous, data-rich research efforts. The pre-trained RouteE models are established using NREL’s Future Automotive Systems Technology Simulator paired with approximately 1 million miles of drive cycle data from the Transportation Secure Data Center, resulting in energy consumption behavior estimates over a representative sample of driving conditions for the United States. Validations have been performed using on-road fuel consumption data for conventional and electrified vehicle powertrains. Transferring the results of the on-road validation to a larger set of real-world origin-destination pairs, it is estimated that implementing the present methodology in a green-routing application would accurately select the route that consumes the least fuel 90% of the time. The novel machine learning techniques used in RouteE make it a flexible and robust tool for a variety of transportation applications.

33 ADVANCED PROPULSION SYSTEMS↗

Cost Reduction of School Bus Fleet Electrification With Optimized Charging and Distributed Energy Resources: Preprint

Considerations for electrifying school buses are presented with an analysis of battery sizing to match bus driving requirements. The charging and vehicle-to-building dispatch of the electric school buses were optimized to evaluate the potential to reduce the impact of the bus charging on the school's electric utility bill. Distributed energy resources (DER) and flexible building loads were also considered with the school bus electrification to evaluate the further reduction in energy costs with enhanced system integration and optimized dispatch. The effect of degradation on the school bus batteries was analyzed to determine if the smart charging and vehicle-to-building battery operation decreases the life of the battery. The results show that there is an opportunity to mitigate the increase of electric utility bills with improved charging controls and bi-directionally operating the school bus batteries to reduce building demand charges. The battery degradation analysis using dispatch with optimized charging and discharging shows acceptable battery life.

24 POWER TRANSMISSION AND DISTRIBUTION↗

Electrified Aircraft Propulsion Systems: Gas Turbine Control Considerations for the Mitigation of Potential Failure Modes and Hazards

This paper provides a high-level review of the potential failure modes and hazards to which electrified aircraft propulsion (EAP) systems are susceptible along with potential gas turbine control-based strategies to assist in the mitigation of those failures. To introduce the types of failures that an EAP system may experience, a generic EAP system is considered consisting of gas turbine engines, mechanical drives, electric machines, power electronics and distribution systems, energy storage devices, and motor driven propulsors. The functionality provided by each of these EAP subsystems is discussed along with their potential failure modes and possible strategies for mitigating those failures. To further illustrate the role of gas turbine controls in mitigating EAP failure modes, an example based on a simulated EAP concept aircraft proposed by NASA is given. The effects of failures are discussed, along with turbomachinery control strategies, including reversionary control modes, and control limit logic

Electrified Aircraft Propulsion↗

Device- and System-Level Thermal Packaging for Electric-Drive Technologies (Final Technical Report)

Final Technical ReportThis project aimed to research, develop, and test electric traction drive system technology for use in vehicle applications that are capable of meeting the targets set by the Department of Energy Vehicle Technologies Office. The project is categorized into three major thrusts: Bonding interfaces for packaging, thermal management of electric vehicle (EV) power inverters, and electric motor thermal management. Device- and System-Level Thermal Packaging for Electric-Drive Technologies project aimed to develop, analyze, and validate transformative approaches in thermal management and packaging for power electronics and electric motor systems, with the ultimate goal of enhancing power density, efficiency, and reliability in electrified transportation platforms.

33 ADVANCED PROPULSION SYSTEMS↗

Turbine Electrified Energy Management with Model Predictive Control

Affordability, sustainability, and efficiency are primary motivators driving the future of NASA aeronautics research. These factors are realized, in part, through the development and implementation of new technologies and strategies enabling efficient, affordable, and safe hybrid-electric aircraft. Research supporting electrified aircraft propulsion control systems exemplifies such new methodologies, offering varied opportunities to integrate electric machines with gas-based turbine engines. For hybrid-electric propulsion systems, current conceptual architectures seek to introduce energy storage and exploit electrical power system components to assist gas-based system components. Capitalizing on the electric machines in hybridized engines, Turbine Electrified Energy Management (TEEM) is a control approach that enhances transient operability to improve overall propulsion and vehicle efficiency by injecting or extracting power from engine shafts. Traditionally implemented with proportional-integral (PI) control, this study expands the application of TEEM by presenting model predictive control (MPC) schemes to execute the TEEM concept. Via cost function design and constraint selection, the transient operability goals for TEEM are considered in the controller designs. The proposed MPCs are simulated on a nonlinear turbofan engine model at two environmental conditions, with comparisons drawn to a baseline PI. Performance is evaluated using compressor maps and two TEEM-specific metrics: transient stack usage and transient excursion integral. Simulation results reveal the developed schemes perform comparably to the benchmark controller and can be implemented in two distinct configurations. Potential modifications for future investigations include cost function measures that optimize energy use, additional performance effectiveness measures, and battery storage capabilities.

Elyse D. Hill↗

Optimal Control Allocation for Distributed Electric Propulsion in a Series/Parallel Partial Hybrid Powertrain

The SUbsonic Single Aft eNgine (SUSAN) Electrofan is a NASA concept jet transport aircraft with a 2040 entry-into-service date. It utilizes electrified aircraft propulsion (EAP) to enable propulsive and aerodynamic benefits to reduce fuel usage, emissions, and cost. The powertrain consists of a single thrust producing, boundary layer-ingesting (BLI) turbofan gas turbine engine (GTE) with generators driving a series/parallel partial hybrid EAP system. The architecture includes 16 underwing contrarotating BLI fans, eight on each side, in a mailslot configuration. The 16 fans run on power extracted from the GTE through four 5 MW motor/generators connected to the Low-Pressure Spool, and a single 1 MW motor/generator on the High-Pressure Spool. The distributed fans can be used by the flight control to augment or replace the rudder function. At top of climb, the power extracted from the GTE for the fans is boosted by batteries. The design provides redundancy, and the capacity for boost means that the fans are designed to be able to provide additional thrust when necessary. These features can be leveraged in case of a fan or generator failure. This paper sets up the optimal control problem of setpoint determination for individual fans in the distributed propulsion system, accounting for electrical string efficiencies, saturations, and failures. The solution minimizes power consumption while maintaining thrust and torque on the airframe for maneuvering. Additionally, thrust that would have been lost due to temporary fan speed or power saturation is optimally redistributed to maintain overall desired thrust and torque on the aircraft. The power extraction range constraints derive from the gas turbine engine design and the small amount of variation allowed for the engine to maintain operability. The problem formulation allows the number and location of fan failures for which the thrust and torque can be maintained to be investigated, which has implications for certification. Simulations of a coordinated turn utilizing the distributed electric propulsion for yaw rate control under different failure scenarios demonstrate the robustness of the powertrain design to failures and help define its limitations.

Distributed Electric Propulsion↗