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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 OSTI2016

Rotation profile flattening and toroidal flow shear reversal due to the coupling of magnetic islands in tokamaks

The electromagnetic coupling of helical modes, even those having different toroidal mode numbers, modifies the distribution of toroidal angular momentum in tokamak discharges. This can have deleterious effects on other transport channels as well as on magnetohydrodynamic (MHD) stability and disruptivity. At low levels of externally injected momentum, the coupling of core-localized modes initiates a chain of events, whereby flattening of the core rotation profile inside successive rational surfaces leads to the onset of a large m/n = 2/1 tearing mode and locked-mode disruption. With increased torque from neutral beam injection, neoclassical tearing modes in the core may phase-lock to each other without locking to external fields or structures that are stationary in the laboratory frame. The dynamic processes observed in these cases are in general agreement with theory, and detailed diagnosis allows for momentum transport analysis to be performed, revealing a significant torque density that peaks near the 2/1 rational surface. However, as the coupled rational surfaces are brought closer together by reducing q{sub 95}, additional momentum transport in excess of that required to attain a phase-locked state is sometimes observed. Rather than maintaining zero differential rotation (as is predicted to be dynamically stable by single-fluid, resistive MHD theory), these discharges develop hollow toroidal plasma fluid rotation profiles with reversed plasma flow shear in the region between the m/n = 3/2 and 2/1 islands. The additional forces expressed in this state are not readily accounted for, and therefore, analysis of these data highlights the impact of mode coupling on torque balance and the challenges associated with predicting the rotation dynamics of a fusion reactor—a key issue for ITER.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2015

Design of a Modular E-Core Flux Concentrating Axial Flux Machine

In this paper a novel E-Core axial flux machine is proposed. The machine has a double stator-single rotor configuration with flux concentrating ferrite magnets, and pole windings across each leg of an E-Core stator. E-Core stators with the proposed flux-concentrating rotor arrangement result in better magnet utilization and higher torque density. The machine also has a modular structure facilitating simpler construction. This paper presents a single phase and a three-phase version of the E-Core machine. Case study for a 1.1 kW, 400 rpm machine for both the single phase and three-phase axial flux machine is presented. The results are verified through 3D finite element analysis.

17 WIND ENERGY↗
DOE OSTI2018

Design Considerations of a Transverse Flux Machine for Direct-Drive Wind Turbine Applications

This paper presents the design considerations of a double-sided transverse flux machine (TFM) for direct-drive wind turbine applications. The proposed TFM has a modular structure with quasi-U stator cores and toroidal ring windings. The rotor is constructed with ferrite magnets in a flux-concentrating setup to achieve high air gap flux density. Pole number selection is critical in the design process of a TFM as it affects both the torque density and power factor under fixed magnetic and changing electrical loading. Several key design ratios are introduced to facilitate the initial design procedure. The effect of pole shaping on back-EMF and inductance is also analyzed. These investigations provide guidance toward the required design of a TFM for direct-drive applications. The analyses are carried out using analytical and three-dimensional finite element analysis (FEA). A proof-of-concept prototype was developed to experimentally validate the FEA results.

17 WIND ENERGY↗
DOE OSTI2017

Analytical Modeling of a Double-Sided Flux Concentrating E-Core Transverse Flux Machine with Pole Windings

In this paper, a nonlinear analytical model based on the Magnetic Equivalent Circuit (MEC) method is developed for a double-sided E-Core Transverse Flux Machine (TFM). The proposed TFM has a cylindrical rotor, sandwiched between E-core stators on both sides. Ferrite magnets are used in the rotor with flux concentrating design to attain high airgap flux density, better magnet utilization, and higher torque density. The MEC model was developed using a series-parallel combination of flux tubes to estimate the reluctance network for different parts of the machine including air gaps, permanent magnets, and the stator and rotor ferromagnetic materials, in a two-dimensional (2-D) frame. An iterative Gauss-Siedel method is integrated with the MEC model to capture the effects of magnetic saturation. A single phase, 1 kW, 400 rpm E-Core TFM is analytically modeled and its results for flux linkage, no-load EMF, and generated torque, are verified with Finite Element Analysis (FEA). The analytical model significantly reduces the computation time while estimating results with less than 10 percent error.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2017

A Comprehensive Review of Permanent Magnet Transverse Flux Machines for Direct Drive Applications

The use of direct drive machines in renewable and industrial applications are increasing at a rapid rate. Transverse flux machines (TFM) are ideally suited for direct drive applications due to their high torque density. In this paper, a comprehensive review of the permanent magnet (PM) TFMs for direct drive applications is presented. The paper introduces TFMs and their operating principle and then reviews the different type of TFMs proposed in the literature. The TFMs are categorized according to the number of stator sides, types of stator cores and magnet arrangement in the rotor. The review covers different design topologies, materials used for manufacturing, structural and thermal analysis, modeling and design optimization and cogging torque minimization in TFMs. The paper also reviews various applications and comparisons for TFMs that have been presented in the literature.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2019

The effect of plasma shape and neutral beam mix on the rotation threshold for RMP-ELM suppression

Varying the neutral beam injection (NBI) mix reveals a clear pedestal-top rotation threshold for edge localized mode (ELM) suppression by resonant magnetic perturbations. Guided by expectations for the RMP penetration mechanism, the rotation threshold is found to correspond to a critical radius for the ExB rotation zero-crossing. No such critical radius is observed for the electron perpendicular rotation zero-crossing. Varying the amount and ratio of power in different NBI source geometries (termed the NBI mix) also reveals that the rotation threshold can be crossed at widely varying total injected NBI torques. Computing the local torque density at the edge, the rotation threshold is found to be crossed when the local edge NBI torque is negative in nearly all discharges. Reducing the upper triangularity (delta_up ) from the ITER-similar value of 0.3 to 0.1 significantly reduces the pedestal height and width. This in turn: 1) Increases the rotation threshold and yields a more outward critical ExB rotation zero-crossing location. 2) Decreases the density threshold, consistent with a comparable collisionality range at lower pedestal temperatures. 3) Increases the input torque requirement, due to observed lower confinement and smaller intrinsic torque. These findings represent an important step along the road to predicting ELM suppression access conditions in future tokamaks such as ITER, where the toroidal rotation is expected to be low and consequently the rotation zero-crossing far from the pedestal-top.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2020

MADE3D™ (Manufacturing and Additive Design of Electric Machines Enabled by Three-Dimensional Printing) [SWR-20-70]

The MADE3D™ software uses advanced neural networks for realizing novel high torque density electric machine designs with desired functional specifications not limited to but including torque, magnetic loading, and mass. This software allows for a reduction in cost of design by using next-generation computational resources including the cloud while still maintaining high accuracy. The design of the neural networks allows for exploration of large design space and possibilities to find more optimal designs and accommodate new manufacturing technologies like 3D printing.

Sethuraman, Latha↗
DOE OSTI2025

Field validation of dynamic mechanical torque measurements using fiber-optic strain sensors for geared wind turbines

Abstract Accurate knowledge of the mechanical loads of wind turbine gearboxes has become essential in modern, highly loaded gearbox designs, as maintaining or even improving gearbox reliability with increasing torque density demands is proving to be challenging. Unfortunately, the traditional method of measuring dynamic mechanical torque using strain gauges placed on the outer surface of a rotating shaft and transmitting the resulting signal is unsuitable for serial deployment due to technical and economic constraints. An alternative method based on fiber-optic strain sensors placed on the stationary outer surface of the gearbox ring gear has been proposed. Like shaft torsion, the radial deformation of the ring gear is proportionate to the rotor torque. Placing the sensors on a stationary component is a cost-effective alternative for serial implementation because the need for complex and expensive data transfer via wireless transmission or a slip ring is eliminated. In this paper, we present the results of an extensive field experiment conducted to evaluate the torque measurement accuracy of this novel sensing solution installed on the gearbox of a Gamesa G97 2-MW wind turbine at the National Renewable Energy Laboratory’s Flatirons Campus. Torque measurements derived from fiber-optic strain sensors placed on the ring gear of the planetary stage are compared to conventional torque measurements from strain gauges placed on the main shaft. Two different torque estimation data processing methods were evaluated, with the method based on operational deflection shapes providing the most accurate results with an average normalized root mean square error below 0.7% for a load revolution distribution analysis. The effect of operating conditions on the torque estimate was also investigated, and the third planet-passing operational deflection shape was found to be the least sensitive to nontorque load-related effects. The fiber-optic strain sensors’ successful operation during the complete test campaign has demonstrated a robust and accurate solution for fleet-wide enhanced gearbox remaining useful life estimation.

17 WIND ENERGY↗
DOE OSTI2025

Field Validation of Dynamic Mechanical Torque Measurements for Geared Wind Turbines

Accurate knowledge of the mechanical loads of wind turbine gearboxes has become essential in modern, highly loaded gearbox designs, as maintaining or even improving gearbox reliability with increasing torque density demands is proving to be challenging. Unfortunately, the traditional method of measuring dynamic mechanical torque using strain gauges placed on the outer surface of a rotating shaft and transmitting the resulting signal is unsuitable for serial deployment due to technical and economic constraints. An alternative method based on fiber-optic strain sensors placed on the stationary outer surface of the gearbox ring gear has been proposed. Like shaft torsion, the radial deformation of the ring gear is proportionate to the rotor torque. Placing the sensors on a stationary component is a cost-effective alternative for serial implementation because the need for complex and expensive data transfer via wireless transmission or a slip ring is eliminated. In this paper, we present the results of an extensive field experiment conducted to evaluate the torque measurement accuracy of this novel sensing solution installed on the gearbox of a Gamesa G97 2-MW wind turbine at the National Renewable Energy Laboratory's Flatirons Campus. Torque measurements derived from fiber-optic strain sensors placed on the ring gear of the planetary stage are compared to conventional torque measurements from strain gauges placed on the main shaft. Two different torque estimation data processing methods were evaluated, with the method based on operational deflection shapes providing the most accurate results with an average normalized root mean square error below 0.7% for a load revolution distribution analysis. The effect of operating conditions on the torque estimate was also investigated, and the third planet-passing operational deflection shape was found to be the least sensitive to nontorque load-related effects. The fiber-optic strain sensors' successful operation during the complete test campaign has demonstrated a robust and accurate solution for fleet-wide enhanced gearbox remaining useful life estimation.

17 WIND ENERGY↗
DOE OSTI2026

Electronic structure of the kagome compound CaTi 3⁢ Bi 4 using high-field torque magnetometry and density functional theory

Here, we report systematic torque magnetometry measurements to investigate the electronic properties of the newly discovered kagome compound CaTi 3 ⁢Bi 4 . Electrical transport, magnetic susceptibility, and thermal measurements reveal no evidence of a magnetic ground state in this material. Torque data obtained in magnetic fields up to 41.5 T exhibit clear de Haas–van Alphen (dHvA) oscillations, with nine distinct frequencies ranging from 13 to 6164 T. Angular-dependent dHvA measurements show that, with the exception of the lowest frequency (13 T), all observed frequencies nearly follow a 1/cos ⁡𝜃 dependence, where 𝜃 is the angle between the crystallographic 𝑐 axis and the magnetic field direction. This behavior is characteristic of quasi-two-dimensional Fermi-surface sheets with nearly circular cross sections. To further elucidate the electronic structure, we performed density functional theory (DFT) calculations of the band structure and Fermi surface. The calculated bands reveal the presence of multiple Dirac points (DP), flat bands (FB), and van Hove singularities (VHS) near the Fermi level. The resulting Fermi surface consists of several quasi-two-dimensional cylindrical sheets, consistent with the experimentally observed 1/cos⁡ 𝜃 dependence. Notably, the theoretical dHvA frequencies, derived from extremal Fermi-surface cross-sectional areas, agree well with the experimental values and reproduce their angular dependence. Remarkably, all experimentally observed frequencies are captured by the DFT predictions. Pressure-dependent calculations up to 10 GPa show that the electronic features—DP, FB, and VHS—evolve systematically with pressure. In particular, the VHS shifts closer to the Fermi level, demonstrating that pressure acts as an effective tuning parameter in this material. These combined experimental and theoretical results provide a comprehensive understanding of the electronic structure of CaTi 3 ⁢Bi 4 and demonstrate how pressure can be used to tune its key electronic features, offering valuable guidance for exploring related kagome materials.

Shtefiienko, Kyryl [West Texas A & M University, C↗
NASA NTRS2019

Electromagnetic Mass and Efficiency of Magnetic Gears for Electrified Aircraft

Magnetic gears are currently being developed for use in a variety of industries such as wind and automotive, because of their higher reliability and lower maintenance cost than their mechanical counterparts. The bulk of magnetic gear development to date has focused on maximizing the technology's volumetric torque density. In contrast, the primary performance metrics for an aircraft's gear box are its mass and efficiency. To that end this paper presents a study of the achievable electromagnetic specific torque and efficiency of concentric magnetic gears. NASA's second magnetic gear prototype is used as the baseline for this study. Achievable electromagnetic specific torque and efficiency trends are presented with respect to higher level design variables such as gear ratio and radius.

Tallerico, Thomas F.↗
DOE OSTI2020

A Comprehensive Review of Permanent Magnet Transverse Flux Machines: Use in Direct-Drive Applications

The use of direct-drive machines in renewable and industrial applications is increasing at a rapid rate. Transverse flux machines (TFMs) are ideally suited for direct-drive applications due to their high torque density. This article presents a comprehensive review of permanent magnet (PM) TFMs for direct-drive applications. It introduces TFMs and their operating principle and reviews the different types of TFMs proposed in the literature. TFMs are categorized by the number of stator sides, types of stator cores, and magnet arrangement in the rotor. The review covers different design topologies, materials used for manufacturing, structural and thermal analyses, modeling, design optimization, and cogging torque minimization in TFMs. The article also examines various applications and comparisons for TFMs presented in the literature.

air gaps↗
DOE OSTI2022

A New Shape Optimization Approach for Lightweighting Electric Machines Inspired by Additive Manufacturing

Minimizing the mass in electric machines while maintaining superior performance is a new requirement for the advancement of drivetrains used in wind energy and electric mobility. Topology optimization (TO) for lightweighting electric machines using traditional approaches typically explores a restricted design space allowed by standard parametrizable geometry and manufacturing, while advanced methods, such as cell-based density approaches, suffer from a lack of robust manufacturability constraints during the optimization process. To overcome these drawbacks, we explore a grid-independent, boundary optimization where the outer shape of the magnet is parameterized using Bezier curves. We conduct a design of experiments (DOE) to study the effect of different magnet shapes on machine performance by varying the control points on the Bezier curves. A machine-learning-based surrogate model is constructed using the data from the DOE to quantify the relationship between the control points, air-gap torque, and mass. The control points are then optimized to maximize the torque density. The approach is used for minimizing electrical steel mass in the International Energy Agency (IEA) 15-MW radial flux direct-drive wind turbine generator. The new approach to shape optimization resulted in smooth and concise shapes that can be easily additively manufactured with up to a 20-ton reduction in electrical steel mass.

additive manufacturing↗
DOE OSTI2022

A Boundary Topology Optimization Approach for Lightweighting Electric Machines Inspired by Additive Manufacturing

Minimizing the mass in electric machines while maintaining superior performance has become a new requirement for the advancement of drivetrains used in wind energy and electric mobility. Topology optimization for light-weighting electric machines using traditional approaches typically explore a restricted design space allowed by standard parametrizable geometry and manufacturing, while advanced methods like cell-based density approaches suffer from a lack of robust manufacturability constraints during the optimization process. To overcome these drawbacks, we explore a grid-independent, boundary TO where the outer shape of the magnet is parameterized using Bezier curves. We conduct a design of experiments (DOE) to study the effect of different magnet shapes on machine performance by varying the control points on the Bezier curves. A machine-learning based surrogate model is constructed using the data from the DOE to quantify the relationship between the control points, air-gap torque and mass. The control points are then optimized to maximize the torque density. The approach is used for minimizing electrical steel mass in the IEA-15MW radial flux direct-drive wind turbine generator. The free-from boundary TO resulted in smooth and concise shapes that can be easily additively manufactured with upto 20-ton reduction in electrical steel mass.

additive manufacturing↗
DOE OSTI2022

A New Shape Optimization Approach for Lightweighting Electric Machines Inspired by Additive Manufacturing: Preprint

Minimizing the mass in electric machines while maintaining superior performance is a new requirement for the advancement of drivetrains used in wind energy and electric mobility. Topology optimization (TO) for lightweighting electric machines using traditional approaches typically explores a restricted design space allowed by standard parametrizable geometry and manufacturing, while advanced methods, such as cell-based density approaches, suffer from a lack of robust manufacturability constraints during the optimization process. To overcome these drawbacks, we explore a grid-independent, boundary TO where the outer shape of the magnet is parameterized using Bezier curves. We conduct a design of experiments (DOE) to study the effect of different magnet shapes on machine performance by varying the control points on the Bezier curves. A machine-learning-based surrogate model is constructed using the data from the DOE to quantify the relationship between the control points, air-gap torque, and mass. The control points are then optimized to maximize the torque density. The approach is used for minimizing electrical steel mass in the International Energy Agency (IEA) 15-MW radial flux direct-drive wind turbine generator. The free-form boundary TO resulted in smooth and concise shapes that can be easily additively manufactured with up to a 20-ton reduction in electrical steel mass.

additive manufacturing↗
NASA NTRS2016

Closed Loop Control Compact Exercise Device for Use on MPCV

Long duration space travel to Mars or to an asteroid will expose astronauts to extended periods of reduced gravity. To combat spaceflight physiological deconditioning, astronauts will use resistive and aerobic exercise regimens for the duration of the space flight to minimize the loss of bone density, muscle mass and aerobic capacity that occurs during exposure to a reduced gravity environment. Unlike the International Space Station (ISS), the mass and volume available for an exercise device in the next generation of spacecraft is limited. Therefore, compact exercise device prototypes are being developed for human in the loop evaluations. The NASA Human Research Program (HRP) is managing Advanced Exercise Concepts (AEC) requirements development and candidate technology maturation for all exploration mission profiles from Multi-Purpose Crew Vehicle (MPCV) exploration missions (e.g., EM-2, up to 21 day) to Mars Transit (up to 1000 day) missions. Numerous technologies have been considered and evaluated against HRP-approved functional requirements and include flywheel, pneumatic and closed-loop microprocessor-controlled motor driven power plants. Motor driven technologies offer excellent torque density and load accuracy characteristics as well as the ability to create custom mechanical impedance (the dynamic relationship between force and velocity) and custom load versus position exercise algorithms. Further, closed-loop motor-driven technologies offer the ability to monitor exercise dose parameters and adapt to the needs of the crewmember for real time optimization of exercise prescriptions. A simple proportional-integral-derivative (PID) controller is demonstrated in a prototype motor driven exercise device with comparison to resistive static and dynamic load set points and aerobic work rate targets. The resistive load term in the algorithm includes a constant force component (Fcmg) as well as inertial component (Fima) and a discussion of system tuning is presented in terms of addressing key functional requirements and human interfaces. The device aerobic modality is modelled as a rowing exercise using ground data sets obtained from Concept 2 rowers as well as competitive rowing1. A discussion of software and electronic implementations are presented which demonstrate unique approaches to meeting the constrained mass, volume and power requirements of the MPCV. . In addition to utilizing traditional PID control, controllers utilizing state feedback with gains solved using a Linear Quadratic Regulator will be developed. Controllability and observability will be utilized to investigate the need for state measurement in the design. As the control system directly interacts with human test subjects, robust methods such as H-infinity are also being investigated.1. Kleshnev V. Biomechanics. In: Rowing, Handbook of Sports Medicine and Science. ed. by Secher N., Voliantis S. IOC Medical Commission, Blackwell Pub. pp. 22-34, 2007

microgravity↗
DOE OSTI2016

On the origin of vorticity in magnetic particle suspensions subjected to triaxial fields

We have recently reported that two classes of time-dependent triaxial magnetic fields can induce vorticity in magnetic particle suspensions. The first class – symmetry-breaking fields – is comprised of two ac components and one dc component. The second class – rational triad fields – is comprised of three ac components. In both cases deterministic vorticity occurs when the ratios of the field frequencies form rational numbers. A strange aspect of these fields is that they produce fluid vorticity without generally having a circulating field vector, such as would occur in a rotating field. It has been shown, however, that the symmetry of the field trajectory, considered jointly with that of the converse field, allows vorticity to occur around one particular field axis. This axis might be any of the field components, and is determined by the relative frequencies of the field components. However, the symmetry theories give absolutely no insight into why vorticity should occur. In this paper we propose a particle-based model of vorticity in these driven fluids. This model proposes that particles form volatile chains that follow, but lag behind, the dynamic field vector. Furthermore, this model is consistent with the predictions of symmetry theory and gives reasonable agreement with previously reported torque density measurements for a variety of triaxial fields.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗
DOE OSTI2019

Electromagnetic analysis of a wind turbine magnetic gearbox

The design of the second stage of a 59:1 multi‐stage magnetic gearbox for a wind turbine demonstrator is presented. The multi‐stage series‐connected magnetic gearbox is composed of a 6.45 first stage and 9.14 second stage. A flux‐focusing spoke‐type rotor typology is used with a unique segmented fully laminated design. The impact of structural design changes is considered with respect to torque density. A new rotor typology is presented that enables the magnetic gearbox to be mechanically assembled first without magnets.

Li, Kang↗