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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 55 records · Page 3
All sourcesNASA NTRSDOE OSTI
DOE OSTI2026

Experimental Results for an Inverter Integrated with A High-Speed Surface Permanent Magnet External Rotor Motor

This work presents the prototyping and testing of a high-speed outer rotor surface permanent magnet motor. The motor employs non-heavy rare-earth permanent magnets and operates at a rated speed of 6,666 rpm. In-slot ceramic heat exchangers are used to cool the windings. The external rotor configuration provides substantial space within the stator bore, which is used for power electronics integration. This integration introduces several design and thermal management challenges that are discussed in the paper. The machine has been prototyped and tested under various operating conditions, and both simulation and experimental results are presented.

Rallabandi, Vandana [ORNL] (ORCID:0000000236241901↗
NASA NTRS1993

Hubble Space Telescope EVA Power Ratchet Tool redesign

The Power Ratchet Tool (PRT) is a self contained, power-driven, 3/8 inch drive ratchet wrench which will be used by astronauts during Extravehicular Activities (EVA). This battery-powered tool is controlled by a dedicated electonic controller. The PRT was flown during the Hubble Space Telescope (HST) Deployment Mission STS-31 to deploy the solar arrays if the automatic mechanisms failed. The PRT is currently intended for use during the first HST Servicing Mission STS-61 as a general purpose power tool. The PRT consists of three major components; the wrench, the controller, and the battery module. Fourteen discrete combinations of torque, turns, and speed may be programmed into the controller before the EVA. The crewmember selects the desired parameter profile by a switch mounted on the controller. The tool may also be used in the manual mode as a non-powered ratchet wrench. The power is provided by a silver-zinc battery module, which fits into the controller and is replaceable during an EVA. The original PRT did not meet the design specification of torque output and hours of operation. To increase efficiency and reliability the PRT underwent a redesign effort. The majority of this effort focused on the wrench. The original PRT drive train consisted of a low torque, high speed brushless DC motor, a face gear set, and a planocentric gear assembly. The total gear reduction was 300:1. The new PRT wrench consists of a low speed, high torque brushless DC motor, two planetary gear sets and a bevel gear set. The total gear reduction is now 75:1. A spline clutch has also been added to disengage the drive train in the manual mode. The design changes to the controller will consist of only those modifications necessary to accomodate the redesigned wrench. The battery design will be unaffected.

Richards, Paul W.↗
DOE OSTI2023

Electrification: 2023 Final Progress Report

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

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2026

Rare‐Earth Reduction in High‐Speed PM‐Assisted Synchronous Reluctance Motors Using Hybrid Magnet Strategies and Design Optimisation for 800 V EVs

The trend towards electrifying transportation systems has stimulated research endeavours aimed at developing electric machines that are not only high speed and efficient but also low‐cost and compact. To support this transition, the US Department of Energy (DOE) has established ambitious targets of $7/kW cost and 12 kW/L power density for the electric drivetrains. This paper attempts to meet these targets by proposing high‐speed permanent magnet assisted synchronous reluctance machine (PMASynRM) topologies enabled by hybrid magnet strategies, combining rare‐earth (RE) magnets with low‐cost, RE‐free alternatives. Modified 2‐layer and 3‐layer U‐shaped rotor configurations, featuring structural reinforcements to withstand high mechanical stress at elevated speeds, are developed. A multi‐objective design optimisation framework is employed to optimise the rotor design, targeting reductions in RE magnet volume, magnet demagnetisation risk and torque ripple while achieving the desired electromagnetic performance. A comprehensive analysis of the optimised rotor designs, compared against a 16,000 rpm, 800 V baseline IPM motor, shows over 70% RE reduction, demagnetisation risk below 3.5% and torque ripple under 10%. Detailed analyses of performance trends across various magnet combinations and rotor configurations highlight the viability of hybrid magnet PMASynRM designs as cost‐effective, robust and energy‐efficient solutions for next‐generation EVs.

33 ADVANCED PROPULSION SYSTEMS↗
NASA NTRS2003

New Technique of High-Performance Torque Control Developed for Induction Machines

Two forms of high-performance torque control for motor drives have been described in the literature: field orientation control and direct torque control. Field orientation control has been the method of choice for previous NASA electromechanical actuator research efforts with induction motors. Direct torque control has the potential to offer some advantages over field orientation, including ease of implementation and faster response. However, the most common form of direct torque control is not suitable for the highspeed, low-stator-flux linkage induction machines designed for electromechanical actuators with the presently available sample rates of digital control systems (higher sample rates are required). In addition, this form of direct torque control is not suitable for the addition of a high-frequency carrier signal necessary for the "self-sensing" (sensorless) position estimation technique. This technique enables low- and zero-speed position sensorless operation of the machine. Sensorless operation is desirable to reduce the number of necessary feedback signals and transducers, thus improving the reliability and reducing the mass and volume of the system. This research was directed at developing an alternative form of direct torque control known as a "deadbeat," or inverse model, solution. This form uses pulse-width modulation of the voltage applied to the machine, thus reducing the necessary sample and switching frequency for the high-speed NASA motor. In addition, the structure of the deadbeat form allows the addition of the high-frequency carrier signal so that low- and zero-speed sensorless operation is possible. The new deadbeat solution is based on using the stator and rotor flux as state variables. This choice of state variables leads to a simple graphical representation of the solution as the intersection of a constant torque line with a constant stator flux circle. Previous solutions have been expressed only in complex mathematical terms without a method to clearly visualize the solution. The graphical technique allows a more insightful understanding of the operation of the machine under various conditions.

Kenny, Barbara H.↗
NASA NTRS1982

Transistorized PWM inverter-induction motor drive system

This paper describes the development of a transistorized PWM inverter-induction motor traction drive system. A vehicle performance analysis was performed to establish the vehicle tractive effort-speed requirements. These requirements were then converted into a set of inverter and motor specifications. The inverter was a transistorized three-phase bridge using General Electric power Darlington transistors. The description of the design and development of this inverter is the principal object of this paper. The high-speed induction motor is a design which is optimized for use with an inverter power source. The primary feedback control is a torque angle control with voltage and torque outer loop controls. A current-controlled PWM technique is used to control the motor voltage. The drive has a constant torque output with PWM operation to base motor speed and a constant horsepower output with square wave operation to maximum speed. The drive system was dynamometer tested and the results are presented.

Peak, S. C.↗
NASA NTRS1988

Two wheeled lunar dumptruck

The design of a two wheel bulk material transport vehicle is described in detail. The design consists of a modified cylindrical bowl, two independently controlled direct drive motors, and two deformable wheels. The bowl has a carrying capacity of 2.8 m (100 ft) and is constructed of aluminum. The low speed, high HP motors are directly connected to the wheels, thus yielding only two moving parts. The wheels, specifically designed for lunar applications, utilize the chevron tread pattern for optimum traction. The vehicle is maneuvered by varying the relative angular velocities of the wheels. The bulk material being transported is unloaded by utilizing the motors to oscillate the bowl back and forth to a height at which dumping is achieved. The analytical models were tested using a scaled prototype of the lunar transport vehicle. The experimental data correlated well with theoretical predictions. Thus, the design established provides a feasible alternative for the handling of bulk material on the moon.

Brus, Michael R.↗
NASA NTRS2003

Safer Roadside Crash Walls Would Limit Deceleration

The figure depicts the aspects of a proposed deceleration-limiting design for crash walls at the sides of racetracks and highways. The proposal is intended to overcome the disadvantages of both rigid barriers and kinetic-energy-absorbing barriers of prior design. Rigid barriers can keep high-speed crashing motor vehicles from leaving roadways and thereby prevent injury to nearby persons and objects, but they can also subject the occupants of the vehicles to deceleration levels high enough to cause injury or death. Kinetic-energy-absorbing barriers of prior design reduce deceleration levels somewhat, but are not designed to soften impacts optimally; moreover, some of them allow debris to bounce back onto roadways or onto roadside areas, and, in cases of glancingly incident vehicles, some of them can trap the vehicles in such a manner as to cause more injury than would occur if the vehicles were allowed to skid along the rigid barriers. The proposed crash walls would (1) allow tangentially impacting vehicles to continue sliding along the racetrack without catching them, (2) catch directly impacting vehicles to prevent them from injuring nearby persons and objects, and (3) absorb kinetic energy in a more nearly optimum way to limit decelerations to levels that human occupants could survive.

Schneider, William C.↗
NASA NTRS1996

40 HP Electro-Mechanical Actuator

This report summarizes the work performed on the 40 BP electro-mechanical actuator (EMA) system developed on NASA contract NAS3-25799 for the NASA National Launch System and Electrical Actuation (ELA) Technology Bridging Programs. The system was designed to demonstrate the capability of large, high power linear ELA's for applications such as Thrust Vector Control (TVC) on rocket engines. It consists of a motor controller, high frequency power source, drive electronics and a linear actuator. The power source is a 25kVA 20 kHz Mapham inverter. The drive electronics are based on the pulse population modulation concept and operate at a nominal frequency of 40 kHz. The induction motor is a specially designed high speed, low inertia motor capable of a 68 peak HP. The actuator was originally designed by MOOG Aerospace under an internal R & D program to meet Space Shuttle Main Engine (SSME) TVC requirements. The design was modified to meet this programs linear rate specification of 7.4 inches/second. The motor and driver were tested on a dynamometer at the Martin Marietta Space Systems facility. System frequency response and step response tests were conducted at the Marshall Space Flight Center facility. A complete description of the system and all test results can be found in the body of the report.

Fulmer, Chris↗
NASA NTRS1996

Electro-Mechanical Actuator. DC Resonant Link Controller

This report summarizes the work performed on the 68 HP electro-mechanical actuator (EMA) system developed on NASA contract for the Electrical Actuation (ELA) Technology Bridging Program. The system was designed to demonstrate the capability of large, high power linear ELAs for applications such as Thrust Vector Control (TVC) on rocket engines. It consists of a motor controller, drive electronics and a linear actuator capable of up to 32,00 lbs loading at 7.4 inches/second. The drive electronics are based on the Resonant DC link concept and operate at a nominal frequency of 55 kHz. The induction motor is a specially designed high speed, low inertia motor capable of a 68 peak HP. The actuator was originally designed by MOOG Aerospace under an internal R & D program to meet Space Shuttle Main Engine (SSME) TVC requirements. The design was modified to meet this programs linear rate specification of 7.4 inches/second. The motor and driver were tested on a dynamometer at the Martin Marietta Space Systems facility. System frequency response, step response and force-velocity tests were conducted at the MOOG Aerospace facility. A complete description of the system and all test results can be found in the body of the report.

Schreiner, Kenneth E.↗
NASA NTRS2012

Performance of Simple Gas Foil Thrust Bearings in Air

Foil bearings are self-acting hydrodynamics devices used to support high speed rotating machinery. The advantages that they offer to process fluid lubricated machines include: high rotational speed capability, no auxiliary lubrication system, non-contacting high speed operation, and improved damping as compared to rigid hydrodynamic bearings. NASA has had a sporadic research program in this technology for almost 6 decades. Advances in the technology and understanding of foil journal bearings have enabled several new commercial products in recent years. These products include oil-free turbochargers for both heavy trucks and automobiles, high speed electric motors, microturbines for distributed power generation, and turbojet engines. However, the foil thrust bearing has not received a complimentary level of research and therefore has become the weak link of oil-free turbomachinery. In an effort to both provide machine designers with basic performance parameters and to elucidate the underlying physics of foil thrust bearings, NASA Glenn Research Center has completed an effort to experimentally measure the performance of simple gas foil thrust bearing in air. The database includes simple bump foil supported thrust bearings with full geometry and manufacturing techniques available to the user. Test conditions consist of air at ambient pressure and temperatures up to 500 C and rotational speeds to 55,000 rpm. A complete set of axial load, frictional torque, and rotational speed is presented for two different compliant sub-structures and inter-pad gaps. Data obtained from commercially available foil thrust bearings both with and without active cooling is presented for comparison. A significant observation made possible by this data set is the speed-load capacity characteristic of foil thrust bearings. Whereas for the foil journal bearing the load capacity increases linearly with rotational speed, the foil thrust bearing operates in the hydrodynamic high speed limit. In this case, the load capacity is constant and in fact often decreases with speed if other factors such as thermal conditions and runner distortions are permitted to dominate the bearing performance.

Bruckner, Robert J.↗
NASA NTRS1970

Low-cost orbiting grinder for cutting ducts

Low-cost, portable machine cuts ducts made from heat-treated alloys. An abrasive wheel, powered by a high-speed air motor mounted on an expandible plug against the inner wall of the duct, gives precise cutting.

Lang, E. J.↗
NASA NTRS1983

High-speed machining of Space Shuttle External Tank (ET) panels

Potential production rates and project cost savings achieved by converting the conventional machining process in manufacturing shuttle external tank panels to high speed machining (HSM) techniques were studied. Savings were projected from the comparison of current production rates with HSM rates and with rates attainable on new conventional machines. The HSM estimates were also based on rates attainable by retrofitting existing conventional equipment with high speed spindle motors and rates attainable using new state of the art machines designed and built for HSM.

Miller, J. A.↗
NASA NTRS1985

AC motor and generator requirements for isolated WECS

After surveying electrically driven loads used on productive farms, the investigators chose three pumps for testing at voltages and frequencies far outside the normal operating range. These loads extract and circulate water and move heat via air, and all are critical to farm productivity. The object was to determine the envelope of supply voltage and frequency over which these loads would operate stably for time intervals under 1 hour. This information is among that needed to determine the feasibility of supplying critical loads, in case of a utility outage, from a wind driven alternator whose output voltage and frequency will vary dramatically in most continental wind regimes. Other related work is surveyed. The salient features and limitations of the test configurations used and the data reduction are described. The development of simulation models suitable for a small computer are outlined. The results are primarily displayed on the voltage frequency plane with the general conclusion that the particular pump models considered will operate over the range of 50 to 90 Hz and a voltage band which starts below rated, decreases as frequency decreases, and is limited on the high side by excessive motor heating. For example, centrifugal pump operating voltage ranges as extensive .4 to 1.4 appear possible. Particular problems with starting, stalling due to lack of motor torque, high speed cavitation, and likely overheating are addressed in a listing of required properties for wind driven alternators and their controllers needed for use in the isolated or stand alone configuration considered.

Park, G. L.↗
NASA NTRS1991

VERDEX: A virtual environment demonstrator for remote driving applications

One of the key areas of the National Advanced Robotics Centre's enabling technologies research program is that of the human system interface, phase 1 of which started in July 1989 and is currently addressing the potential of virtual environments to permit intuitive and natural interactions between a human operator and a remote robotic vehicle. The aim of the first 12 months of this program (to September, 1990) is to develop a virtual human-interface demonstrator for use later as a test bed for human factors experimentation. This presentation will describe the current state of development of the test bed, and will outline some human factors issues and problems for more general discussion. In brief, the virtual telepresence system for remote driving has been designed to take the following form. The human operator will be provided with a helmet-mounted stereo display assembly, facilities for speech recognition and synthesis (using the Marconi Macrospeak system), and a VPL DataGlove Model 2 unit. The vehicle to be used for the purposes of remote driving is a Cybermotion Navmaster K2A system, which will be equipped with a stereo camera and microphone pair, mounted on a motorized high-speed pan-and-tilt head incorporating a closed-loop laser ranging sensor for camera convergence control (currently under contractual development). It will be possible to relay information to and from the vehicle and sensory system via an umbilical or RF link. The aim is to develop an interactive audio-visual display system capable of presenting combined stereo TV pictures and virtual graphics windows, the latter featuring control representations appropriate for vehicle driving and interaction using a graphical 'hand,' slaved to the flex and tracking sensors of the DataGlove and an additional helmet-mounted Polhemus IsoTrack sensor. Developments planned for the virtual environment test bed include transfer of operator control between remote driving and remote manipulation, dexterous end effector integration, virtual force and tactile sensing (also the focus of a current ARRL contract, initially employing a 14-pneumatic bladder glove attachment), and sensor-driven world modeling for total virtual environment generation and operator-assistance in remote scene interrogation.

Stone, Robert J.↗