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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 73 records · Page 4

Concept Design a 1.4 MW Inverter for Rotor Loss Minimization in a Partially Superconducting Motor

Partially superconducting machines with cryocooler-cooled rotors are a potential near term technology that can achieve the motor performance needed by future fixed wing electric aircraft. For this type of machine, minimizing cryogenic heat load is one of the keys for enabling high machine performance. Rotor eddy current loss is often the most difficult cryogenic heat load to mitigate due to current ripple from the motor drive. This paper presents the concept design for a 20 kW/kg, 99.5 percent efficient motor drive that has sufficiently low current ripple to enable high performance partially superconducting machines by minimizing eddy current loss in the rotor. The motor drive concept design uses a resonant, interleaved, and multilevel topology to achieve these high-performance metrics with little current ripple. Rotor magnetic loss analysis using NASA’s 1.4 MW High Efficiency Megawatt Motor (HEMM) is used in the design process to down select the motor drive topology and show that the final design generates less than 5 W of magnetic loss in the rotor.

Concept design↗

Double-V block fingers with cruciform recess

In a robot having a gripper including a pair of fingers and a drive motor for driving the fingers toward and away from one another while the fingers remain parallel to each other, the fingers consist of finger pads, which interface with a handle on an object to be grasped, and a shank, which attaches the fingers to the robot gripper. The double-V finger has two orthogonal V-grooves forming in the center of the finger pads and recessed cruciform. The double-V finger is used with a handle on the object to be grasped which is the negative of the finger pads. The handle face consists of V-shaped pads capped with a rectangular cruciform. As the gripper is brought into place near the handle, the finger pads are lined up facing the handle pads. When the finger pad and the handle pad are in proper alignment, the rectangular ridges on the handle fall inside the rectangular grooves on the finger, and the grip is complete.

Voellmer, George M.↗

Controller for a High-Power, Brushless dc Motor

Driving and braking torques controllable. Control circuit operates 7-kW, 45-lb-ft (61-N-m), three-phase, brushless dc motor in both motor and generator modes. In motor modes, energy from power source is pulse-width modulated to motor through modified "H-bridge" circuit, in generator mode, energy from motor is pulse-width modulated into bank of load resistors to provide variable braking torques. Circuit provides high-resolution torque control in both directions over wide range of speeds and torques. Tested successfully at bus voltages up to 200 Vdc and currents up to 45 A.

Fleming, David J.↗

Driving an Active Vibration Balancer to Minimize Vibrations at the Fundamental and Harmonic Frequencies

Vibrations of a principal machine are reduced at the fundamental and harmonic frequencies by driving the drive motor of an active balancer with balancing signals at the fundamental and selected harmonics. Vibrations are sensed to provide a signal representing the mechanical vibrations. A balancing signal generator for the fundamental and for each selected harmonic processes the sensed vibration signal with adaptive filter algorithms of adaptive filters for each frequency to generate a balancing signal for each frequency. Reference inputs for each frequency are applied to the adaptive filter algorithms of each balancing signal generator at the frequency assigned to the generator. The harmonic balancing signals for all of the frequencies are summed and applied to drive the drive motor. The harmonic balancing signals drive the drive motor with a drive voltage component in opposition to the vibration at each frequency.

Holliday, Ezekiel S.↗

Baseline tests of the Kordesh hybrid passenger vehicle

Performance test results are presented for a four-passenger Austin A40 sedan that was converted to a heat-engine-alternator-and battery-powered hybrid. It is propelled by a conventional, gasoline-fueled, heat-engine-driven alternator and a traction pack powering a series-wound, 10 hp direct-current electric drive motor. The 16 hp gasoline engine drives the 7 kilowatt alternator, which provides electrical power to the drive motor or to the 96 volt traction battery through a rectifier. The propulsion battery consists of eight 12 volt batteries connected in series. The electric motor is coupled to a four-speed standard transmission, which drives the rear wheels. Power to the motor is controlled by a three-step foot throttle, which actuates relays that control armature current and field excitation. Conventional hydraulic brakes are used.

Soltis, R. F.↗

SRS Computer Animation and Drive Train System

The spinning rocket simulator (SRS) is an ongoing project at Oral Roberts University. The goal of the SRS is to gather crucial data concerning a spinning rocket under thrust for the purpose of analysis and correction of the coning motion experienced by this type of spacecraft maneuver. The computer animation simulates a virtual, scale model of the component of the SRS that represents the spacecraft itself. This component is known as the (VSM), or virtual spacecraft model. During actual physical simulation, this component of the SRS will experience a coning. The goal of the animation is to cone the VSM within that range to accurately represent the motion of the actual simulator. The drive system of the SRS is the apparatus that turns the actual simulator. It consists of a drive motor, motor mount and chain to power the simulator into motion. The motor mount is adjustable and rigid for high torque application. A digital stepper motor controller actuates the main drive motor for linear acceleration. The chain transfers power from the motor to the simulator via sprockets on both ends.

Arthun, Daniel↗

Design Study of a Coupled Inner-Stator Magnetically Geared Motor for Electric Aircraft Applications

Electric aircraft require high performance and high reliability electric motor drivetrains. A geared electric motor drivetrain will outperform a direct drive motor drivetrain in most applications. Traditional mechanical gearing, however, has mechanical contact-based wear and failure modes that result in added maintenance costs and require an oil lubrication system. Magnetically geared motor drives are a potential technology for electric aircraft applications capable of enabling the benefits of a geared drive without the maintenance, reliability, and lubrication system cost of mechanical gears. In this paper, a topology of magnetically geared motor, an inner stator magnetically geared motor, is explored to estimate its achievable performance for electric aircraft applications. Optimization results on the topology show that it can achieve greater than 15 Nm/kg and 96% efficiency at 100 kW of power.

Thomas Tallerico↗

Design Study of a Coupled Inner-Stator Magnetically Geared Motor for Electric Aircraft Applications

Abstract- Electric aircraft require high performance and high reliability electric motor drivetrains. A geared electric motor drivetrain will outperform a direct drive motor drivetrain in most applications. Traditional mechanical gearing, however, has mechanical contact-based wear and failure modes that result in added maintenance costs and require an oil lubrication system. Magnetically geared motor drives are a potential technology for electric aircraft applications capable of enabling the benefits of a geared drive without the maintenance, reliability, and lubrication system cost of mechanical gears. In this paper, a topology of magnetically geared motor, an inner-stator magnetically geared motor, is explored to estimate its achievable performance for electric aircraft applications. Optimization results on the topology show that it can achieve greater than 15 Nm/kg specific torque and 96% efficiency at 100 kW of power.

Thomas Tallerico↗

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↗

Reliability Models and Demonstration of a Fault-Tolerant Motor Concept for Vertical Takeoff and Landing Vehicles

This report documents the completion of the Revolutionary Vertical Lift Technology Project Annual Performance Indicator 24-3.2.4.1: “Apply and document reliability prediction for high reliability motor concept.” Two modeling tools were completed for calculation of reliability of fault-tolerant (FT) motors, and key FT operations of a modular FT motor were demonstrated experimentally. The two models are complementary tools for the stakeholder and user community. Both models employ Markov chain theory. The first model is a time-homogeneous Markov chain model, and the second is a time-inhomogeneous Markov-Weibull model. This report’s main sections are as follows: 1.0 Introduction, 2.0 Theory, 3.0 Motor Reliability Models, 4.0 Validation of FT Operation by Hardware Demonstration, and 5.0 Concluding Remarks. Novel contributions to the field include development of a modular FT motor concept for electrified vertical takeoff and landing (eVTOL) application, solution methods to solve the reliability calculations, development of figures of merit, and the introduction of “linked chains” to formulate a building-block approach for time-inhomogeneous Markov-Weibull modeling of motor reliability. Example case studies have been completed, and results are provided and discussed herein. A four-module FT motor concept was developed to a preliminary-design level of detail. This eVTOL FT motor concept was designed for galvanic, magnetic, and thermal isolation of stator winding faults. The reliability of the concept motor was calculated using a time-inhomogeneous Markov chain model. Employing average failure rate as a metric, 570 times greater reliability was achieved as compared to a baseline motor without fault tolerance. A demonstrator motor was built and tested. The testing demonstrated the key features of FT operation and validated the essential premises of the FT motor concepts presented herein. The experiments included successful demonstration of the feasibility of the following four key FT features: (1) terminal open-circuit operation, (2) thermal isolation after fault, (3) terminal short-circuit operation, and (4) internal short-circuit operation. These works indicate that FT modular motor drives offer promise for addressing the daunting reliability gap that electric aircraft propulsor drives are facing relative to the best conventional motor drive technology that is available today.

Electric Motor↗

An Impulse Electric Motor for Driving Recording Instruments

The chief purpose in undertaking the development of this synchronous motor was the creation of a very small, compact power source, capable of driving the film drums of the recording aircraft instruments designed by the staff of the National Advisory Committee for Aeronautics.

Joachim, W F↗

Pulse-Width-Modulating Driver for Brushless dc Motor

High-current pulse-width-modulating driver for brushless dc motor features optical coupling of timing signals from low-current control circuitry to high-current motor-driving circuitry. Provides high electrical isolation of motor-power supply, helping to prevent fast, high-current motor-driving pulses from being coupled through power supplies into control circuitry, where they interfere with low-current control signals.

Salomon, Phil M.↗

Design Studies on Mechanically Geared, Magnetically Geared, and Direct Drive Drivetrains for UAM Applications

Urban air mobility vehicles require high reliability and high performance electric motor drive trains. In this paper, a design optimization study is carried out to compare mechanically geared, magnetically geared, and direct drive motor drivetrain topology achievable performance in a 100 kW hover power quad rotor propulsor application. Design studies are carried out accounting for a nominal mission profile. Studies are carried out assuming constant propulsor rotor RPMs of 400, 1000, 2000, and 3000 RPM. Results show that mechanically geared drives are the lightest at all RPMs but their weight benefit over direct drive and magnetically geared decays with increased rotor RPM. Direct drive is shown to always achieve the highest efficiency due to its lower motor speed resulting in low electrical frequencies. Magnetically geared drivetrains are shown to need some requirement refinement or technology improvement to provide significant benefit over direct drive drivetrains.

Thomas Tallerico↗

Design Studies on Mechanically Geared, Magnetically Geared, and Direct Drive Drivetrains for UAM Applications

Urban air mobility vehicles require high reliability and high performance electric motor drive trains. In this paper, a design optimization study is carried out to compare mechanically geared, magnetically geared, and direct drive motor drivetrain topology achievable performance in a 100 kW hover power quad rotor propulsor application. Design studies are carried out accounting for a nominal mission profile. Studies are carried out assuming constant propulsor rotor RPMs of 400, 1000, 2000, and 3000 RPM. Results show that mechanically geared drives are the lightest at all RPMs but their weight benefit over direct drive and magnetically geared decays with increased rotor RPM. Direct drive is shown to always achieve the highest efficiency due to its lower motor speed resulting in low electrical frequencies. Magnetically geared drivetrains are shown to need some requirement refinement or technology improvement to provide significant benefit over direct drive drivetrains.

Thomas Tallerico↗

Angular-displacement mechanism

Redundant-motor drive system, utilizing two electric motors, generates angular displacement to rotate mechanical or optical components in limited arc. Either motor can drive system while other remains stationary. Since stationary motor is not back-driven, system energy requirement is effectively reduced.

Calvert, J. A.↗

Development of a drive system for a sequential space camera

Breadboard models of single and dual motor drives for the shutter, claw and magazine of a space camera system were designed and tested. The single motor technique utilizes a single electronically commutated motor to drive the claw and shutter without resorting to a solenoid actuated clutch for pulse operation. Shutter speed is established by a combination of the cinemode speed and the opening of the conventional DAC two piece shutter. Pulse mode operation is obtained by applying power at a fixed clock rate and removing power at an appropriate point in the mechanical cycle such that the motor comes to rest by system friction. The dual motor approach utilizes a stepper motor to drive the shutter and an electronically commutated dc motor to drive the claw and magazine functions. The motors are synchronized electronically.

Sharpsteen, J. T.↗

Self indexing latch system

A self-latching jaw assembly is described which includes a pair of jaws for latching a fitting of an associated structure such as the keel fitting of a space telescope. The jaw assembly automatically locates the fitting received on a positioning pedestal and latches it in its original location on the pedestal without need of precision alignment. The first jaw is actuated and moved to the right whereupon a reciprocating plunger, extended from the nose of the jaw senses the hub of the spool. A jaw position responsive switch is then actuated to terminate the drive motor of the jaw. The astronaut will then actuate the drive motor of the jaw and the jaw will move to the left, whereupon the standoff will engage the face of the jaw in a latching position. In the latching position, the noses of the jaws will be under the flanges of the spool.

John C Gibson↗