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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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NASA Reference Motor Designs for Electric Vertical Takeoff and Landing Vehicles

Electric and hybrid electric vertical takeoff and landing vehicles require high performance and high reliability electric motor drivetrains. Failure analysis of NASA’s Revolutionary Vertical Lift Technologies’ reference vehicles pointed to current electric motor drivetrain reliability being below what is needed to meet the expected stringent reliability requirements for Urban Air Mobility vehicles [1]. In this paper, design studies are carried out for UAM vehicle electric motors to produce reference designs. The primary intent of these reference motor designs is to provide guidance for UAM motor reliability model development and technology advancement. They additionally provide high fidelity motor sizing information for vehicle designers and references for different technologies or motor topologies to be traded against.

Thomas Tallerico↗
DOE OSTI2026

Advancing the HERO WEC Through Integrated Modeling, Testing, and Field Deployments

The Hydraulic and Electric Reverse Osmosis Wave Energy Converter (HERO WEC) was developed by the National Laboratory of the Rockies as a modular platform for advancing wave-powered desalination technologies. Designed to operate in either a hydraulic or electric configuration, the system enables direct comparison of mechanical-to-water and electrical-to-water conversion pathways using a single hardware architecture. Deployments in 2022 and 2024 at the Jennette's Pier test site in North Carolina demonstrated freshwater production between 60 and 300 gallons per day, including successful operation in wave heights as low as 0.25 m. A structured evaluation approach combining numerical modeling of hydrodynamic and power take-off response, controlled laboratory testing, and in-ocean field deployments has been used to characterize and refine system performance. Specifically, insights from these efforts are now informing the second-generation HERO WEC (V2) to increase robustness and overall survivability. Changes from the original prototype include improved drivetrain components, refined geometry, enhanced control systems, and design. The HERO WEC platform continues to serve as an open-access research asset supporting broader marine energy and desalination development.

16 TIDAL AND WAVE POWER↗
DOE OSTI2016

NREL and DONG Energy Collaboration for Grid Simulator Controls and Testing: Cooperative Research and Development Final Report, CRADA Number CRD-13-527

The National Renewable Energy Laboratory (NREL) and DONG Energy are interested in collaborating for the development of control algorithms, modeling, and grid simulator testing of wind turbine generator systems involving NWTC's advanced Controllable Grid Interface (CGI). NREL and DONG Energy will work together to develop control algorithms, models, test methods, and protocols involving NREL's CGI, as well as appropriate data acquisition systems for grid simulation testing. The CRADA also includes work on joint publication of results achieved from modeling and testing efforts. Further, DONG Energy will send staff to NREL on a long-term basis for collaborative work including modeling and testing. NREL will send staff to DONG Energy on a short-term basis to visit wind power sites and participate in meetings relevant to this collaborative effort. DOE has provided NREL with over 10 years of support in developing custom facilities and capabilities to enable testing of full-scale integrated wind turbine drivetrain systems in accordance with the needs of the US wind industry. NREL currently operates a 2.5MW dynamometer and is in the processes of commissioning a 5MW dynamometer and a grid simulator (referred to as a 'Controllable Grid Interface' or CGI). DONG Energy is the market leader in offshore wind power development, with currently over 1 GW of on- and offshore wind power in operation, and 1.3 GW under construction. DONG Energy has on-going R&D projects involving high voltage DC (HVDC) transmission.

17 WIND ENERGY↗
DOE OSTI2022

Integration of Pumped Heat Energy Storage with Fossil-Fired Power Plant (Final Report)

The project team of Southwest Research Institute ® (SwRI ® ), Malta Inc. (Malta), and Luminant Generation Company LLC (Luminant) completed a feasibility study for the integration of a 100-MW, 10-hour (1000-MWh) Malta Pumped Heat Energy Storage (MPHES) system with multiple full-sized fossil-fired electricity generation units (EGU) in Luminant portfolio. MPHES is a long-duration, molten-salt-energy storage technology that uses turbomachinery and heat exchangers to transfer energy to a thermal storage media when charging, and removes the heat in a similar fashion when discharging. With high round trip efficiency (60-65%) and long lifespan (30+ years), MPHES provides economic benefits to the fossil-asset owners that can be scaled to integrate with assets across their portfolio. This technology uses hardware components, workforce personnel, and skillsets similar to those used by fossil EGUs, allowing for synergy when co-locating the two technologies. Luminant has approximately 39,000 megawatts of generation across 12 states, operating in six of the seven competitive markets in the U.S. and powered by a diverse portfolio of natural gas, nuclear, coal, and solar facilities. The DeCordova plant in Granbury, Texas, a simple cycle natural gas peaker power plant, was used as the fossil-fired asset in this project. The local market in Granbury, Texas has many influences, including several nearby power plants, a Luminant-owned nuclear plant (Comanche Peak), and substantial wind energy, which causes both negative pricing at night and high market volatility. Reducing false starts of the DeCordova plant and better responding to market volatility would be an economic advantage. Luminant is currently integrating battery storage plant on site to begin addressing these challenges. Integrating long-duration storage, like MPHES, would expand this capability beyond one hour of storage and have the potential to greatly reduce the total number of gas turbine starts. The MPHES charging requirement could help offset the overnight operating costs of Comanche Peak, which cannot load follow, and the nearby Luminant-owned Wise County combined cycle plant that cycles too often. Following the assessment of Luminant’s ERCOT-based portfolio for integration compatibility with Malta’s PHES system and the project tasks of conceptual study, technoeconomic analysis, technology gap assessment, and commercialization plan, the project team effort has resulted in several key outcomes: (1) Identification of market trends in a high-wind penetration market outside a major metropolitan area; (2) Creation of a dispatching model for the MPHES system and the pairing of Li-ion battery with a gas turbine in a real time market; (3) Revenue and cost estimations for operating MPHES alongside a gas peaker plant with real dispatching considerations and comparison with variations in the Malta implementation, including doubling the storage capacity and using two discharge drivetrains; (4) Potential carbon emission reductions possible by replacing gas turbine operation with Malta PHES operation; and (5) Summary of literature-based future market predictions for Texas.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2015

Development of a 5 MW reference gearbox for offshore wind turbines: 5 MW reference gearbox

This paper presents detailed descriptions, modeling parameters and technical data of a 5MW high-speed gearbox developed for the National Renewable Energy Laboratory offshore 5MW baseline wind turbine. The main aim of this paper is to support the concept studies and research for large offshore wind turbines by providing a baseline gearbox model with detailed modeling parameters. This baseline gearbox follows the most conventional design types of those used in wind turbines. It is based on the four-point supports: two main bearings and two torque arms. The gearbox consists of three stages: two planetary and one parallel stage gears. The gear ratios among the stages are calculated in a way to obtain the minimum gearbox weight. The gearbox components are designed and selected based on the offshore wind turbine design codes and validated by comparison to the data available from large offshore wind turbine prototypes. All parameters required to establish the dynamic model of the gearbox are then provided. Moreover, a maintenance map indicating components with high to low probability of failure is shown. The 5 MW reference gearbox can be used as a baseline for research on wind turbine gearboxes and comparison studies. It can also be employed in global analysis tools to represent a more realistic model of a gearbox in a coupled analysis.

17 WIND ENERGY↗
DOE OSTI2014

Effects of increasing tip velocity on wind turbine rotor design.

A reduction in cost of energy from wind is anticipated when maximum allowable tip velocity is allowed to increase. Rotor torque decreases as tip velocity increases and rotor size and power rating are held constant. Reduction in rotor torque yields a lighter weight gearbox, a decrease in the turbine cost, and an increase in the capacity for the turbine to deliver cost competitive electricity. The high speed rotor incurs costs attributable to rotor aero-acoustics and system loads. The increased loads of high speed rotors drive the sizing and cost of other components in the system. Rotor, drivetrain, and tower designs at 80 m/s maximum tip velocity and 100 m/s maximum tip velocity are created to quantify these effects. Component costs, annualized energy production, and cost of energy are computed for each design to quantify the change in overall cost of energy resulting from the increase in turbine tip velocity. High fidelity physics based models rather than cost and scaling models are used to perform the work. Results provide a quantitative assessment of anticipated costs and benefits for high speed rotors. Finally, important lessons regarding full system optimization of wind turbines are documented.

17 WIND ENERGY↗
DOE OSTI2026

Optimized Gear Selection to Maximize Energy Savings in Electric Traction Drives for Medium and Heavy Duty Vehicles

Multi‑gear transmission systems are commonly used in electric traction drives for medium and heavy‑duty vehicles, while most passenger‑vehicle electric drivetrains rely on a single fixed ratio to reduce cost, weight, and complexity. Using multiple gear ratios can enable downsizing of the motor and inverter while still meeting performance requirements. Additionally, appropriately chosen ratios allow the motor to operate more frequently in high‑efficiency regions, improving overall energy usage and reducing operating costs over the drive cycle. This paper presents a systematic approach for selecting optimal gear ratios for electric drive systems. A neural‑network model is first developed to represent motor losses across the full torque–speed range using data generated from finite element analysis. This model enables fast, accurate evaluation of motor efficiency under varying operating conditions. A genetic‑algorithm‑based optimization framework is then applied to identify gear ratios that maximize energy cost savings over the drive cycle, with the resulting optimal ratios stored for real‑time implementation.

Gadiyar, Nishanth [ORNL] (ORCID:0000000348267524)↗
DOE OSTI2019

A Prognostics and Health Management Framework for Wind

Operation and maintenance costs are a major driver for levelized cost of energy of wind power plants and can be reduced through optimized operation and maintenance practices accomplishable by various prognostics and health management (PHM) technologies. In recent years, the wind industry has become more open to adopting PHM solutions, especially those focusing on diagnostics. However, prognostics activities are, in general, still at the research and development stage. On the other hand, the industry has a request to estimate a component's remaining useful life (RUL) when it has faulted, and this is a key output of prognostics. Systematically presenting PHM technologies to the wind industry by highlighting the RUL prediction need potentially helps speed up its acceptance and provides more benefits from PHM to the industry. In this paper, we introduce a PHM for wind framework. It highlights specifics unique to wind turbines and features integration of data and physics domain information and models. The output of the framework focuses on RUL prediction. To demonstrate its application, a data domain method for wind turbine gearbox fault diagnostics is presented. It uses supervisory control and data acquisition system time series data, normalizes gearbox temperature measurements with reference to environmental temperature and turbine power, and leverages big data analytics and machine-learning techniques to make the model scalable and the diagnostics process automatic. Another physics-domain modeling method for RUL prediction of wind turbine gearbox high-speed-stage bearings failed by axial cracks is also discussed. Bearing axial cracking has been shown to be the prevalent wind turbine gearbox failure mode experienced in the field and is different from rolling contact fatigue, which is targeted during the bearing design stage. The method uses probability of failure as a component reliability assessment and RUL prediction metric, which can be expanded to other drivetrain components or failure modes. The presented PHM for wind framework is generic and applicable to both land-based and offshore wind turbines.

17 WIND ENERGY↗
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↗
DOE OSTI2014

Effect of Tip-Speed Constraints on the Optimized Design of a Wind Turbine

This study investigates the effect of tip-velocity constraints on system levelized cost of energy (LCOE). The results indicate that a change in maximum tip speed from 80 to 100~m/s could produce a 32% decrease in gearbox weight (a 33% reduction in cost) which would result in an overall reduction of 1%-9% in system LCOE depending on the design approach. Three 100~m/s design cases were considered including a low tip-speed ratio/high-solidity rotor design, a high tip-speed ratio/ low-solidity rotor design, and finally a flexible blade design in which a high tip-speed ratio was used along with removing the tip deflection constraint on the rotor design. In all three cases, the significant reduction in gearbox weight caused by the higher tip-speed and lower overall gear ratio was counterbalanced by increased weights for the rotor and/or other drivetrain components and the tower. As a result, the increased costs of either the rotor or drivetrain components offset the overall reduction in turbine costs from down-sizing the gearbox. Other system costs were not significantly affected, whereas energy production was slightly reduced in the 100~m/s case low tip-speed ratio case and increased in the high tip-speed ratio case. This resulted in system cost of energy reductions moving from the 80~m/s design to the 100~m/s designs of 1.2% for the low tip-speed ratio, 4.6% for the high tip-speed ratio, and 9.5% for the final flexible case (the latter result is optimistic because the impact of deflection of the flexible blade on power production was not modeled). Overall, the results demonstrate that there is a trade-off in system design between the maximum tip velocity and the overall wind plant cost of energy, and there are many trade-offs within the overall system in designing a turbine for a high maximum tip velocity.

17 WIND ENERGY↗
DOE OSTI2017

Non-steady wind turbine response to daytime atmospheric turbulence

Relevant to drivetrain bearing fatigue failures, we analyse non-steady wind turbine responses from interactions between energy-dominant daytime atmospheric turbulence eddies and the rotating blades of a GE 1.5 MW wind turbine using a unique dataset from a GE field experiment and computer simulation. Time-resolved local velocity data were collected at the leading and trailing edges of an instrumented blade together with generator power, revolutions per minute, pitch and yaw. Wind velocity and temperature were measured upwind on a meteorological tower. The stability state and other atmospheric conditions during the field experiment were replicated with a large-eddy simulation in which was embedded a GE 1.5 MW wind turbine rotor modelled with an advanced actuator line method. Both datasets identify three important response time scales: advective passage of energy-dominant eddies (≈25–50 s), blade rotation (once per revolution (1P), ≈3 s) and sub-1P scale (<1 s) response to internal eddy structure. Large-amplitude short-time ramp-like and oscillatory load fluctuations result in response to temporal changes in velocity vector inclination in the aerofoil plane, modulated by eddy passage at longer time scales. Generator power responds strongly to large-eddy wind modulations. Lastly, we show that internal dynamics of the blade boundary layer near the trailing edge is temporally modulated by the non-steady external flow that was measured at the leading edge, as well as blade-generated turbulence motions.

17 WIND ENERGY↗
DOE OSTI2018

Integrated Boosting and Hybridization for Extreme Fuel Economy and Downsizing

The objective of this project was to develop, demonstrate, and evaluate commercialization of a highly efficient downsized engine by electrification of the air delivery and waste heat recovery system and optimizing energy usage to achieve significant fuel economy improvement at a commercially viable cost. The system consists of an Electrically Assisted Variable speed Supercharger (EAVS), driven by an electric motor and the engine through a planetary gear train, that provides engine boost pressure and provides the mild hybrid functions of engine start/stop, torque assist, and brake energy recovery. In the exhaust path of the engine is the electric Waste Heat Recovery (eWHR) system, a roots-based expander driven by another electric motor, that enables exhaust gas energy recovery along with controlled back pressure on the engine. The two electric motors are powered by a 48V rechargeable lithium-ion battery. Further, the EAVS system coupled to an EGR valve enables very precise high exhaust recirculation rates to control the NOx emissions. Through two budget periods, the project team of Eaton, Isuzu, Southwest Research Institute and AVL designed and developed the EAVS and eWHR systems, integrated with an Isuzu diesel engine, and validated the target fuel economy performance and emissions by engine dynamometer testing and vehicle level simulations. GT Power model-based analyses results were used to size the EAVS and eWHR systems for the 1.9L Isuzu Spark engine. The two systems were built and the functional testing was carried out to verify the boosting performance of the superchargers. Following the baseline engine dynamometer testing, the two systems were integrated with the engine and the fuel economy performance and emissions were determined by combined steady state and transient testing over three drive cycles, namely, FTP75, NEDC and HWFET. The EAVS/eWHR system demonstrated 4% improvement in fuel economy for the NEDC cycle in engine dyno testing, correlating well with vehicle simulation results (5.3%). The simulation results indicated that the combination of hybrid functions and drivetrain optimization, fuel economy improvement of more than 20% was feasible with the system. The commercialization study to evaluate the cost of the system and the scalability for different engine/vehicle classes was planned for the final budget period but not completed as the project was closed at the end of budget period two.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2021

A proposed criteria to identify wind turbine drivetrain bearing loads that induce roller slip based white-etching cracks

In this article, the type of roller slip behavior that may result in the formation of white-etching cracks (WECs) in wind turbine gearbox bearings is identified. A new hypothesis based on the inner raceway normal contact load magnitude at the time of roller slip is proposed as the probable cause of WECs. For this purpose, the maximum normal contact loads are identified when roller slip occurs in high-speed shaft bearings at different mean wind speeds. Subsequently, the annual probability of occurrence of the maximum normal loads are obtained. The probability of maximum load under slip exceeding a limit probability is hypothesized as a probable cause for WEC. In order to apply the proposed hypothesis, two different wind turbines high-speed shaft bearings are used: the cylindrical roller bearing of the General Electric 1.5 SLE turbine and the tapered roller bearing of Vestas V52 turbine. Both the chosen bearings are on the generator side of the high-speed shaft. For both turbines, measurement data together with analytical models are used for identifying the slip and the maximum normal contact loads. We propose forecasting the probability of exceedance of a threshold maximum normal contact load level during slip to identify the possibility for inducing WECs.

17 WIND ENERGY↗
DOE OSTI2021

Investigation of Main Bearing Operating Conditions in a Three-Point Mount Wind Turbine Drivetrain

Wear related failures of spherical roller bearings in the main bearing position of three-point mount wind turbines have been higher than expected and can contribute to higher than anticipated operation-and-maintenance costs. In this paper, the operational conditions of such a main bearing, including measured axial displacement and velocity subject to the estimated axial loads are described for an instrumented, commercial wind turbine. The field measurements suggest a maximum axial speed between the bearing rings that is less than 2 millimeters per second. It is estimated that the axial speed between the ring and rollers is approximately 25% of this value. When compared to a speed of rolling from approximately 200-352 millimeters per second, the measured axial sliding is therefore significantly less than 1% of the speed of rolling. Previous numerical studies of lubricant film formation in rolling contacts have shown that the effect of axial sliding starts to be noticeable only when this ratio exceeds 10%; therefore, the axial velocity represents only a small disturbance to the nominal pure rolling case, and the influence on oil film building can be neglected. A simple analytic model of the main bearing motion was also developed and demonstrated similar displacement and velocity characteristics.

49 EE - Wind and Water Power Program - Wind (EE-4W↗
DOE OSTI2021

Investigation of main bearing operating conditions in a three-Point mount wind turbine drivetrain

Wear-related failures of spherical roller bearings in the main bearing position of three-point mount wind turbines have been higher than expected and can contribute to higher than anticipated operation-and-maintenance costs. In this paper, the operational conditions of such a main bearing—including measured axial displacement and velocity subject to the estimated axial loads—are described for an instrumented, commercial wind turbine. The field measurements suggest a maximum axial speed between the bearing rings that is less than 2 millimeters per second. It is estimated that the axial speed between the ring and rollers is approximately 25% of this value. When compared to a speed of rolling from approximately 200–352 millimeters per second, the measured axial sliding is therefore significantly less than 1% of the speed of rolling. Previous numerical studies of lubricant film formation in rolling contacts have shown that the effect of axial sliding starts to be noticeable only when this ratio exceeds 10%; therefore, the axial velocity represents only a small disturbance to the nominal pure rolling case, and the influence on oil film building can be neglected. A simple analytic model of the main bearing motion was also developed and demonstrated similar displacement and velocity characteristics.

17 WIND ENERGY↗
DOE OSTI2021

Reliability‐based layout optimization in offshore wind energy systems

Abstract Existing methods for optimizing wind array layouts typically use power or cost objectives and rarely consider reliability‐based objectives. Component and system failure rates, however, are dependent on location‐specific wind conditions, are influenced by array layout and wake interactions, and have a direct and significant impact on capital costs, operational costs, and power production. Although wind power plant models exist that calculate wind loads with sufficient resolution to capture component loading dynamics from wind conditions, they are computationally expensive and thus not suitable for research applications requiring many evaluations, particularly optimization. This study describes the development of computationally efficient, reliability‐based layout optimization methods, enabling us to explore the relationship between component reliability and layout optimization. These methods include the surrogate modeling of the planet bearing life based on varying wind conditions simulated in FAST.Farm and the formulation of reliability‐based objectives based on failure cost and power production models. Through demonstration of this method, we explore how wind conditions, objective functions, and capacity density influence reliability‐based layout optimization. Results indicate that considering reliability alongside power production can reduce failure costs associated with replacement costs and downtime while maintaining or improving power production. Our conclusions highlight the opportunity for wind power plant developers to integrate reliability and operational expenditures alongside performance and capital expenditure objectives in plant design and development to improve plant performance and costs.

17 WIND ENERGY↗