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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 109 records · Page 6
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Emerging magnetic materials for electric vehicle drive motors

Abstract Increasing demand for electric vehicles (EVs) is increasing demand for the permanent magnets that drive their motors, as approximately 80% of modern EV drivetrains rely on high-performance permanent magnets to convert electricity into torque. In turn, these high-performance permanent magnets rely on rare earth elements for their magnetic properties. These elements are “critical” (i.e., at risk of limiting the growth of renewable energy technologies such as EVs), which motivates an exploration for alternative materials. In this article, we overview the relevant fundamentals of permanent magnets, describe commercialized and emerging materials, and add perspective on future areas of research. Currently, the leading magnetic material for EV motors is Nd 2 Fe 14 B, with samarium-cobalt compounds (SmCo 5 and Sm 2 Co 17 ) providing the only high-performing commercialized alternative. Emerging materials that address criticality concerns include Sm 2 Fe 17 N 3 , Fe 16 N 2 , and the L1 0 structure of FeNi, which use lower cost elements that produce similar magnetic properties. However, these temperature-sensitive materials are incompatible with current metallurgical processing techniques. We provide perspective on how advances in low-temperature synthesis and processing science could unlock new classes of high-performing magnetic materials for a paradigm shift beyond rare earth-based magnets. In doing so, we explore the question: What magnetic materials will drive future EVs? Graphical abstract

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2021

PNNL ARENA Cable Motor Test Bed Update

A major focus of the Light Water Reactor Sustainability (LWRS) Cable Nondestructive Examination (NDE) 2021 research is to acquire new equipment and integrate it with existing NDE instruments for a cable motor test bed which has been dubbed the Accelerated and Real Time Experimental Nodal Analysis or “ARENA”. All the primary components have been received and are being staged in the 2410 Stevens building on PNNL’s Richland campus. Building modifications to support a plug-in 480VAC receptacle have been completed and details of the system operating procedure (SOP) are in review. The approved SOP is required before the system is energized but is expected before July 2021. The ARENA system will support planned cable tests for 2021 and beyond that cannot conveniently be performed with on-site installations of cable test equipment including: (1) NDE Tests including Frequency Domain Reflectometry (FDR), Time Domain Reflectometry (TDR), Tan Delta (TD) Impedance measurements, Low Frequency Dielectric Spectroscopy (DS) measurements, standard multi-meter resistance checks, withstand tests and other bulk and distributed tests from the instrument panel with and without motors connected. (2) Online energized live wire tests using partial discharge instruments and LIVE-WIRE spread-spectrum TDR instruments. (3) Cable tests with partially submerged cable segments (including ability to submerge live cable segments). (4) Cable tests with partially or completely thermally aged segments (including ability to expose energized cable segments to thermal aging and use online monitoring instruments to monitor cable performance. (5) Ability to introduce low resistance simulations of connector or splice faults to off-line and on-line instrument setups.

42 ENGINEERING↗
DOE OSTI2024

Emerging magnetic materials for electric vehicle drive motors [Slides]

Increasing demand for electric vehicles (EVs) is increasing demand for the permanent magnets that drive their motors, as approximately 80% of modern EV drivetrains rely on high-performance permanent magnets to convert electricity into torque. In turn, these high-performance permanent magnets rely on rare earth elements for their magnetic properties. These elements are "critical" (i.e., at risk of limiting the growth of renewable energy technologies such as EVs), which motivates an exploration for alternative materials. In this article, we overview the relevant fundamentals of permanent magnets, describe commercialized and emerging materials, and add perspective on future areas of research. Currently, the leading magnetic material for EV motors is Nd 2 Fe 14 B, with samarium-cobalt compounds (SmCo 5 and Sm 2 Co 17 ) providing the only high-performing commercialized alternative. Emerging materials that address criticality concerns include Sm 2 Fe 17 N 3 , Fe 16 N 2 , and the L10 structure of FeNi, which use lower cost elements that produce similar magnetic properties. However, these temperature-sensitive materials are incompatible with current metallurgical processing techniques. We provide perspective on how advances in low-temperature synthesis and processing science could unlock new classes of high-performing magnetic materials for a paradigm shift beyond rare earth-based magnets. In doing so, we explore the question: What magnetic materials will drive future EVs?

42 ENGINEERING↗
DOE OSTI2022

CFD simulations of electric motor end ring cooling for improved thermal management

Proper thermal management of an electric motor for vehicle applications extends its operating range. One cooling approach is to impinge Automatic Transmission Fluid (ATF) onto the rotor end ring. Increased ATF coverage correlates to enhanced heat transfer. Computational Fluid Dynamics (CFD) analytical tools provide a mechanism to assess motor thermal management prior to hardware fabrication. The complexity of the fluid flow (e.g., jet atomization, interface tracking, wall impingement) and heat transfer makes these simulations challenging. Computational costs are high when solving these flows on high-speed rotating meshes. Typically, a Volume-of Fluid (VOF) technique (i.e., two-fluid system) is used to resolve ATF dynamics within this rotating framework. Suitable numerical resolution of the relevant physics for thin films under strong inertial forces at high rotor speeds is computationally expensive, further increasing the run times. In this work, a numerical study of rotor-ring cooling by ATF is presented using a patent automated Cartesian cut-cell based method coupled with Automatic Mesh Refinement (AMR). This approach automatically creates the Cartesian mesh on-the-fly and can effectively handle complex rotating geometries by adaptively refining the mesh based on local gradients in the flow field which results in better resolution of the air-ATF interface. A Single non-inertial Reference Frame (SRF) approach is used to account for the rotating geometry and to further improve the overall computational efficiency. Quasi-steady state conditions are targeted in the analysis of the results. Important physics such as ATF jet structure, velocity detail near the air-jet interface, ATF coverage/accumulation on the ring surface, and cooling capacity are presented for a low-resolution Reynolds averaged Navier-Stokes (RANS), high-resolution RANS, and high-resolution Large-Eddy Simulation (LES) models. Computations are scaled over hundreds of cores on a supercomputer to maximize turnaround time. Each numerical approach is shown to capture the general trajectory of the oil jet prior to surface impingement. The high-resolution LES simulation, however, is superior in capturing small scale details and heat transfer between the free jet and surrounding air.

42 ENGINEERING↗
DOE OSTI2023

CRISPR/Cas9 Directed Reprogramming of iPSC for Accelerated Motor Neuron Differentiation Leads to Dysregulation of Neuronal Fate Patterning and Function

Neurodegeneration causes a significant disease burden and there are few therapeutic interventions available for reversing or slowing the disease progression. Induced pluripotent stem cells (iPSCs) hold significant potential since they are sourced from adult tissue and have the capacity to be differentiated into numerous cell lineages, including motor neurons. This differentiation process traditionally relies on cell lineage patterning factors to be supplied in the differentiation media. Genetic engineering of iPSC with the introduction of recombinant master regulators of motor neuron (MN) differentiation has the potential to shorten and streamline cell developmental programs. We have established stable iPSC cell lines with transient induction of exogenous LHX3 and ISL1 from the Tet-activator regulatory region and have demonstrated that induction of the transgenes is not sufficient for the development of mature MNs in the absence of neuron patterning factors. Comparative global transcriptome analysis of MN development from native and Lhx-ISL1 modified iPSC cultures demonstrated that the genetic manipulation helped to streamline the neuronal patterning process. However, leaky gene expression of the exogenous MN master regulators in iPSC resulted in the premature activation of genetic pathways characteristic of the mature MN function. Dysregulation of metabolic and regulatory pathways within the developmental process affected the MN electrophysiological responses.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2024

Electric Motor Thermal Management

During FY 2022, NREL efforts focused on supporting collaborations with external research partners within the Electric Drive Technologies research consortium. The poster highlights collaborations with SNL, ORNL, and Georgia Tech. The collaboration with SNL utilized NREL's experimental capabilities to mechanically characterize SNL-provided material samples for motor applications. The collaboration with ORNL supported efforts to refine the design of a high-speed, non-heavy-rare-earth outer-rotor motor. The collaboration with Georgia Tech focused on a novel cooling technique for electric machines. NREL supported the effort by leading the thermal analysis and design of advanced machines.

ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2024

Tutorial - Electric Motor and Integrated Traction Drive Thermal Management

The share of vehicles with fully electric propulsion systems is constantly increasing, and so is their traction drive power. The continuous push to increase power of electric vehicle (EV) traction drives necessitates their efficient cooling to prevent damage to temperature sensitive components of the drive system and achieving higher power outputs in a smaller footprint. With increasing power and power density of electric traction drives, their thermal management is becoming increasingly challenging. This tutorial will provide an overview of thermal management approaches for electric motors and power electronics in EV applications. It will review examples of current industry solutions for power-dense electric motor cooling, power electronics (inverter) cooling, their integration concepts and thermal management system solutions. We'll look at the advantages and challenges of power electronics integration into a single traction drive unit and respective thermal management system concepts. We'll talk about barriers to implementation of a unified thermal management system. The tutorial will also review key aspects of thermal management system design: modeling and simulation using FEA and CFD tools, experimental characterization, and general workflow for thermal management system evaluation.

ADVANCED PROPULSION SYSTEMS,DIRECT ENERGY CONVERSI↗
DOE OSTI2022

Extremum-Seeking-Based Ultra-local Model Predictive Control and Its Application to Electric Motor Speed Regulation

Electric vehicle (EV) market is rapidly expanding. As a critical component of EV, an electric motor needs to accurately follow a reference speed signal while respecting the electrical current constraint for safety. Those requirements are usually formulated as a model predictive control (MPC) problem. However, the performance of traditional model-based MPC depends on the accuracy of the system model, which may not always be guaranteed in reality. Therefore, we utilize a data-driven, model-free predictive control strategy, called ultra-local MPC (ULMPC), to control the speed of an electric motor. To further enhance the control performance of ULMPC, we employ the extremum-seeking control (ESC) to tune the control gain of the ULMPC online. Simulation and hardware experiments demonstrate the enhancement of the extremum-seeking-based ULMPC over a constant-gain ULMPC.

Zhou, Yujing↗
DOE OSTI2020

Scale-free, programmable design of morphable chain loops of kilobots and colloidal motors

Micron-scale robots require systems that can morph into arbitrary target configurations controlled by external agents such as heat, light, electricity, and chemical environment. Achieving this behavior using conventional approaches is challenging because the available materials at these scales are not programmable like their macroscopic counterparts. To overcome this challenge, we propose a design strategy to make a robotic machine that is both programmable and compatible with colloidal-scale physics. Our strategy uses motors in the form of active colloidal particles that constantly propel forward. We sequence these motors end-to-end in a closed chain forming a two-dimensional loop that folds under its mechanical constraints. We encode the target loop shape and its motion by regulating six design parameters, each scale-invariant and achievable at the colloidal scale. We demonstrate the plausibility of our design strategy using centimeter-scale robots called kilobots . We use Brownian dynamics simulation to explore the large design space beyond that possible with kilobots, and present an analytical theory to aid the design process. Multiple loops can also be fused together to achieve several complex shapes and robotic behaviors, demonstrated by folding a letter shape “M,” a dynamic gripper , and a dynamic pacman . The material-agnostic, scale-free, and programmable nature of our design enables building a variety of reconfigurable and autonomous robots at both colloidal scales and macroscales.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Enhanced tunable cavity development for axion dark matter searches using a piezoelectric motor in combination with gears

Most search experiments sensitive to quantum chromodynamics (QCD) axion dark matter benefit from microwave cavities, as electromagnetic resonators, that enhance the detectable axion signal power and thus the experimental sensitivity drastically. As the possible axion mass spans multiple orders of magnitude, microwave cavities must be tunable and it is desirable for the cavity to have a tunable frequency range that is as wide as possible. Since the tunable frequency range generally increases as the dimension of the conductor tuning rod increases for a given cylindrical conductor cavity system, we developed a cavity system with a large dimensional tuning rod in order to increase this. Here we, for the first time, employed not only a piezoelectric motor, but also gears to drive a large and accordingly heavy tuning rod, where such a combination to increase driving power can be adopted for extreme environments as is the case for axion dark matter experiments: cryogenic, high-magnetic-field, and high vacuum. Thanks to such higher power derived from the piezoelectric motor and gear combination, we realized a wideband tunable cavity whose frequency range is about 42% of the central resonant frequency of the cavity, without sacrificing the experimental sensitivity too much.

47 OTHER INSTRUMENTATION↗
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↗
DOE OSTI2025

Heat Pipe Enhanced Thermal Management System for GaN Switches in an Integrated Modular Motor Drive for Aircraft Propulsion

This paper presents the process of sizing a heat pipe enhanced thermal management system (TMS) for GaN switches in an integrated modular motor drive (IMMD) powering a 250 kW aircraft propulsion electric motor. A test setup mimicking the TMS and GaN switches assembly is constructed. The condenser chamber of the TMS is modeled in ANSYS Fluent while the GaN switches assembly is modeled in ANSYS Thermal allowing us to verify heat spreader temperature under test conditions and estimate GaN temperatures under test and actual application operating conditions.

DIRECT ENERGY CONVERSION↗
DOE OSTI2025

Integrated On-Board Charger for Dual Motor Based Electric Vehicle Power Train

This paper presents an integrated on-board charger for dual motor based electric vehicle (EV) power train with silicon carbide semiconductor switch-based traction inverters. The proposed charger architecture reconfigures the traction inverters to be used in the battery charging mode, thereby eliminating several high frequency switches and their accessories. The motor windings are reused as line inductors for the power factor correction (PFC) rectifier stage in the charging mode thereby reducing the requirements of magnetic components. The architectures reduce the cost, weight, and volume of the EV power train. Simulation results are presented to demonstrate the working principle of the proposed architecture.

Mukherjee, Subho [ORNL] (ORCID:0009000672297925)↗
DOE OSTI2020

Enhanced Performance of Dual Inverter with a Floating Capacitor for Motor Drive Applications

This paper studies a dual inverter supplied by a DC-link and a floating capacitor (FC), emerged as a promising inverter topology for motor drive applications. For this type of inverter, the voltage ratio between the DC-link and the FC can be actively controlled. This ratio design is crucial as it essentially defines both the DC-link voltage utilization and the inverter output quality. Several voltage ratios have previously been discussed to enhance the dual inverter performance, but only one aspect, either the voltage utilization or the output quality, is investigated. As a result, although one performance aspect can be improved, the other aspect has been adversely affected. In this work, a comparative study considering both aspects is carried out for all the possible voltage ratios. Based on this analysis, the optimal ratios for different inverter modulation indices are identified. This is followed by proposing a ratio selection strategy to double the voltage utilization without degrading the output quality. Furthermore, this strategy enables an electric drive to work at a higher maximum speed without flux weakening for a given DC-link voltage. The claimed advantages have been proved by experimental tests on an open-end windings induction motor drive.

42 ENGINEERING↗
DOE OSTI2021

Flow Assisted Evaporative Cooling for Electric Motor

This paper examines a novel concept of flow assisted latent heat driven two-phase evaporative cooling (EC) confined in-between slot liner and active-winding of electric motor. Wicking micro-structure enhanced PDMS liner axially sucks coolant in the form of thin film between the PDMS liner and active-winding and eventually enables thin film evaporation on the outer surface of the active-winding. Therefore, EC based thermal management eliminates contact resistance between the winding and slot-liner and, enhances the heat extraction from the winding without compromising the electro-magnetic performance. Two-way coupled electro-magnetic (EM) – computational fluid dynamics/heat transfer (CFD/HT) and EM - lumped parameter thermal network (LPTN) models have been developed to assess the electro-thermal performance of the EC under steady and transient conditions. Taking a case study of a 125 kW jacket cooled BMW i3 motor and dielectric coolant FC-84, EC is shown to be capable of handling a maximum steady state rms current density of 26 A/mm2 at a evaporative heat transfer coefficient of 5,000 W/m2.K, which is about 78.7% higher compared to the traditional jacket cooling (JC). In case of EC, a maximum steady state and transient rms current density of 30 A/mm2 (106.2% higher compared to the JC), and 40.8 A/mm2 have been realized by using high thermal conductivity epoxy (1.9 W/m.K) impregnation material. Thermal performance of the EC is also assessed and compared with JC over a dynamic drive cycle. Lastly, a motorette testing has been performed to demonstrate the applicability of the proposed EC method and to validate the developed modeling framework.

42 ENGINEERING↗
DOE OSTI2025

Motor neurons in the tunicate caudal central nervous system reveal homology to the vertebrate spinal cord

ABSTRACT Invertebrate chordates, such as the tunicate Ciona, can offer insight into the evolution of the chordate phylum. Anatomical features shared between invertebrate chordates and vertebrates may be taken as evidence of their presence in a common chordate ancestor. The central nervous systems (CNSs) of Ciona larvae and vertebrates share a similar anatomy despite the Ciona CNS having only ∼180 neurons. However, the depth of conservation between the Ciona CNS and those of vertebrates is not resolved. The Ciona caudal CNS, while appearing spinal cord-like, has hitherto been thought to lack motor neurons, bringing into question its homology with the vertebrate spinal cord. We show here that the Ciona larval caudal CNS does, in fact, have functional motor neurons along its length, pointing to the presence of a functional spinal cord-like structure at the base of the chordates.

Kourakis, Matthew J.↗
DOE OSTI2020

Manufacturing Hybrid Copper-Aluminum Rotors for High Power Induction and Permanent Magnet Electric Motors: CRADA 475 [Abstract only]

General Motors Research & Development (GM R&D) and Pacific Northwest National Laboratory (PNNL) will develop an electric rotor manufacturing technology with the potential of making electric motors lighters and more efficient. This will be achieved by developing a solid phase joining method to effectively join the Copper shorting bars to Aluminum end cap.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2023

Motor with Advanced Concepts for High power density and INtegrated cooling for Efficiency (MACHINE)

Raytheon Technologies Research Center (RTRC) is the central research and development (R&D) organization for RTX, and has extensive expertise in the design, modeling and analysis of high-performance electrical machines and thermal management for all its business units. The proposing team consists of researchers from RTRC and John Deere (JD), will be referred as “Team”. Each organization a has long track record of successful R&D of materials, manufacturing, components, and systems for energy efficiency applications. Motor power density and efficiency are limited by fundamental physical trade-offs between electromagnetics, thermal management, and structural design considerations. The team is proposing to utilize novel technologies and multi-physics design methods to develop a Motor with Advanced Concepts for High power density and INtegrated cooling for Efficiency (MACHINE), demonstrating an 8X improvement in power density.

33 ADVANCED PROPULSION SYSTEMS↗