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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 1,477 records · Page 82
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

A Fast-Response High-Accuracy Overvoltage Protection Circuit for Soft-Switching Current-Source Converters

Although voltage-source converters (VSCs) have been a focus of research for decades and are widely applied in numerous applications, they face great challenges in short-circuit failures, high dv/dt and electromagnetic interference (EMI), especially using wide bandgap devices. Instead, current-source converters (CSCs) are attracting increasing attention in recent years owing to their friendliness to short-circuit faults, improved EMI, etc. For CSCs, overvoltage is the most catastrophic failure since the semiconductor devices can hardly withstand an overvoltage for a short pulse. In this paper, a fast-response high-accuracy overvoltage protection (OVP) circuit is proposed to protect CSCs from overvoltage damage. It also features a small form factor, good noise-immunity, friendly retrofit capability, and no need for active switches. In this paper, the operating principle and design guideline of the proposed OVP circuit is introduced. Its effectiveness is validated in soft-switching solid-state transformer (S4T) at 500 V. In experiments, the voltage detection error of less than 5% and a propagation delay of fewer than 400 ns have been achieved.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2022

A Single-Stage Multilevel AC-DC Bidirectional Converter With Natural Grid Harmonic Elimination

Generally, AC-DC converters have an AC-DC stage followed by a DC-DC stage. In these two stage approaches, the AC-DC stage is hard-switched, whereas the DC-DC stage is soft-switched. Therefore, the devices in the AC-DC stage can be switched only at tens of kHz to avoid excessive switching losses, thus limiting the bandwidth of the current control loop. Hence, the control of these converters with distorted grid voltages requires multiple harmonic compensation loops or other complex control algorithms in order for the grid currents to comply with IEEE standards. By integrating both the stages, the devices in the AC-DC stage can also be soft-switched, thus facilitating higher switching frequency, and thereby higher current control bandwidth. This paper proposes an integrated multilevel bidirectional AC-DC converter with improved control bandwidth and disturbance rejection. It is shown experimentally that the high bandwidth current control loop of the converter can reject grid harmonic current disturbances, without the need for any compensation loops or complex control techniques, and comply with IEEE standards.

30 DIRECT ENERGY CONVERSION↗
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 OSTI2015

Estimate of Fuel Consumption and GHG Emission Impact on an Automated Mobility District: Preprint

This study estimates the range of fuel and emissions impact of an automated-vehicle (AV) based transit system that services campus-based developments, termed an automated mobility district (AMD). The study develops a framework to quantify the fuel consumption and greenhouse gas (GHG) emission impacts of a transit system comprised of AVs, taking into consideration average vehicle fleet composition, fuel consumption/GHG emission of vehicles within specific speed bins, and the average occupancy of passenger vehicles and transit vehicles. The framework is exercised using a previous mobility analysis of a personal rapid transit (PRT) system, a system which shares many attributes with envisioned AV-based transit systems. Total fuel consumption and GHG emissions with and without an AMD are estimated, providing a range of potential system impacts on sustainability. The results of a previous case study based of a proposed implementation of PRT on the Kansas State University (KSU) campus in Manhattan, Kansas, serves as the basis to estimate personal miles traveled supplanted by an AMD at varying levels of service. The results show that an AMD has the potential to reduce total system fuel consumption and GHG emissions, but the amount is largely dependent on operating and ridership assumptions. The study points to the need to better understand ride-sharing scenarios and calls for future research on sustainability benefits of an AMD system at both vehicle and system levels.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2017

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

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

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2020

Design of BLDC Motor Diagnostic Device Based on Surge Test for Phase to Ground Fault

BLDC motor is essential in the industrial world, especially it been used for an electric vehicle. The benefit of using BLDC motor is that it has high rate efficiency and low mechanical losses. However, to know the isolation condition of winding and increase reliability, it needs to be tested. With the implementation of surge test based fault detection device of BLDC motor, the condition of BLDC motor can be monitored and maintained according to analysis of its condition. The surge test method used because it is sensitive in detecting the initial damage in the isolation failure process on stator winding. A surge voltage is generated from the Cockroft-Walton and switching circuit with capacitors. The result is analyzed using Error Area Ratio (EAR). The test result shows that the higher the value of resistance and inductance, the smaller the frequency of the surge wave. When the BLDC motor in a parallel short circuit condition, the threshold value of the EAR test-reff has a minimum value of 5.28%, an average of 13.52%, and a maximum of 28.55%.

BLDC motor↗
DOE OSTI2020

Enabling Seamless Integration of EV Charging Infrastructure with Weak Electric Grids

Widespread adoption of Electric Vehicles (EVs) for light, medium, and heavy-duty applications has gained significant interest. Based on ownership and user preferences, light duty and local delivery medium-duty EVs are typically connected to grid distribution networks whereas larger medium duty and heavy-duty EVs are typically connected to distribution or even sub-transmission networks. Challenges with at-scale EVs and charging infrastructure supporting them include interoperability, distribution network upgrades, surge in demand charges, power quality issues, voltage stability, etc. Based on real-world data, steady-state and dynamic assessments of light-duty EV charging with a focus on DC Fast Charging (DCFC) for weak distribution grids is presented. Three main areas of contributions in this paper include - steady state and dynamic power quality measurements and assessments using real world data, transient assessments of light duty EV integration with weak distribution networks (IEEE 13 node feeder system) under grid-connected and microgrid modes, and formulation of an intelligent charging decision algorithm to enable an impact-minimal charging.

actionable intelligence↗
DOE OSTI2014

Thermal Performance and Reliability Characterization of Bonded Interface Materials (BIMs): Preprint

Thermal interface materials are an important enabler for low thermal resistance and reliable electronics packaging for a wide array of applications. There is a trend towards bonded interface materials (BIMs) because of their potential for low thermal resistivity (< 1 mm2K/W). However, BIMs induce thermomechanical stresses in the package and can be prone to failures and integrity risks. Deteriorated interfaces can result in high thermal resistance in the package and degradation and/or failure of the electronics. DARPA's Thermal Management Technologies program has addressed this challenge, supporting the development of mechanically-compliant, low resistivity nano-thermal interface (NTI) materials. In this work, we describe the testing procedure and report the results of NREL's thermal performance and reliability characterization of an initial sample of four different NTI-BIMs.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2016

Evaluation of Performance and Opportunities for Improvements in Automotive Power Electronics Systems: Preprint

Thermal management strategies for automotive power electronic systems have evolved over time to reduce system cost and to improve reliability and thermal performance. In this study, we characterized the power electronic thermal management systems of two electric-drive vehicles--the 2012 Nissan LEAF and 2014 Honda Accord Hybrid. Tests were conducted to measure the insulated-gate bipolar transistor-to-coolant thermal resistances for both steady-state and transient conditions at various coolant flow rates. Water-ethylene glycol at a temperature of 65 degrees C was used as the coolant for these experiments. Computational fluid dynamics and finite element analysis models of the vehicle's power electronics thermal management system were then created and validated using experimentally obtained results. Results indicate that the Accord module provides lower steady-state thermal resistance as compared with the LEAF module. However, the LEAF design may provide improved performance in transient conditions and may have cost benefits.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2018

Road Network State Estimation Using Random Forest Ensemble Learning

Network-scale travel time prediction not only enables traffic management centers (TMC) to proactively implement traffic management strategies, but also allows travelers make informed decisions about route choices between various origins and destinations. In this paper, a random forest estimator was proposed to predict travel time in a network. The estimator was trained using two years of historical travel time data for a case study network in St. Louis, Missouri. Both temporal and spatial effects were considered in the modeling process. The random forest models predicted travel times accurately during both congested and uncongested traffic conditions. The computational times for the models were low, thus useful for real-time traffic management and traveler information applications.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2016

Circulating Current Suppressing Control’s Impact on Arm Inductance Selection for Modular Multilevel Converter

Arm inductor in a modular multilevel converter (MMC) is used to limit the circulating current and dc short circuit fault current. The circulating current in MMC is dominated by second-order harmonic, which can be largely reduced with circulating current suppressing control. By analyzing the mechanism of the circulating current suppressing control, it is found that the circulating current at switching frequency becomes the main harmonic when suppression control is implemented. Unlike the second-order harmonic that circulates only within the three phases, switching frequency harmonic also flows through the dc side and may further cause high-frequency dc voltage harmonic. This article develops the theoretical relationship between the arm inductance and switching frequency circulating current, which can be used to guide the arm inductance selection. The experimental results with a downscaled MMC prototype verify the existence of the switching frequency circulating current and its relationship with arm inductance.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2022

Reliability and Lifetime Prediction Model of Sintered Silver Under High-Temperature Cycling

Although excellent reliability has been reported for sintered silver as a die-attach material under both thermal and power cycling loads in power electronics applications, the promise of this material as a large-area attachment at temperatures beyond 200 degrees C needs to be investigated. This paper presents insights into the thermomechanical behavior and reliability of sintered silver under extreme thermal cycling conditions. In this study, we bonded sintered silver samples and subjected it to a thermal cycling profile of -40 °C to 200 °C with high ramp rates. We periodically monitored samples under thermal cycling to detect the presence of any failure mechanisms using a scanning acoustic microscope. We also included 95Pb5Sn solder in the study to obtain reference data. Results show the occurrence of cracks in sintered silver followed by a rapid rate of crack growth that exceeded the failure criterion in just 50 cycles. The predominant failure mechanism we observed was adhesive failure. As a large-area attachment, solder exhibited a higher reliability than sintered silver but failed within 100 cycles. Finally, we performed thermomechanical modeling to compute strain energy density values and correlated these with the experimentally observed crack growth rates to formulate a lifetime prediction model for sintered silver.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2021

Reliability Analysis of Large-Area, Low Pressure-Assisted Silver Sintering for Medium-Voltage Power Modules

Multi-layer insulating ceramic substrates can enable medium-voltage (MV) power modules with reduced peak electric field. This benefit is particularly important for MV silicon carbide (SiC) MOSFETs due to their higher operating voltages. Large-area, low-pressure assisted silver sintering is a potential solution for bonding substrates to create a multi-layer structure. The voiding content and defect density of the bond used to create the multi-layer substrate stack-up is critical to the reliability of the power module and the thermal performance, as this bond is in the primary path for heat dissipation in the power module structure. Here, samples of two-layer direct bonded aluminum (DBA) stacks have been fabricated and subjected to thermal cycling to analyze their reliability. Passive thermal cycling from -40 degrees C to 200 degrees C was performed. Cross-sections were cut at pre-determined intervals and imaged with Scanning Electron Microscopy (SEM). After 1000 thermal cycles, adhesive failures are observed between the sintered silver and the DBA surface. Cross-sections were cut and imaged via optical microscope and SEM. Thermal analyzer measurements are recorded on a 10-kV SiC power module utilizing the sintered DBA substrate stacks.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2023

Active Reconditioning of Retired Lithium-ion Battery Packs from Electric Vehicles for Second Life Applications

Utilizing the remaining capacity in retired lithium-ion (Li-ion) batteries from electric vehicles (EVs) for second-life applications has shown economic and environmental benefits. However, achieving homogeneity among the capacities of cells before their second life is critical to exploit the benefits. This article proposes a new active reconditioning approach with the potential to make short-term reconditioning of batteries before second life feasible. A control objective map determines each cell's state-of-charge (SOC) operating window based on its capacity relative to other cells. The SOC reference translates into distinct differential currents through the cells, wherein the higher-capacity cells undergo more frequent and deep charge and discharge cycles than their lower-capacity counterparts. The proposed solution achieves capacity homogeneity within the battery pack with low reconditioning time and minimal fade in the overall pack capacity. The feasibility of the reconditioning approach under varying load and environmental conditions is assessed through simulations, encompassing factors such as the number of cycles per day, depth-of-discharge, battery pack temperature, and cell resting time at different SOCs. Furthermore, the simulation model employs a battery pack with sixteen series-connected 75 Ah Kokam lithium nickel manganese cobalt oxide (NMC) cells with a 3.6% initial capacity imbalance. A reconditioning time of 1.3 months is achieved with a final capacity imbalance of 0.1% and an overall capacity fade of 0.005%, thereby confirming the viability of the reconditioning process. Moreover, experimental validation using eight retired battery cells from a Nissan Leaf demonstrates a substantial decrease in the capacity imbalance of cells from 9.4% to 2.15% within 78 days, effectively affirming the efficacy of the proposed reconditioning scheme.

25 ENERGY STORAGE↗
DOE OSTI2019

Thread/OpenThread: A Compromise in Low-Power Wireless Multihop Network Architecture for the Internet of Things

Extending an Internet subnet by connecting resource-constrained nodes (e.g., embedded sensors and actuators) over multiple wireless hops is necessary to support the future Internet of Things (IoT). RPL, the IPv6 routing standard for low-power and lossy networks, tried to achieve this goal but has not seen wide adoption in practice. As an alternative, Thread is a recently standardized low-power network protocol for IoT, driven by the Thread group, an industry consortium led by Google/Nest. Here, we provide a comparative analysis of the technical aspects of RPL and Thread based on their specifications, explaining why using Thread, as opposed to RPL, may make sense for the future Internet. Specifically, the fundamental differences between RPL and Thread are their respective scopes and multihop network architectures, which result in Thread's unique design and advantages over RPL. Lastly, we evaluate Thread in an indoor multihop wireless testbed using OpenThread, an official open source implementation of Thread. This work serves as the first analysis of the Thread protocol in academia.

30 DIRECT ENERGY CONVERSION↗