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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 1,549 records · Page 86
All sourcesNASA NTRSDOE OSTI
DOE OSTI2018

Additive Manufacturing: A New Paradigm for the Next Generation of High-Power-Density Direct-Drive Electric Generators: Preprint

In recent years, there has been a growing demand for high-power-density direct-drive generators in the wind industry owing to their high reliability, torque per-unit volume, and conversion efficiencies. However, direct-drive wind turbine generators are very large, low-speed electric machines, which pose remarkable design and manufacturing issues that challenge their upscaling potential and cost of implementation. With air-gap tolerance as the main design driver, the need for high stiffness shifts the focus toward support-structure design that forms a significant portion of the generator's total mass. Existing manufacturing processes allow the use of segmented-steel-weldment disk or spoke-arm assemblies that yield stiffer structures per unit mass but tend to be heavier and more expensive to build. As a result, there is a need for a transformative approach to realize lightweight designs that can also facilitate series production at competitive costs. Inspired by recent developments in metal additive manufacturing (AM), we explore a new freedom in the structural design space with a high potential for weight savings in direct-drive generators. This includes the feasibility of using nonconventional complex geometries, such as lattice-based structures as structurally efficient options. Powder-binder jetting of a sand-cast mold was identified as the most feasible AM technology to produce large-scale generator rotor structures with complex geometry. A parametric optimization study was performed and optimized results within deformation and mass constraints were found for each design. The response to the maximum Maxwell stress due to unbalanced magnetic pull was also explored for each design. Further, a topology optimization was applied for each parameter-optimized design to validate results and provide insights into further mass reduction. These novel designs catered for AM are compared in both deflection and mass to conventional rotor designs using NREL's systems engineering design tool, GeneratorSE. The optimized lattice design with a Ubeam truss resulted in a 24% reduction in structural mass of the rotor and 60% reduction in radial deflection. It is demonstrated that additive manufacturing shifts the focus from manufacturability constraints toward lower mass.

17 WIND ENERGY↗
DOE OSTI2018

Additive Manufacturing: A New Paradigm for the Next Generation of High-Power-Density Direct-Drive Electric Generators

In recent years, there has been a growing demand for high-power-density direct-drive generators in the wind industry owing to their high reliability, torque per unit volume, and conversion efficiencies. However, direct-drive wind turbine generators are very large, low-speed electric machines, which pose remarkable design and manufacturing issues that challenge their upscaling potential and cost of implementation. With air-gap tolerance as the main design driver, the need for high stiffness shifts the focus toward support-structure design that forms a significant portion of the generator's total mass. Existing manufacturing processes allow the use of segmented-steel-weldment disk or spoke-arm assemblies that yield stiffer structures per unit mass but tend to be heavier and more expensive to build. As a result, there is a need for a transformative approach to realize lightweight designs that can also facilitate series production at competitive costs. Inspired by recent developments in metal additive manufacturing (AM), we explore a new freedom in the structural design space with a high potential for weight savings in direct-drive generators. This includes the feasibility of using nonconventional complex geometries, such as lattice-based structures as structurally efficient options. Powder-binder jetting of a sand-cast mold was identified as the most feasible AM technology to produce large-scale generator rotor structures with complex geometry. A parametric optimization study was performed and optimized results within deformation and mass constraints were found for each design. The response to the maximum Maxwell stress due to unbalanced magnetic pull was also explored for each design. Further, a topology optimization was applied for each parameter-optimized design to validate results and provide insights into further mass reduction. These novel designs catered for AM are compared in both deflection and mass to conventional rotor designs using NREL's systems engineering design tool, GeneratorSE. The optimized lattice design with a U-beam truss resulted in a 24% reduction in structural mass of the rotor and 60% reduction in radial deflection. It is demonstrated that additive manufacturing shifts the focus from manufacturability constraints toward lower mass.

17 WIND ENERGY↗
DOE OSTI2017

Cogging Torque Minimization in Transverse Flux Machines

This paper presents the design considerations in cogging torque minimization in two types of transverse flux machines. The machines have a double stator-single rotor configuration with flux concentrating ferrite magnets. One of the machines has pole windings across each leg of an E-Core stator. Another machine has quasi-U-shaped stator cores and a ring winding. The flux in the stator back iron is transverse in both machines. Different methods of cogging torque minimization are investigated. Key methods of cogging torque minimization are identified and used as design variables for optimization using a design of experiments (DOE) based on the Taguchi method. A three-level DOE is performed to reach an optimum solution with minimum simulations. Finite element analysis is used to study the different effects. Two prototypes are being fabricated for experimental verification.

24 POWER TRANSMISSION AND DISTRIBUTION↗
NASA NTRS1992

Modelling and design for PM/EM magnetic bearings

A mathematical model of a permanent magnet/electromagnet (PM/EM) radially active bearing is presented. The bearing is represented by both a reluctance model and a stiffness model. The reluctance model analyzes the magnetic circuit of the PM/EM bearings. By combining the two models, the performance of the bearing can be predicted given geometric dimensions, permanent magnet strength, and the parameters of the EM coils. The overall bearing design including the PM and EM design is subject to the performance requirement and physical constraints. A study of these requirements and constraints is discussed. The PM design is based on the required magnetic flux for proper geometric dimensions and magnet strength. The EM design is based on the stability and force slew rate consideration, and dictates the number of turns for the EM coils and the voltage and current of the power amplifier. An overall PM/EM bearing design methodology is proposed and a case study is also demonstrated.

Pang, D.↗
DOE OSTI2013

Ultra-Efficient and Power Dense Electric Motors for U. S. Industry

The primary purpose of this project was to combine the ease-of-installation and ease-of-use attributes of industrial induction motors with the low-loss and small size and weight advantages of PM motors to create an ultra-efficient, high power density industrial motor that can be started across-the-line or operated from a standard, Volts/Hertz drive without the need for a rotor position feedback device. PM motor products that are currently available are largely variable speed motors that require a special adjustable speed drive with rotor position feedback. The reduced size and weight helps to offset the magnet cost in order make these motors commercially viable. The scope of this project covers horsepower ratings from 20 - 500. Prototypes were built and tested at ratings ranging from 30 to 250 HP. Since fans, pumps and compressors make up a large portion of industrial motor applications, the motor characteristics are tailored to those applications. Also, since there is extensive use of adjustable frequency inverters in these applications, there is the opportunity to design for an optimal pole number and operate at other than 60 Hz frequency when inverters are utilized. Designs with four and eight pole configurations were prototyped as part of this work. Four pole motors are the most commonly used configuration in induction motors today. The results of the prototype design, fabrication, and testing were quite successful. The 50 HP rating met all of the design goals including efficiency and power density. Tested values of motor losses at 50 HP were 30% lower than energy efficient induction motors and the motor weight is 35% lower than the energy efficient induction motor of the same rating. Further, when tested at the 30 HP rating that is normally built in this 286T frame size, the efficiency far exceeds the project design goals with 30 HP efficiency levels indicating a 55% reduction in loss compared to energy efficient motors with a motor weight that is a few percentage points lower than the energy efficient motor. This 30 HP rating full load efficiency corresponds to a 46% reduction in loss compared to a 30 HP NEMA Premium ® efficient motor. The cost goals were to provide a two year or shorter efficiency-based payback of a price premium associated with the magnet cost in these motors. That goal is based on 24/7 operation with a cost of electricity of 10 cents per kW-hr. Similarly, the 250 HP prototype efficiency testing was quite successful. In this case, the efficiency was maximized with a slightly less aggressive reduction in active material. The measured full load efficiency of 97.6% represents in excess of a 50% loss reduction compared to the equivalent NEMA Premium Efficiency induction motor. The active material weight reduction was a respectable 14.5% figure. This larger rating demonstrated both the scalability of this technology and also the ability to flexibly trade off power density and efficiency. In terms of starting performance, the 30 - 50 HP prototypes were very extensively tested. The demonstrated capability included the ability to successfully start a load with an inertia of 25 times the motor's own inertia while accelerating against a load torque following a fan profile at the motor's full nameplate power rating. This capability will provide very wide applicability of this motor technology. The 250 HP prototype was also tested for starting characteristics, though without a coupled inertia and load torque. As a result it was not definitively proven that the same 25 times the motor's own inertia could be started and synchronized successfully at 250 HP. Finite element modeling implies that this load could be successfully started, but it has not yet been confirmed by a test.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2022

A compact design for an electric driven hydraulic gear machine capable of multiple quadrant operation

This paper presents an innovative design of an integrated electro-hydraulic (EH) flow generation unit able to operate in multiple quadrants. The proposed unit is composed of a hydraulic machine which can operate in either pumping or motoring mode, and an electric machine, which can operate as electric motor or generator. The adopted morphological integration of the two unit fulfills the goals of maximizing compactness, power to weight ratio, energy efficiency and quietness. Furthermore, the design results from a numerical optimization procedure that includes detailed simulation of both the electric machine and the hydraulic machine, using simulation tools previously developed by the authors, but combined for the first time in this work. After describing the optimization procedure, the paper focuses on the design integration aspects of the novel unit. A 9 kW prototype of the integrated unit was also fabricated and tested to verify its performance. Tests results show a measured overall energy efficiency up to 69%, demonstrating the potentials of the proposed concept, despite some limitations present in the first prototypes which could be addressed in future design refinements.

42 ENGINEERING↗
DOE OSTI2022

An integrated supply chain analysis for cobalt and rare earth elements under global electrification and constrained resources

As global electrification becomes more prominent, demand is projected to increase for electric vehicles (EVs), their components (EV batteries, rare earth traction motors), and their raw materials (cobalt, rare earths). To analyze the supply chain constraints associated with these components and raw materials, a system dynamics model was developed to simulate the interactions between the rare earth and cobalt supply chains. The results showed that under current understanding of raw material resources, production of the projected volume of EVs could be inadequate. To meet the aggressive EV volume sale projections set by the International Energy Agency, EV manufacturers will need to implement a large portion of traction motors without rare earths and utilize non-cobalt batteries as much as possible. On the supply side, a much faster ramp-up than what being modeled would be needed to meet much higher demand than current market forecasts.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2015

Mössbauer spectroscopy study of Al distribution in BaAl{sub x}Fe{sub 12−x}O{sub 19} thin films

Barium hexagonal ferrite (BaM) films grown on Si are a good candidate material for new-generations of on-wafer microwave devices operating at frequencies above 40 GHz. Doping BaM with Al increases the value of anisotropy field even more, and in combination with a large value of remanence, would allow one to create a self-biasing material/structure that would eliminate the need for permanent bias magnets in millimeter wave devices. To examine the occupation of Fe sublattices by Al ions, we carried out Conversion Electron Mössbauer Spectroscopy (CEMS) measurements at room temperature and zero magnetic field (after magnetizing the samples in a strong magnetic field). The spectra can be reasonably fitted with three components (sub-spectra) corresponding to different Fe sublattices. There are significant changes in the spectra with the addition of Al: The magnetic hyperfine field decreases for all three components, and their relative contributions also change remarkably. These observations are in agreement with the fact that the Al substitutes Fe, thus lowering the component contributions and the value of the hyperfine field. In addition, our previous XRD analysis indicates increasing grain misalignment with Al content, further supporting the CEMS data.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2013

Laboratory Studies of the Short-term Responses of Freshwater Fish to Electromagnetic Fields

Hydrokinetic energy technologies are being proposed as an environmentally preferred means of generating electricity from river and tidal currents. Among the potential issues that must be investigated in order to resolve environmental concerns are the effects on aquatic organisms of electromagnetic fields created by underwater generators and transmission cables. The behavioral responses of common freshwater fishes to static and variable electromagnetic fields (EMF) that may be emitted by hydrokinetic projects were evaluated in laboratory experiments. Various fish species were exposed to either static (DC) EMF fields created by a permanent bar magnet or variable (AC) EMF fields created by a switched electromagnet for 48 h, fish locations were recorded with a digital imaging system, and changes in activity level and distribution relative to the magnet position were quantified at 5-min intervals. Experiments with fathead minnows, redear sunfish, striped bass, lake sturgeon, and channel catfish produced mixed results. Except for fathead minnows there was no effect on activity level. Only redear sunfish and channel catfish exhibited a change in distribution relative to the position of the magnet with an apparent attraction to the EMF source. In separate experiments, rapid behavioral responses of paddlefish and lake sturgeon to onset of the AC field were recorded with high-speed video. Paddlefish did not react to a variable, 60-Hz magnetic field like that which would be emitted by an AC generator or cable, but lake sturgeon consistently responded to the variable, AC-generated magnetic field with a variety of altered swimming behaviors. These results will be useful for determining under what circumstances cables or generators need to be positioned to minimize interactions with sensitive species.

electromagnetic↗
DOE OSTI2016

The DOE Next-Generation Drivetrain for Wind Turbine Applications: Gearbox, Generator, and Advanced Si/SiC Hybrid Inverter System: Preprint

This paper reports on the design and testing results from the U.S. Department of Energy Next-Generation Wind Turbine Drivetrain Project. The drivetrain design reduces the cost of energy by increasing energy capture through drivetrain efficiency improvements; by reducing operation and maintenance costs through reducing gearbox failures; and by lowering capital costs through weight reduction and a series of mechanical and electronic innovations. The paper provides an overview of the drivetrain gearbox and generator and provides a deeper look into the power converter system. The power converter has a number of innovations including the use of hybrid silicon (Si)/silicon carbide (SiC) isolated baseplate switching modules. Switching energies are compared between SiC and Si PIN diodes. The efficiency improvement by use of the SiC diode in a three-level converter is also described. Finally, a brief discussion covering utility interconnect requirements for turbines is provided with a particular focus on utility events that lead to high transient torque loads on drivetrain mechanical elements.

17 WIND ENERGY↗
DOE OSTI2025

Implementation of Advanced Grid Support Functionalities by Smart Operation of Residential Loads with low Cost Converter Interface

This paper investigates a grid-supportive load concept for small-scale residential appliances, focusing on a residential refrigerator. Power consumption is adjusted based on grid conditions to achieve IEEE-1547 grid support functions. Two key aspects are presented: a low-cost refrigerator converter with Lyapunov energy function-based local controllers for speed control, and the impact on a standard microgrid system, demonstrating advanced grid support from the load side. This method enhances grid resilience and reliability and can be extended to other residential loads. The study contributes to efficient and robust grid-supportive load management systems, showing promising performance. This approach has the potential to improve overall grid stability and can be adapted for various types of residential appliances. The modeling and simulations in MATLAB/Simulink and PLECS confirm the feasibility and effectiveness of the proposed solution. Future work will explore real-world implementation and scalability of this concept for broader applications.

grid supportive loads (GSL)↗
DOE OSTI2020

Contoured PPM-EMAT Design for Ultrasonic Communication On Metallic Pipe Channels

Ultrasonic guided waves can be used as the carriers of information in ultrasonic communication for pipe or plate channels. Permanent Periodic Magnet (PPM) Electromagnetic Acoustic Transducer (EMAT) can potentially provide unique capabilities for a communication system as a non-contact transmitter and receiver, which can selectively generate different modes of shear-horizontal (SH) waves. The SH wave shows the potentials in achieving high bitrate without error in ultrasonic communication. However, when a steel pipe is used as the communication channel, especially one with a radius comparable to the size of the transducer, no guided wave signal can be excited or detected by existing PPM-EMAT's with flat coupling surface. In this paper, a 3D printed magnet holder is designed which can shape the magnet array. Also, the transmitter/receiver coils are made of flexible printed circuit which can fit over the curvature of the pipe channels. The contoured PPM-EMAT transmitter and receiver can conform to the surface of the steel pipe channel in order to generate and detect torsional waves. Experimental tests of signal transmission with PPM-EMAT on a 160cm-long stainless steel pipe determine the optimal frequency for communication to be 916KHz. Information transmission experimental results confirm the validity of contoured PPM-EMAT for communication with a bitrate of 5kbps.

Huang, Xin↗
DOE OSTI2019

Modeling and Steady-State Analysis of a Rotary Transformer-Based Field Excitation System for Wound Rotor Synchronous Machine

Wound rotor synchronous motors are gaining attention as an alternative to the permanent magnet-based synchronous motors for electric vehicle traction. Rotary transformers have been proposed for the field excitation of these motors to avoid the disadvantages of the slip rings and brushes arrangement. Conventional rotary transformers use small airgap and as a result can be limited in operating speed unless costly high precision manufacturing is used. This paper proposes a novel rotary transformer-based excitation system that overcomes these disadvantages. Modeling and analysis of the proposed system is provided. Simulation results using the developed model and PLECs shows very good agreement for fundamental frequency. Furthermore, a steady state study of the field excitation system using harmonic balance technique is carried out to show dependencies of the output controlled variables on the input variables in the presence of system parameter variations. With series resonant compensations, the open-loop control of the proposed excitation system is robust against variation of field winding resistance with temperature.

Haruna, Josiah↗
DOE OSTI2024

Wave Energy Converter Power Take-Off Modeling and Validation From Experimental Bench Tests

This article describes the implementation of a new numerical model of the power take-off system installed in the Monterey Bay Aquarium Research Institute wave energy converter, a device developed to provide power to various oceanic research missions. The simultaneous presence of hydraulic, pneumatic, and electrical subsystems in the power take-off system represents a significant challenge in forging an accurate model able to replicate the main dynamic characteristics of the system. The validation of the new numerical model is addressed by comparing simulations with the measurements obtained during a series of bench tests. Data from the bench tests show good agreement with the numerical model. The validated model provides deeper insights into the complex nonlinear dynamics of the power take-off system and will support further performance improvements in the future.

16 TIDAL AND WAVE POWER↗
DOE OSTI2022

Techno-Economic Implications of Electrical Machine Scaling for Wave Energy Converters

The sizing of an electrical machine for a Wave Energy Converter (WEC) can have a substantial impact on the overall sizing, cost, and rating of the device. An electrical generator is typically part of the power take-off system, which is the mechanism by which the energy absorbed by the prime mover is transformed into usable electrical energy. For practically all WECs, the rate of change of actuation is predominantly determined by the wave resource (i.e., the wave height and frequency), and devices will see a sinusoidal varying velocity according to the wave conditions. The same can then be said for both directly and indirectly coupled power take-offs with electrical generators. This techno-economic study investigates electrical machine scaling and associated cost implications through core machine design theory, manufacturer data, supporting literature, and the Reference Model Project sponsored by the U.S. Department of Energy. The Reference Model Project was a partnered effort to develop open-source marine energy point designs as reference models to benchmark marine energy technology performance and costs, methods for design and analysis of marine energy technologies, estimations for capital costs, operational costs, and levelized cost of energy. The results from this study show torque is directly related to (1) the physical size of the machine required to increase the air-gap sheer stresses, (2)the amount of active material, (3) the support structure, (4) bearing size and rating, and (5) offshore cable rating, all of which have a significant effect on overall system costs in terms of both capital and operational expenditures. This paper aims to be a critical benchmark in helping determine an "optimal" nameplate rating for wave energy devices and their associated power take-offs. With an optimized rating and sizing process, WEC costs can be reduced and overall performance can be improved.

cables↗