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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 19 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2017

Multilayered Film Capacitors for Advanced Power Electronics and Electric Motors for Electric Traction Drives

Biaxially oriented polypropylene (BOPP) film capacitors are the most suitable technology for high voltage, high temperature, and high ripple current power electronic systems in high performance electric vehicles (EVs). These capacitors, however, occupy 1/4th to 1/3rd of the power electronic unit and have a 50% voltage derating above 85 °C due to their drastically deteriorated breakdown strength and lifetime at high temperature. Development of a new dielectric material system for capacitors to increase temperature use and reduce size is critical in many EV related applications. Multilayer dielectric film developed by PolymerPlus and team has demonstrated improved dielectric constant and breakdown strength as compared to BOPP films. In this program, several film formulations were developed and investigated for dielectric performance and further down-selected for production scale up. Because this technology uses commercial polymers, fabrication of film rolls to demonstrate scalability for initial capacitor fabrication trials was successfully achieved. The film production feasibility, metallization and capacitor prototype fabrication was successfully demonstrated in Year 1 of the program. In Year 2 of the program, film production scale-up leading to significantly large film quantities for metallization and capacitor fabrication led to 600 µF size capacitors. Capacitor characterization was also completed during this year.

25 ENERGY STORAGE↗
DOE OSTI2023

Aircraft electric motor

Aircraft electric motors are described. The aircraft electric motors include a motor unit having a rotor and a stator, wherein the stator includes a plurality of windings and cooling channels arranged to provide cooling to the plurality of windings, a drive unit configured to drive operation of the motor unit, and a cooling system having at least one directional feature forming a portion of at least one cooling channel, the at least one directional feature configured to prevent backflow of a cooling fluid that passes through the at least one cooling channel.

Alahyari, Abbas A.↗
DOE OSTI2014

Electric Motor Thermal Management for Electric Traction Drives (Presentation)

Thermal constraints place significant limitations on how electric motors ultimately perform. Finite element analysis and computational fluid dynamics modeling approaches are being increasingly utilized in the design and analysis of electric motors. As the models become more sophisticated, it is important to have detailed and accurate knowledge of material thermal properties and convective heat transfer coefficients. In this work, the thermal properties and inter-lamination thermal contact resistances were measured for different stator lamination materials. Also, convective heat transfer coefficients of automatic transmission fluid (ATF) jets were measured to better understand the heat transfer of ATF impinging on motor copper windings. Experiments were carried out at various ATF temperatures and jet velocities to quantify the influence of these parameters on heat transfer coefficients.

30 DIRECT ENERGY CONVERSION↗
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 OSTI2017

Superhigh-speed electric motors

Superhigh-speed electric motors, with rotor speed up to 500000 rpm and power up to 100 W, are of interest for surface micromachining. A mathematical model of such motors is developed by means of Ansys Maxwell software. The motors are experimentally studied.

42 ENGINEERING↗
DOE OSTI2014

FY2014 Oak Ridge National Laboratory Annual Progress Report for the Power Electronics and Electric Motors Program

The US Department of Energy (DOE) announced in May 2011 a new cooperative research effort comprising DOE, the US Council for Automotive Research (composed of automakers Ford Motor Company, General Motors Company, and Chrysler Group), Tesla Motors, and representatives of the electric utility and petroleum industries. Known as U.S. DRIVE (Driving Research and Innovation for Vehicle efficiency and Energy sustainability), it represents DOE’s commitment to developing public–private partnerships to fund high-risk–high-reward research into advanced automotive technologies. The new partnership replaces and builds upon the partnership known as FreedomCAR (derived from “Freedom” and “Cooperative Automotive Research”) that ran from 2002 through 2010 and the Partnership for a New Generation of Vehicles initiative that ran from 1993 through 2001. Oak Ridge National Laboratory’s (ORNL’s) Advanced Power Electronics and Electric Motors (APEEM) subprogram within the DOE Vehicle Technologies Office (VTO) provides support and guidance for many cutting-edge automotive technologies now under development. Research is focused on developing revolutionary new power electronics (PE), electric motor, and traction drive system (TDS) technologies that will leapfrog current on-the-road technologies, leading to lower cost and better efficiency in transforming battery energy to useful work. The research and development (R&D) is also aimed at achieving a greater understanding of and improvements in the way the various new components of tomorrow’s automobiles will function as a unified system to improve fuel efficiency through research in more efficient TDSs.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2015

System and method to determine electric motor efficiency using an equivalent circuit

A system and method for determining electric motor efficiency includes a monitoring system having a processor programmed to determine efficiency of an electric motor under load while the electric motor is online. The determination of motor efficiency is independent of a rotor speed measurement. Further, the efficiency is based on a determination of stator winding resistance, an input voltage, and an input current. The determination of the stator winding resistance occurs while the electric motor under load is online.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2016

Electric Motor Thermal Management R&D. Annual Report

With the push to reduce component volumes, lower costs, and reduce weight without sacrificing performance or reliability, the challenges associated with thermal management increase for power electronics and electric motors. Thermal management for electric motors will become more important as the automotive industry continues the transition to more electrically dominant vehicle propulsion systems. The transition to more electrically dominant propulsion systems leads to higher-power duty cycles for electric drive systems. Thermal constraints place significant limitations on how electric motors ultimately perform, and as thermal management improves, there will be a direct trade-off between motor performance, efficiency, cost, and the sizing of electric motors to operate within the thermal constraints. The goal of this research project is to support broad industry demand for data, analysis methods, and experimental techniques to improve and better understand motor thermal management. Work in FY15 focused on two areas related to motor thermal management: passive thermal performance and active convective cooling. Passive thermal performance emphasized the thermal impact of materials and thermal interfaces among materials within an assembled motor. The research tasks supported the publication of test methods and data for thermal contact resistances and direction-dependent thermal conductivity within an electric motor. Active convective cooling focused on measuring convective heat-transfer coefficients using automatic transmission fluid (ATF). Data for average convective heat transfer coefficients for direct impingement of ATF jets was published. Also, experimental hardware for mapping local-scale and stator-scale convective heat transfer coefficients for ATF jet impingement were developed.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2025

Experiments in 3D Printing Electric Motors

This paper catalogues a series of experiments we conducted to explore how to 3D print a DC electric motor. The individual parts of the electric motor were 3D printed but assembled by hand. First, we focused on a rotor with soft magnetic properties, for which we adopted ProtoPasta TM , which is a commercial off-the-shelf PLA filament incorporating iron particles. Second, we focused on the stator permanent magnets, which were 3D printed through binder jetting. Third, we focused on the wire coils, for which we adopted a form of laminated object manufacture of copper wire. The chief challenge was in 3D printing the coils, because the winding density is crucial to the performance of the motor. We have demonstrated that DC electric motors can be 3D printed and assembled into a functional system. Although the performance was poor due to the wiring problem, we showed that the other 3D printing processes were consistent with high performance. Nevertheless, we demonstrated the principle of 3D printing electric motors.

3D printed motor↗
DOE OSTI2014

FY 2013 Annual Progress Report for the Advanced Power Electronics and Electric Motors Program

The Advanced Power Electronics and Electric Motors (APEEM) technology area within the DOE Vehicle Technologies Office (VTO) provides support and guidance for many cutting-edge automotive technologies now under development. Research is focused on developing revolutionary new power electronics (PE), electric motor, and traction drive system (TDS) technologies that will leapfrog current on-the-road technologies, leading to lower cost and better efficiency in transforming battery energy to useful work. The research and development (R&D) is also aimed at achieving a greater understanding of and improvements in the way the various new components of tomorrow’s automobiles will function as a unified system to improve fuel efficiency through research in more efficient TDSs.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2014

Electric Motor Thermal Management R&D (Presentation)

Thermal constraints place significant limitations on how electric motors ultimately perform. Without the ability to remove heat, the motor cannot operate without sacrificing performance, efficiency, and reliability. Finite element analysis and computational fluid dynamics modeling approaches are being increasingly utilized in the design and analysis of electric motors. As the models become more sophisticated, it is important to have detailed and accurate knowledge of both the passive thermal performance and the active cooling performance. In this work, we provide an overview of research characterizing both passive and active thermal elements related to electric motor thermal management. To better characterize the passive thermal performance, the effective thermal properties and inter-lamination thermal contact resistances were measured for different stator lamination materials. The active cooling performance of automatic transmission fluid (ATF) jets was also measured to better understand the heat transfer coefficients of ATF impinging on motor copper windings. Ford's Mercon LV was the ATF evaluated in this study. The presentation provides an overview of prior work with a focus on describing future plans for research to be performed during FY15.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2015

Electric motor for laser-mechanical drilling

A high power laser drilling system utilizing an electric motor laser bottom hole assembly. A high power laser beam travels within the electric motor for advancing a borehole. High power laser drilling system includes a down hole electrical motor having a hollow rotor for conveying a high power laser beam through the electrical motor.

42 ENGINEERING↗
DOE OSTI2017

Electric motor for laser-mechanical drilling

A high power laser drilling system utilizing an electric motor laser bottom hole assembly. A high power laser beam travels within the electric motor for performing a laser operation. A system includes a down hole electrical motor having a hollow rotor for conveying a high power laser beam having a wavelength less than 1060 nm through the electrical motor.

42 ENGINEERING↗
DOE OSTI2024

Aircraft electric motor having a stator heat pipe cooling scheme

Aircraft electric motors are described. The aircraft electric motors include a motor unit having a rotor and a stator, wherein the stator includes a plurality of windings and cooling channels arranged to provide cooling to the plurality of windings, a drive unit configured to drive operation of the motor unit, and a cooling system. The cooling system includes an oscillating heat pipe containing a first working fluid, wherein the oscillating heat pipe is arranged to pick up heat from at least one winding, the oscillating heat pipe having an evaporator section arranged in thermal contact with the at least one winding and a condenser section arranged away from the evaporator section and a heat pickup portion arranged to receive a second working fluid to remove heat from the condenser section of the oscillating heat pipe.

Saviers, Kimberly Rae↗
DOE OSTI2025

An Additively Manufactured Fe-3Si Stator for a High-Performance Electrical Motor

Additive manufacturing (AM) has the potential to produce novel high-performance electrical machines, enabling the direct printing of complex shapes and the simultaneous processing of multiple feedstocks in a single build. We examined the properties and functional performance of Fe-3 wt.% Si materials that were printed via selective laser melting, machined down to thin laminates, and stacked to form a stator core of a prototype brushless permanent-magnet electrical motor. Big Area Additive Manufacturing of Nd2Fe14B (NdFeB)–polyphenylene sulfide (PPS) bonded magnets was performed, with them then being magnetized and used for the rotor. The magnetic, mechanical, and electrical properties of the as-printed and various heat-treated thin laminates and the back electromotive force (EMF) of the electrical motors at different rotational speeds were measured. The thin laminates exhibit a maximum relative permeability of 7494 at an applied field of 0.8 Oe and a core loss of about 20 W/lb at 60 Hz with the maximum induction of 15 kg. In addition to the demonstration of AM printing, motor assembly, and complete characterization of printed Fe-3 wt.% Si, this report highlights the areas of improvement needed in printing technologies to achieve AM built electrical motors and the need for isotropic microstructure refinements to make the laminates appropriate for high-mechanical-strength and low-loss rotational electrical devices.

36 MATERIALS SCIENCE↗
DOE OSTI2013

FY2013 Oak Ridge National Laboratory Annual Progress Report for the Power Electronics and Electric Motors Program

The US Department of Energy (DOE) announced in May 2011 a new cooperative research effort comprising DOE, the US Council for Automotive Research (composed of automakers Ford Motor Company, General Motors Company, and Chrysler Group), Tesla Motors, and representatives of the electric utility and petroleum industries. Known as U.S. DRIVE (Driving Research and Innovation for Vehicle efficiency and Energy sustainability), it represents DOE’s commitment to developing public–private partnerships to fund high-risk–high-reward research into advanced automotive technologies. The new partnership replaces and builds upon the partnership known as FreedomCAR (derived from “Freedom” and “Cooperative Automotive Research”) that ran from 2002 through 2010 and the Partnership for a New Generation of Vehicles initiative that ran from 1993 through 2001. Oak Ridge National Laboratory’s (ORNL’s) Advanced Power Electronics and Electric Motors (APEEM) subprogram within the DOE Vehicle Technologies Office (VTO) provides support and guidance for many cutting-edge automotive technologies now under development. Research is focused on developing revolutionary new power electronics (PE), electric motor, and traction drive system (TDS) technologies that will leapfrog current on-the-road technologies, leading to lower cost and better efficiency in transforming battery energy to useful work. The research and development (R&D) is also aimed at achieving a greater understanding of and improvements in the way the various new components of tomorrow’s automobiles will function as a unified system to improve fuel efficiency through research in more efficient TDSs. In supporting the development of advanced vehicle propulsion systems, the APEEM subprogram fosters the development of technologies that will significantly improve efficiency, costs, and fuel economy.

motors↗
DOE OSTI2012

FY2011 Advanced Power Electronics and Electric Motors Annual Progress Report

The Advanced Power Electronics and Electric Motors (APEEM) program within the DOE Vehicle Technologies Program (VTP) provides support and guidance for many cutting-edge automotive technologies now under development. Research is focused on developing revolutionary new power electronics (PE), electric motor (EM), thermal management, and traction drive system technologies that will leapfrog current on-the-road technologies. The research and development (R&D) is also aimed at achieving a greater understanding of and improvements in the way the various new components of tomorrow’s automobiles will function as a unified system to improve fuel efficiency.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗