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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 sources NASA NTRS DOE OSTI

NASA NTRS2012

Implementation of a Non-Metallic Barrier in an Electric Motor

Electric motors that run in pure oxygen must be sealed, or "canned," for safety reasons to prevent the oxygen from entering into the electrical portion of the motor. The current canning process involves designing a metallic barrier around the rotor to provide the separation. This metallic barrier reduces the motor efficiency as speed is increased. In higher-speed electric motors, efficiency is greatly improved if a very thin, nonmetallic barrier can be utilized. The barrier thickness needs to be approximately 0.025-in. (.0.6-mm) thick and can be made of a brittle material such as glass. The motors, however, designed for space applications are typically subject to high-vibration environments. A fragile, non-metallic barrier can be utilized in a motor assembly if held in place by a set of standard rubber O-ring seals. The O-rings provide the necessary sealing to keep oxygen away from the electrical portion of the motor and also isolate the fragile barrier from the harsh motor vibration environment. The compliance of the rubber O-rings gently constrains the fragile barrier and isolates it from the harsh external motor environment. The use of a non-metallic barrier greatly improves motor performance, especially at higher speeds, while isolating the electronics from the working fluid with an inert liner.

M?Sadoques, George↗

NASA NTRS2026

Manufacturing Process Development of a Carbon Fiber Reinforced Polymer Composite Shaft for Electric Motors

Electric aircraft applications require electric motors with increased specific power and efficiency. Composite structural components in motors are a potential solution for reducing motor mass, reducing magnetic losses, and limiting undesired conduction paths for fault, electromagnetic interference, or common-mode currents. In this report, manufacturing trials for a high-speed carbon fiber reinforced polymer composite motor shaft are presented. Four prototype shafts were produced using a hybrid biaxial/triaxial fabric that was circumferentially wrapped onto an additively manufactured high-temperature washout mandrel. An additional traditional overbraid approach was also evaluated and shows promise for high-rate, high-performance parts using automated manufacturing. This paper discusses the shaft design, manufacturing methods explored, material selection, the manufacturing trials, and the lessons learned. The results of this manufacturing investigation show feasibility for manufacturing composite shafts for electric motors.

Electric moto shaft↗

NASA NTRS2005

Power Requirements Determined for High-Power-Density Electric Motors for Electric Aircraft Propulsion

Future advanced aircraft fueled by hydrogen are being developed to use electric drive systems instead of gas turbine engines for propulsion. Current conventional electric motor power densities cannot match those of today s gas turbine aircraft engines. However, if significant technological advances could be made in high-power-density motor development, the benefits of an electric propulsion system, such as the reduction of harmful emissions, could be realized.

Johnson, Dexter↗

NASA NTRSDate not supplied

Update on Electric Motor Noise

Electric motors like those used in concept Advanced Air Mobility vehicles generate noise relevant to the acoustic profile of those vehicles. This work presents ongoing efforts to study, understand, and predict the noise generated by these types of motors. Efforts to perform experimental and simulation investigations of motor vibration modes are presented. Then recent acoustic measurements of operating motors and the resonant tones they generate is discussed. Lastly an update of ongoing efforts to measure real world vehicles is provided.

Electric motor noise↗

NASA NTRS2022

Urban Air Mobility Electric Motor Winding Insulation Reliability: Challenges in the Design and Qualification of High Reliability Electric Motors and NASA’s Research Plan

This work was motivated by the needs of the emerging Urban Air Mobility (UAM) concept. Guided by analyses of concept vehicles, electric motor winding insulation reliability was identified as a subsystem limiting the vehicle reliability. This paper covers NASA’s understanding of the current state-of-the-art for electric motor winding insulation reliability, life modeling and qualification testing in the context of UAM. The needed improvements to the accepted practice for qualification of high reliability UAM motors are highlighted. NASA’s Revolutionary Vertical Lift Technologies Project strives to develop new testing methods to support the rating and qualification of UAM motor winding insulation. We describe assumptions used to frame a research approach, and we outline a NASA RVLT research plan for motor winding insulation.

Thomas Tallerico↗

NASA NTRS1983

Preliminary assessment of the tradeoffs between the electric motor and the transmission in electric vehicles

The efficiency, weight, and cost of various propulsion system for 4-passenger electric vehicles are compared. These systems comprise the electric motor and the required speed reducing transmission to obtain the appropriate speed at the wheel. Three types of motors, dc synchronous, and squirrel-cage were considered at 6000 ycm and 24 000 rpm for a peak power of 40 kW. Two types of gearing selected were a single speed differential and a differential with a differential with a 4-speed gearbox. Only components that were readily realizable within present state-of-the-art were considered.

Levi, E.↗

NASA NTRS2014

Nano-Magnets and Additive Manufacturing for Electric Motors

High power density is required for application of electric motors in hybrid electric propulsion. Potential path to achieve high power density in electric motors include advanced materials, lightweight thermal management, lightweight structural concepts, high power density power electronics, and advanced manufacturing. This presentation will focus on two key technologies for achieving high power density, advanced magnets and additive manufacturing. The maximum energy product in current magnets is reaching their theoretical limits as a result of material and process improvements. Future improvements in the maximum energy product for magnets can be achieved through development of nanocomposite magnets combining the hard magnetic phase and soft magnetic phase at the nanoscale level. The presentation will provide an overview of the current state of development for nanocomposite magnets and the future path for doubling the maximum energy product. The other part of the presentation will focus on the role of additive manufacturing in fabrication of high power density electric motors. The presentation will highlight the potential opportunities for applying additive manufacturing to fabricate electric motors.

materials↗

NASA NTRS1973

Investigation of vibration characteristics of electric motors

The vibration characteristics of electric motors were analyzed using mathematical statistics methods. The equipment used and the method of conducting the test are described. Curves are developed to show the visualization of the electric motor vibrations in the vertical direction. Additional curves are included to show the amplitude-phase frequency characteristic of dynamic rotor-housing vibrations at the first lug and the same data for the second lug of the electric motor. Mathematical models were created to show the transmission function of the dynamic rotor housing system.

Bakshis, A. K.↗

NASA NTRS2004

Cryogenic Electric Motor Tested

Technology for pollution-free "electric flight" is being evaluated in a number of NASA Glenn Research Center programs. One approach is to drive propulsive fans or propellers with electric motors powered by fuel cells running on hydrogen. For large transport aircraft, conventional electric motors are far too heavy to be feasible. However, since hydrogen fuel would almost surely be carried as liquid, a propulsive electric motor could be cooled to near liquid hydrogen temperature (-423 F) by using the fuel for cooling before it goes to the fuel cells. Motor windings could be either superconducting or high purity normal copper or aluminum. The electrical resistance of pure metals can drop to 1/100th or less of their room-temperature resistance at liquid hydrogen temperature. In either case, super or normal, much higher current density is possible in motor windings. This leads to more compact motors that are projected to produce 20 hp/lb or more in large sizes, in comparison to on the order of 2 hp/lb for large conventional motors. High power density is the major goal. To support cryogenic motor development, we have designed and built in-house a small motor (7-in. outside diameter) for operation in liquid nitrogen.

Brown, Gerald V.↗

NASA NTRS2011

Lightweight High Efficiency Electric Motors for Space Applications

Lightweight high efficiency electric motors are needed across a wide range of space applications from - thrust vector actuator control for launch and flight applications to - general vehicle, base camp habitat and experiment control for various mechanisms to - robotics for various stationary and mobile space exploration missions. QM Power?s Parallel Path Magnetic Technology Motors have slowly proven themselves to be a leading motor technology in this area; winning a NASA Phase II for "Lightweight High Efficiency Electric Motors and Actuators for Low Temperature Mobility and Robotics Applications" a US Army Phase II SBIR for "Improved Robot Actuator Motors for Medical Applications", an NSF Phase II SBIR for "Novel Low-Cost Electric Motors for Variable Speed Applications" and a DOE SBIR Phase I for "High Efficiency Commercial Refrigeration Motors" Parallel Path Magnetic Technology obtains the benefits of using permanent magnets while minimizing the historical trade-offs/limitations found in conventional permanent magnet designs. The resulting devices are smaller, lower weight, lower cost and have higher efficiency than competitive permanent magnet and non-permanent magnet designs. QM Power?s motors have been extensively tested and successfully validated by multiple commercial and aerospace customers and partners as Boeing Research and Technology. Prototypes have been made between 0.1 and 10 HP. They are also in the process of scaling motors to over 100kW with their development partners. In this paper, Parallel Path Magnetic Technology Motors will be discussed; specifically addressing their higher efficiency, higher power density, lighter weight, smaller physical size, higher low end torque, wider power zone, cooler temperatures, and greater reliability with lower cost and significant environment benefit for the same peak output power compared to typically motors. A further discussion on the inherent redundancy of these motors for space applications will be provided.

Robertson, Glen A.↗

NASA NTRS1973

Investigation of a vibration-damping unit for reduction in low-frequency vibrations of electric motors

The vibroacoustical characteristics of different types of electric motors are discussed. It is shown that the basic source of low frequency vibrations is rotor unbalance. A flexible damping support, with an antivibrator, is used to obtain the vibroacoustical effect of reduction in the basic harmonic of the electric motor. A model of the electric motor and the damping apparatus is presented. Mathematical models are developed to show the relationships of the parameters. The basic purpose in using a calculation model id the simultaneous replacement of the exciting force created by the rotor unbalance and its inertial rigidity characteristics by a limiting kinematic disturbance.

Grigoryey, N. V.↗

NASA NTRS2018

Liquid Rocket Engine with Hybrid Electric Motor Driven Pump

A nuclear thermal rocket with a superconducting electric motor driven boost pump submerged within a tank of liquid hydrogen, where the boost pump is driven by both an electric motor and a turbine. The boost pump can be submerged in liquid hydrogen so that the electric motor operates as a superconducting motor. Also, a turbopump for a rocket engine can include both a turbine and an electric motor to drive the liquid oxidizer and liquid fuel pumps of the turbopump.

Pinera, Alejandro↗

NASA NTRS2018

Electric Motor Noise from Small Quadcopters: Source Characteristics - Part II

The increased interest in electric motors for propulsion systems has driven interest in quantifying the contribution of electric motor noise to the overall sound levels and possible human annoyance of the propulsion system. This work presents acoustic measurements of electric motors used for small quadcopters to quantify the sound produced by a number of outrunning motors with different types of controllers. Results are presented for loaded and unloaded motors as installed and uninstalled configurations. Motor resonance frequencies were measured and computed. Current probe measurements showed that the supply current from the controllers contained significant harmonic content for the conventional and sinewave controllers. Acoustic results showed motor noise is typically radiated at frequencies near the mode 2 vibration frequency at roughly 5000 Hz. Electric motor noise was evident in the spectra produced by many of the motor-controller combinations for motors loaded with propellers with levels often greater than those for the motor alone due to increase in the stator magnetic flux density with increased current. An installed configuration produced increases in acoustic radiation over that of the uninstalled motor in a frequency range near the mode 1 vibration frequency near 1200 Hz. A companion paper (Part I - Acoustic Measurements), focuses on source identification using a phased array and directivity characteristics for a baseline configuration.

Motor Resonance Frequencies↗

NASA NTRS1979

Hall devices improve electric motor efficiency

Efficiency of electric motors and generators is reduced by radial magnetic forces created by symmetric fields within device. Forces are sensed and counteracted by Hall devices on excitation or control windings. Hall generators directly measure and provide compensating control of anu asymmetry, eliminating additional measurements needed for calibration feedback control loop.

Haeussermann, W.↗

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↗

NASA NTRS2018

Electric Motor Noise from Small Quadcopters: Part II - Source Characteristics

The increased interest in electric motors for aircraft propulsion systems has driven interest in quantifying the contribution of electric motor noise to the overall sound levels and possibly human annoyance of the propulsion system. This work presents acoustic measurements of electric motors used for small quadcopters to quantify the sound produced by a number of outrunner motors with different types of controllers. Results are presented for loaded and unloaded motors as well as installed and uninstalled configurations. Motor resonance frequencies were measured and computed. Current probe measurements showed significant harmonic content in the supply current from the controllers for both the conventional and sinewave controllers. Acoustic results showed motor noise is typically radiated at frequencies near that for azimuthal vibration mode number 2 of the rotor which occurs at roughly 5000 Hz. Electric motor noise was evident in the spectra produced by many of the motor-controller combinations for motors loaded with propellers with levels often greater than those for the motor alone due to increases in the stator magnetic flux density with increased current. An installed quadcopter configuration produced increases in acoustic radiation over that of the uninstalled motor in a frequency range near the 1200 Hz azimuthal vibration mode 1 of the rotor.

Henderson, Brenda↗

NASA NTRS2024

Preliminary Measurements of Partial Discharge Inception Voltage Degradation with Constant Temperature Aging of Magnet Wire Twisted Pairs for Electric Aircraft Motors

Electric aircraft require high reliability electric motors to meet the stringent safety standards of the aviation industry. Motor winding insulation lifetime and reliability models for electric aircraft applications are needed to enable design of high reliability and high-performance electric motors for aviation applications. Three primary stresses effect the lifetime of motor winding insulation: thermochemical, mechanical, and electrical. This paper presents preliminary experiments on twisted pairs of magnet wire targeting understanding the thermo-chemical degradation of motor winding insulation through constant temperature thermal aging. Three types of magnet wire twisted pairs where tested: polyimide insulated magnet wire, epoxy coated polyimide insulated magnet wire, and epoxy potted polyimide magnet wire. The degradation of the samples over time at temperature was tracked using partial discharge inception voltage measurements. These initial experiments were used for development of procedures and expertise in partial discharge testing and thermo-chemical aging to inform future testing. The preliminary nature of these experiments should be noted when viewing the results. Lessons learned from the experiments are documented.

Thomas Tallerico↗

NASA NTRS2018

Electric Motor Noise from Small Quadcopters: Part 1 - Acoustic Measurements

There is increased interest in using electric motors to drive propulsors across a range of small air vehicle classes. Applications include both vertical lift and conventional takeoff and landing systems for Small Unmanned Aircraft Systems. Mission profiles call for integrating these systems into urban airspaces exposing populated areas to new noise sources. In addition to the propulsor noise from rotors and propellers, electric motors are expected to contribute to the overall sound levels and possibly human annoyance. This work presents acoustic measurements of electric motors used for small quadcopters to characterize the sound and identify sources with and without a propeller. Free field microphone measurements were used to determine directivity and a phased microphone array was used to identify sound sources. A companion paper (Part II - Source Characteristics and Prediction) compares the far field results with current probe measurements of the signal driving the motor, the structural response of the motor case, and describes prediction methods of electric motor noise.

Electric Propulsion↗