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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 OSTI2023

Combined Dimensional and Topology Optimization of Synchronous Machine Rotors Using a Material Density Interpolation Method

This article presents a magneto-structural combined dimensional and topology optimization technique for interior permanent magnet synchronous machine (IPMSM) and wound field synchronous machine (WFSM) rotors. Dimensional changes to the permanent magnet (PM) and rotor winding location or size are accomplished by interpolating or projecting a smoothed Heaviside rectangular function representing the presence of PM material onto the IPMSM rotor design domain mesh, whereas the presence of copper material for WFSM rotor is interpolated in the same manner. A density based Solid Isotropic Material with Penalization (SIMP) topology optimization approach is then used to vary the presence of electrical steel in mesh elements to form flux barriers around the PM. The proposed method enforces a defined shape for the PM without requiring the mesh in the design domain to be deformed. Four examples are presented to demonstrate the technique: Two flat bar IPMSM, one V-shaped IPMSM, and a WFSM. Here, a comparative study is performed on one of the flat bar IPMSMs using Metamodel of Optimal Prognosis (MOP) based method.

33 ADVANCED PROPULSION SYSTEMS↗
NASA NTRS2024

Design of an In-Slot Cooled Air-Core Flux-Focusing Permanent Magnet Synchronous Machine for Electric Aircraft Applications

High performance and reliable permanent magnet synchronous machines are potentially a key technology for enabling reduced emissions in future generations of sustainable aircraft. In this paper, a novel air-core flux focusing permanent magnet synchronous machine with carbon fiber shafting for aviation applications is presented. A low-fidelity analytical sizing tool is detailed for the motor topology. The sizing tool is used to explore design trades and create an example 100 kW flux-focusing motor for eVTOL applications. Higher fidelity finite element analysis was used to validate the predicted performance of the motor. The selected design is able to achieve roughly 97 percent efficiency and 6 kW/kg at a continuous operating power of 100 kW.

Jonathan Gutknecht↗
DOE OSTI2023

Generalized Circuit Representation for a Synchronous Machine

In this letter, a generalized circuit representation for a synchronous machine is presented. This circuit represents voltage and current relationship and can be used for dynamic and harmonic analysis. A distinct feature of the circuit is the use of Laplace transform variable s , which simplifies both calculus and frame conversion. Two derivation approaches are presented. Here, the first approach starts from a steady-state circuit representation, while the second approach starts from the dq-frame dynamic model of a synchronous generator. Both arrive at the same representation.

42 ENGINEERING↗
DOE OSTI2026

Brushless Excitation for Wound-field Synchronous Machines using Multi-harmonic Windings

Wound-field synchronous machines (WFSM) are promising alternatives to electric machines with permanent magnets (PM). The ability to control the rotor field in these machines makes them well-suited to safety critical applications, while the absence of rare-earth permanent magnets makes these machines sustainable. The WFSM rotor excitation schemes have traditionally used carbon brushes, which significantly reduces the reliability of these machines, limiting their widespread adoption. To overcome this limitation and improve the reliability of WFSMs, several brushless rotor excitation schemes have been developed. However, most of these systems require additional windings or dedicated power electronics, making them expensive and limiting achievable power-density. In this paper a new brushless excitation scheme is proposed. In this scheme, a multiphase, multi-harmonic stator winding is designed. This winding can independently control two spatial harmonics in the airgap of the machine; the first to create torque and the second to wirelessly transfer power to the rotor to excite it.

Gadiyar, Nishanth [ORNL] (ORCID:0000000348267524)↗
DOE OSTI2024

Virtual Synchronous Machine Grid-Forming Inverter Model Specification (REGFM_B1)

This report describes a generic virtual synchronous machine (VSM) grid-forming inverter (GFM) model - REGFM_B1. The initial model specification was proposed by Pacific Northwest National Laboratory (PNNL), General Electric (GE), and Electric Power Research Institute (EPRI). Siemens Gamesa Renewable Energy (SGRE) also provided inputs to the specification. The model specification has been revised multiple times based on the discussions between all the contributors listed in this report. This work was funded by the Universal Interoperability for Grid-Forming Inverters (UNIFI) Consortium. This generic model is developed to help the utility industry understand the concept of VSM GFMs. The model could be used to represent equipment for long-term planning studies where vendor-specific models are not available. As equipment mature and improve, generic models will be updated to capture the new functionalities of GFMs. It is not intended that these models will always remain representative of all future GFM technologies.

24 POWER TRANSMISSION AND DISTRIBUTION↗
NASA NTRS1982

General Theory of the Double Fed Synchronous Machine

Motor and generator operation of a double-fed synchronous machine were studied and physically and mathematically treated. Experiments with different connections, voltages, etc. were carried out. It was concluded that a certain degree of asymmetry is necessary for the best utilization of the machine.

El-Magrabi, M. G.↗
DOE OSTI2026

Modeling and Power-Hardware-in-the-Loop Validation of Synchronous Machine Governor

This paper introduces the development of a high-fidelity gas turbine governor model using a programmable logic controller for power-hardware-in-the-loop (PHIL) validation. The governor model is integrated with the National Renewable Energy Laboratory's (NREL) PHIL test bed, featuring a 2-MVA synchronous machine and a 2.5-MW variable-speed drive, to emulate NG-driven HRSGs and CTs under various operational scenarios. The primary objective of this research is to study the grid-connected and islanding operations of conventional generation sources, with representative startup sequences including turbine purge, ignition, speed ramp-up, synchronization, and breaker closure. Preliminary results of the generator governor model on NREL PHIL platform, particularly using the 2.5-MW dynamometer system, offered significant insights into the modeling techniques, hardware integration, scaling, and real-world simulation dynamics.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2025

Synchronous Machine Governor Upgrade

Conventional generation sources play a critical role in the stability and reliability of the electrical grid, particularly as we transition towards more renewable energy sources. To understand and accurately emulate their behavior for optimizing grid operations and ensuring seamless integration with renewable technologies, it is essential to better emulate the grid- and plant-level impacts of conventional generation sources, such as natural gas (NG) driven heat recovery steam generators (HRSGs) and combustion turbines (CTs). Therefore, a governor model is developed in a programmable logic controller (PLC) to investigate the performance of the conventional generator under various dynamic operating conditions and to identify the impact on grid stability in a controlled environment. The governor model aims to enable the hardware-in-the-loop (HIL) based emulation of these conventional generation sources using the existing 2 MVA synchronous machine/generator that is driven by a flexible 2.5 MW variable speed drive. This setup will allow us to replicate the dynamic characteristics and response behaviors of NG-driven HRSGs and CTs. The controls for the emulated conventional plants follow the industry standard and are adjustable, ensuring they accurately reflect the operational capabilities and limitations of real-world systems. These controls include load-following capabilities, ramp rates, startup and shutdown sequences, and emissions characteristics. By incorporating these adjustable controls, we aim to capture the nuanced impacts of conventional generation, such as their ability to provide ancillary services like frequency regulation, voltage support, and spinning reserve. In this report, we simulate two types of dynamic operations: grid-connected and islanding. For each dynamic operation, representative starting sequences are tested, including turbine purge, ignition, speed ramping up, generator excitation and synchronizing, and breaker close. The HIL based tests provides insights for field deployment, specifically the high-fidelity governor model provides results to predict the potential stability and reliability risk and suggest possible integration measures (e.g., generation and load balancing, tuning of governor control parameters). Ultimately, this enhanced emulation capability will be integrated into our Advanced Research on Integrated Energy Systems (ARIES), enabling us to conduct comprehensive studies on the interactions between conventional and renewable energy sources. By better understanding these interactions, we can develop strategies to optimize the overall performance and reliability of the grid. This will support the deployment of advanced grid management techniques, such as demand response, grid-forming inverters, and energy storage systems. The main contributions are summarized as follows: (1) This report introduces a PLC-based governor model for gas turbines. This model accurately simulates the dynamic behavior of conventional generation sources under various operational scenarios; (2) The model is integrated with an HIL testbed that includes a 2.5 MW variable speed drive and a 2 MVA synchronous machine. This setup enables realistic, real-time emulation of conventional power plants, particularly NG driven HRSGs and CTs; (3) The developed model is adaptable to various gas turbine configurations and allows for precise control over parameters such as MW ramp rates. This flexibility makes it a valuable tool for future research and industry collaboration; and (4) By incorporating the model into the National Renewable Energy Laboratory's Advanced Research on Integrated Energy Systems, the report lays the groundwork for future studies on interactions between conventional and renewable energy sources, enhancing the ability to develop advanced grid management strategies.

24 POWER TRANSMISSION AND DISTRIBUTION↗
NASA NTRS2023

Analytical Design and Performance Estimation Methods for Aircraft Permanent Magnet Synchronous Machines

The design of an electric motor drivetrain is a complex multiphysics problem. Low fidelity motor drivetrain sizing can be a key tool in the design cycle of an electric motor drivetrain and for system level studies of aircraft configurations. However, low fidelity sizing can lead to misleading results if all the physics involved in a motor design are not properly accounted for. This paper provides details on modeling approaches for initial design and sizing of permanent magnet synchronous electric machines. The goal of this paper is to provide the reader an understanding of the key principles of motor design and some modeling approaches to perform initial sizing of an electric motor and its inverter.

Thomas F. Tallerico↗
DOE OSTI2023

Wound-Field Synchronous Machine-System Integration toward 8X Power Density and Commercialization

In support of VTO's Electric Drive R&D activity, the Electric Drive Technologies (EDT) Consortium, a multi-disciplinary team of national labs and universities, coordinates and conducts a portfolio of research to advance the state-of-the-art in electric drive technologies. The Consortium established the following strategic goal listed below: (EDT Research Consortium Strategic Goal (compared to 2015 baseline)) A 125K electric traction drive system: (1) 8X power density improvement, or 1/10 the volume (33 kW/L), (2) 1/2 the cost ($\$$3.3/kW), (3) 2X useful life (300,000 miles), and (4) 100 kW/L inverter and a <20,000 rpm, 50kW/L electric motor The objective of this project is to design a Wound Field Synchronous Machine with 8X power density improvement and cost below $\$$3.3/kW.

42 ENGINEERING↗
NASA NTRS1995

Advanced Propulsion Power Distribution System for Next Generation Electric/Hybrid Vehicle: Preliminary System Studies - Phase 1

The report essentially summarizes the work performed in order to satisfy the above project objective. In the beginning, different energy storage devices, such as battery, flywheel and ultra capacitor are reviewed and compared, establishing the superiority of the battery. Then, the possible power sources, such as IC engine, diesel engine, gas turbine and fuel cell are reviewed and compared, and the superiority of IC engine has been established. Different types of machines for drive motor/engine generator, such as induction machine, PM synchronous machine and switched reluctance machine are compared, and the induction machine is established as the superior candidate. Similar discussion was made for power converters and devices. The Insulated Gate Bipolar Transistor (IGBT) appears to be the most superior device although Mercury Cadmium Telluride (MCT) shows future promise. Different types of candidate distribution systems with the possible combinations of power and energy sources have been discussed and the most viable system consisting of battery, IC engine and induction machine has been identified. Then, HFAC system has been compared with the DC system establishing the superiority of the former. The detailed component sizing calculations of HFAC and DC systems reinforce the superiority of the former. A preliminary control strategy has been developed for the candidate HFAC system. Finally, modeling and simulation study have been made to validate the system performance. The study in the report demonstrates the superiority of HFAC distribution system for next generation electric/hybrid vehicle.

Bose, Bimal K.↗
DOE OSTI2024

Electromagnetic Design Optimization Integrated with Mechanical Stress Analysis of PM-Assisted Synchronous Reluctance Machine Topologies Enabled with a Blend of Magnets

Permanent Magnet-Assisted Synchronous Reluctance Machines (PMASynRM) provide a low-cost alternative to Surface PM Machines due to the use of relatively lower grades of rare-earth (RE) or RE-free magnets, as the performance degradation due to weaker magnets is compensated by the presence of reluctance torque. However, the weaker magnets suffer from a high risk of demagnetization, leading to unreliable motor operation. Using a blend of RE and RE-free magnets has the potential to overcome this issue. This paper proposes to blend different grades of various rare-earth (RE) and rare-earth-free (RE-free) magnets in six different combinations and utilizes them in two-layer and three-layer U-shaped PMASynRM topologies with both eight-pole and six-pole variations. The rotor of the various designs is then optimized using a differential evolution (DE) based optimization algorithm to obtain low-cost designs with reduced RE magnet volume and minimum demagnetization risk. The optimization of each design is also integrated with the evaluation of mechanical stresses in the rotor laminations so as to maintain the stresses below the material yield strength. Furthermore, the various performance metrics, such as toque–speed/power–speed characteristics, demagnetization, and efficiency maps, are evaluated for each of the optimized and mechanically feasible designs. A quantitative comparison of the various optimized designs is also obtained to highlight the various trade-offs. The results indicate the feasibility of meeting the baseline torque requirement across the entire speed range, even with a 100% reduction in RE magnet volume and less than 5% demagnetization risk, while achieving a cost reduction exceeding 50%. Moreover, the two-layer, eight-pole designs exhibit relatively higher performance, whereas the three-layer, eight-pole designs are found to be the most economical option.

design optimization↗
NASA NTRS2003

Ultra-High-Power-Density Motor Being Developed for Future Aircraft

To support the Revolutionary Aeropropulsion Concept Program, NASA Glenn Research Center' s Structural Mechanics and Dynamics Branch is developing a compact, nonpolluting, bearingless electric machine with electric power supplied by fuel cells for future more-electric aircraft. The use of such electric drives for propulsive fans or propellers depends on the successful development of ultra-high-power-density machines that can generate power densities of 50 hp/lb or more, whereas conventional electric machines generate usually 0.2 hp/lb. One possible candidate for such ultra-high-power-density machines, a round-rotor synchronous machine with an engineering current density as high as 20 000 A/cm2 was selected to investigate how much torque and power can be produced. A simple synchronous machine model that consists of rotor and stator windings and back-irons was considered first. The model had a sinusoidally distributed winding that produces a sinusoidal distribution of flux P poles. Excitation of the rotor winding produced P poles of rotor flux, which interacted with the P stator poles to produce torque.

Choi, Benjamin B.↗
DOE OSTI2024

Repurposing Inactive Oil and Gas Wells for Energy Storage: Maximizing the Potential Via Optimal Drivetrain Control: Preprint

In recent years, there has been a growing emphasis on utilizing energy storage to enhance grid resilience against disruptive events. While renewable energy supply continues to expand, gravity-based solutions like pumped hydro remain dominant in the commercial space. However, their geographical limitations constrain availability, scalability, and increase costs for co-locating solar and wind energy. An alternative approach proposes repurposing idle oil and gas wells located closer to existing grid infrastructure, offering a promising and cost-effective solution. This paper addresses the optimization and control of a regenerative drive system coupled to an interior permanent magnet synchronous machine in a 300-meter well with a 100-Newton weight. The study employs a dynamic MATLAB/Simulink model to simulate the operation of the electric drivetrain system during storage and discharge operations. The results demonstrate an initial round-trip efficiency of 85.9% for the electrical system alone and identify crucial factors for maximizing efficiency. The optimized operation and control of the electromechanical drivetrain system hold great potential for minimizing the levelized cost of storage while maximizing efficiency and revenue generation.

ENERGY STORAGE,ENGINEERING↗
NASA NTRS1993

Design and application of electromechanical actuators for deep space missions

The annual report Design and Application of Electromechanical Actuators for Deep Space Missions is presented. The reporting period is 16 Aug. 1992 to 15 Aug. 1993. However, the primary focus will be work performed since submission of our semi-annual progress report in Feb. 1993. Substantial progress was made. We currently feel confident in providing guidelines for motor and control strategy selection in electromechanical actuators to be used in thrust vector control (TVC) applications. A small portion was presented in the semi-annual report. At this point, we have implemented highly detailed simulations of various motor/drive systems. The primary motor candidates were the brushless dc machine, permanent magnet synchronous machine, and the induction machine. The primary control implementations were pulse width modulation and hysteresis current control. Each of the two control strategies were applied to each of the three motor choices. With either pulse width modulation or hysteresis current control, the induction machine was always vector controlled. A standard test position command sequence for system performance evaluation is defined. Currently, we are gathering all of the necessary data for formal presentation of the results. Briefly stated for TVC application, we feel that the brushless dc machine operating under PWM current control is the best option. Substantial details on the topic, with supporting simulation results, will be provided later, in the form of a technical paper prepared for submission and also in the next progress report with more detail than allowed for paper publication.

Haskew, Tim A.↗
DOE OSTI2026

Propulsion System Design using a Dual 3-Phase PM Synchronous Reluctance Machine with X-Type Multi-Level GaN Inverter

— A propulsion system design is exhibited here that comprises of an X-type GaN power module based dual multi-level inverter and a PM Synchronous Reluctance motor. With the critical benefits of multi-level operation, namely low common mode EMI noise, low switching loss, low current Total Harmonic Distortion (THD), smoother torque and lower iron loss, this topology targets high system-level efficiency and high power density while using reduced rare earth (RE) elements in its motor. General Motors and Purdue University jointly designed and developed this 800V class, highly scalable traction drive that can deliver 200+ kW of power suitable for C-SUV to truck vehicle class. The 3-phase electric machine design utilizes dual winding with 6 terminals to work in line with the GaN X-type inverter, and results in a tractive solution that ensures higher machine efficiency while reducing cost and uncertainty related to use and availability of heavy rare earth/rare earth elements in its rotor.

MOMEN, FAIZUL [General Motors LLC, Detroit, MI (Un↗