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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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Optimized Generator Designs for the DTU 10-MW Offshore Wind Turbine using GeneratorSE

Compared to land-based applications, offshore wind imposes challenges for the development of next generation wind turbine generator technology. Direct-drive generators are believed to offer high availability, efficiency, and reduced operation and maintenance requirements; however, previous research suggests difficulties in scaling to several megawatts or more in size. The resulting designs are excessively large and/or massive, which are major impediments to transportation logistics, especially for offshore applications. At the same time, geared wind turbines continue to sustain offshore market growth through relatively cheaper and lightweight generators. However, reliability issues associated with mechanical components in a geared system create significant operation and maintenance costs, and these costs make up a large portion of overall system costs offshore. Thus, direct-drive turbines are likely to outnumber their gear-driven counterparts for this market, and there is a need to review the costs or opportunities of building machines with different types of generators and examining their competitiveness at the sizes necessary for the next generation of offshore wind turbines. In this paper, we use GeneratorSE, the National Renewable Energy Laboratory's newly developed systems engineering generator sizing tool to estimate mass, efficiency, and the costs of different generator technologies satisfying the electromagnetic, structural, and basic thermal design requirements for application in a very large-scale offshore wind turbine such as the Technical University of Denmark's (DTU) 10-MW reference wind turbine. For the DTU reference wind turbine, we use the previously mentioned criteria to optimize a direct-drive, radial flux, permanent-magnet synchronous generator; a direct-drive electrically excited synchronous generator; a medium-speed permanent-magnet generator; and a high-speed, doubly-fed induction generator. Preliminary analysis of leveled costs of energy indicate that for large turbines, the cost of permanent magnets and reliability issues associated with brushes in electrically excited machines are the biggest deterrents for building direct-drive systems. The advantage of medium-speed permanent-magnet machines over doubly-fed induction generators is evident, yet, variability in magnet prices and solutions to address reliability issues associated with gearing and brushes can change this outlook. This suggests the need to potentially pursue fundamentally new innovations in generator designs that help avoid high capital costs but still have significant reliability related to performance.

17 WIND ENERGY↗

GeneratorSE: A Sizing Tool for Variable-Speed Wind Turbine Generators

This report documents a set of analytical models employed by the optimization algorithms within the GeneratorSE framework. The initial values and boundary conditions employed for the generation of the various designs and initial estimates for basic design dimensions, masses, and efficiency for the four different models of generators are presented and compared with empirical data collected from previous studies and some existing commercial turbines. These models include designs applicable for variable-speed, high-torque application featuring direct-drive synchronous generators and low-torque application featuring induction generators. In all of the four models presented, the main focus of optimization is electromagnetic design with the exception of permanent-magnet and wire-wound synchronous generators, wherein the structural design is also optimized. Thermal design is accommodated in GeneratorSE as a secondary attribute by limiting the winding current densities to acceptable limits. A preliminary validation of electromagnetic design was carried out by comparing the optimized magnetic loading against those predicted by numerical simulation in FEMM4.2, a finite-element software for analyzing electromagnetic and thermal physics problems for electrical machines. For direct-drive synchronous generators, the analytical models for the structural design are validated by static structural analysis in ANSYS.

17 WIND ENERGY↗

Electric machine

A permanent magnet machine includes a stator having a stator core, a plurality of stator teeth and plurality of stator windings coupled to the stator core. The stator is configured to generate a stator magnetic rotating field when the stator windings are excited with an electric current. The stator magnetic rotating field includes both synchronous sub-harmonic and super-harmonic components. The permanent magnet machine also includes a rotor that is disposed within the stator. The rotor includes a rotor core and a plurality of rotor magnets that are coupled to the rotor core. The rotor magnets are further configured to have a predefined orientation profile such that when the stator windings are excited with an electric current, sub-harmonic and super-harmonic magnetic rotating fields are generated in the rotor magnetic field. The stator sub-harmonic and super-harmonic magnetic rotating fields interact with the rotor sub-harmonic and super-harmonic magnetic rotating fields and produce an aiding torque on in the permanent magnet machine.

42 ENGINEERING↗

Torque ripple reduction in electric machines

An electric machine, such as an Internal Permanent magnet or Synchronous Reluctance machine, having X phases, that includes a stator assembly, having M slots, with a stator core and stator teeth, that is further configured with stator windings to generate a stator magnetic field when excited with alternating currents and extends along a longitudinal axis with an inner surface that defines a cavity; and a rotor assembly, having N poles, disposed within the cavity which is configured to rotate about the longitudinal axis, wherein the rotor assembly includes a shaft, a rotor core located circumferentially around the shaft. The machine is configured such that a value k=M/(X*N) wherein k is a non-integer greater than about 1.3. The electric machine may alternatively, or additionally, include a non-uniformed gap between the exterior surface of the rotor spokes and the interior stator surface of the stator.

42 ENGINEERING↗

Permanent-magnet-less machine having an enclosed air gap

A permanent magnet-less, brushless synchronous system includes a stator that generates a magnetic rotating field when sourced by an alternating current. An uncluttered rotor disposed within the magnetic rotating field is spaced apart from the stator to form an air gap relative to an axis of rotation. A stationary excitation core spaced apart from the uncluttered rotor by an axial air gap and a radial air gap substantially encloses the stationary excitation core. Some permanent magnet-less, brushless synchronous systems include stator core gaps to reduce axial flux flow. Some permanent magnet-less, brushless synchronous systems include an uncluttered rotor coupled to outer laminations. The quadrature-axis inductance may be increased in some synchronous systems. Some synchronous systems convert energy such as mechanical energy into electrical energy (e.g., a generator); other synchronous systems may convert any form of energy into mechanical energy (e.g., a motor).

42 ENGINEERING↗

Wound Field and Hybrid Synchronous Machines for EV Traction with Brushless Capacitive Rotor Field Excitation (Final Report)

This project focused on the development of wound field synchronous machines (WFSMs) and hybrid excitation synchronous machines (HESMs) with brushless capacitive power transfer for the field excitation. The target application for the machines developed is the main traction motor in electric vehicles. The magnetization in these types of machines is provided by a field winding on the rotor which is excited with DC current. The magnetization level in the machine can be varied by changing the magnitude of the field current. The variable magnetization or field is one of the key features of WFSMs. WFSMs are commonly used as generators however they have several attractive features for automotive traction applications. 1) No use of permanent magnet: Rare earth permanent magnets are primarily mined and processed in China. They have been subject to large price and supply variations and their export may be restricted during times of geopolitical tension. 2) Easy field weakening: Wound field synchronous machines have complete control of their field excitation. With proper design, this type of machine can electromagnetically have an infinite constant power speed range. 3) High power factor: With proper choice of the field excitation, WFSMs may be operated with high or even unity power factor. This potentially allows for the inverter connected to the stator winding to be downsized. In comparison induction machines and interior permanent magnet synchronous machines must supply reactive power to the stator increasing the kVA rating and cost of the inverter. 4) Reduced iron losses at high speed: By reducing the field excitation, the iron loss in the stator can be reduced. This is in comparison to interior permanent magnet synchronous machines which must use stator current to buck or reduce the flux produced by the permanent magnets. Generally, WFSMs have their highest efficiency at high speed. 5) Torque output at high temperatures: The magnetization provided by the field winding only depends on the field current and not on the field winding temperature. This is in contrast to permanent magnet machines where the permanent magnet flux decreases as the magnet temperature increases. Historically a number of approaches have been developed to provide DC current to the rotating field winding in WFSM’s including brushes and slip rings, low frequency brushless exciters, and high frequency rotary transformers and rectifiers. In this project, a different approach was used: brushless capacitive power transfer. Brushless capacitive power transfer uses two sets of rotating capacitors or electrodes in which an AC electric field is established by a high frequency inverter. A displacement current can flow through the airgap in the rotating capacitors which is rectified on the rotor using a diode bridge. The potential advantage of capacitive power transfer is that there is no need for heavy iron to guide magnetic flux. The electric flux lines terminate on the charges on the rotary capacitor surfaces. This should also limit the electric field outside the rotary capacitor airgaps. The main challenge with capacitive power transfer is that the capacitance and surface area of the rotating capacitors is small. Because capacitive power transfer systems are essentially a dual of a magnetic system, an Ampere per Hertz relationship is characteristic versus a Volts per Hertz relationship. A very high frequency power inverter must be used to provide sufficient excitation to the field winding. The concept of using capacitive power transfer to excite a high performance WFSM was initially developed in a previous U.S.A. Dept. of Energy project, DE-EE0006829. This project focused on increasing the power density of the WFSMs and reducing the cost and manufacturing complexity of the capacitive power transfer system. This project has demonstrated that WFSMs with brushless capacitive field power transfer can provide a high-power density and low-cost automotive powertrain technology.

33 ADVANCED PROPULSION SYSTEMS↗

Analysis of Grid-Forming Inverter Controls for Grid-Connected and Islanded Microgrid Integration

Autonomous grid-forming (GFM) inverter testbeds with scalable platforms have attracted interest recently. In this study, a self-synchronized universal droop controller (SUDC) was adopted, tested, and scaled in a small network and a test feeder using a real-time simulation tool to operate microgrids without synchronous generators. We presented a novel GFM inverter control adoption to better understand the dynamic behavior of the inverters and their scalability, which can impact the distribution system (DS). This paper provides a steady-state and transient analysis of the GFM power inverter controller via simulation to better understand voltage and frequency stabilization and ensure that the critical electric loads are not affected during a prolonged power outage. The controllers of the GFM inverter are simulated in HYPERSIM to examine voltage and frequency fluctuations. This analysis includes assessing the black start capability for photovoltaic microgrids, both grid-connected and islanded, during transient fault conditions. The high photovoltaic PV penetration levels open exciting opportunities and challenges for the DS. The GFM inverter control demonstrated appropriate response times for synchronization, connection, and disconnection to the grid. The DS has become more resilient and independent of fossil fuels by increasing the penetration of inverter-based distributed energy resources (DERs).

Ward, Laura (ORCID:0000000345501581)↗

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.↗

Stability Assessment of a System Comprising a Single Machine and Inverter with Scalable Ratings

From the inception of power systems, synchronous machines have acted as the foundation of large-scale electrical infrastructures and their physical properties have formed the cornerstone of system operations. However, power electronics interfaces are playing a growing role as they are the primary interface for several types of renewable energy sources and storage technologies. As the role of power electronics in systems continues to grow, it is crucial to investigate the properties of bulk power systems in low inertia settings. In this paper, we assess the properties of coupled machine-inverter systems by studying an elementary system comprised of a synchronous generator, three-phase inverter, and a load. Furthermore, the inverter model is formulated such that its power rating can be scaled continuously across power levels while preserving its closed-loop response. Accordingly, the properties of the machine-inverter system can be assessed for varying ratios of machine-to-inverter power ratings and, hence, differing levels of inertia. After linearizing the model and assessing its eigenvalues, we show that system stability is highly dependent on the interaction between the inverter current controller and machine exciter, thus uncovering a key concern with mixed machine-inverter systems and motivating the need for next-generation grid-stabilizing inverter controls.

24 POWER TRANSMISSION AND DISTRIBUTION↗

A nonlinear interface integrated lever mechanism for piezoelectric footstep energy harvesting

Harnessing footstep energy allows for a unique method of power generation from a largely untapped resource, with applications such as instantly charging mobile and wearable electronic devices. This letter presents an easily integrated heel charger to efficiently convert kinematic walking energy into electricity. The heel charger uses a multilayered levered piezoelectric (L-Pie) mechanism associated with a nonlinear mechanical-synchronized switching on inductor circuit (M-SSHI) interface. It tactfully switches on when the foot contacts the ground, and switches off when the foot is lifted. This design takes full advantage of the user's weight, and amplifies footstep displacement by utilizing the lever mechanism to gain maximum deformation of multilayer piezoelectric patches. The experimental results show that the fabricated two-level multilayer L-pie has a top performance of 13.60 mW of AC RMS, a mechanical to AC power conversion efficiency of 7.87%, and a DC RMS power of 6.13 mW, an AC to DC power conversion efficiency of 45.07%, under a harmonic excitation of 2.3 Hz (mimicking fast walking speed: 6.2 km/h for men, 5.55 km/h for women). With an optimal load of 210 kΩ, the two-level L-pie using the M-SSHI has an improvement of 206.45% in DC RMS power compared to a standard 4-diode bridge energy harvesting circuit. Finally, the L-pie design works more efficiently under large force excitation, even with small displacement, which makes this technology optimal for footstep energy harvesting.

42 ENGINEERING↗

Stability Assessment of a System Comprising a Single Machine and Inverter with Scalable Ratings

Synchronous machines have traditionally acted as the foundation of large-scale electrical infrastructures and their physical properties have formed the cornerstone of system operations. However, with the increased integration of distributed renewable resources and energy-storage technologies, there is a need to systematically acknowledge the dynamics of power-electronics inverters - the primary energy-conversion interface in such systems - in all aspects of modeling, analysis, and control of the bulk power network. In this paper, we assess the properties of coupled machine-inverter systems by studying an elementary system comprised of a synchronous generator, three-phase inverter, and a load. The inverter model is formulated such that its power rating can be scaled continuously across power levels while preserving its closed-loop response. Accordingly, the properties of the machine-inverter system can be assessed for varying ratios of machine-to-inverter power ratings. After linearizing the model and assessing its eigenvalues, we show that system stability is highly dependent on the inverter current controller and machine exciter, thus uncovering a key concern with mixed machine-inverter systems and motivating the need for next-generation grid-stabilizing inverter controls.

24 POWER TRANSMISSION AND DISTRIBUTION↗

Particle Beam Acceleration Using 3 Petawatt Laser Pulses

The Zettawatt-Equivalent Ultrashort pulse laser System (ZEUS) is presently operational at the Gerard Mourou Center for Ultrafast Optical Science (CUOS) at the University of Michigan. ZEUS is a significant upgrade of the previous high power laser systems at CUOS and consists of two beamlines thatoperate in perfect synchronization. The 500 TW beamline became operational in 2023, 2 PW operation started in 2025 and full 3 PW power levels will be available in 2026. It is presently the highest power laser system in the US. In this grant the high field science group at CUOS has leveraged this unique high power laser facility to investigate laser wake field acceleration (LWFA) in ultra-high power laser plasma interactions and have shown how this can scale for future electron–positron colliders at high energy. The dual beam experimental configuration enables flexibility for many frontier experiments in laser-driven acceleration research, in particular, enabling extended channelling/acceleration experiments, positron generation/acceleration experiments and proof-of-principle transverse pumping “dephasingless” electron acceleration experiment and theory. LWFA may be able to miniaturize particle accelerators for high energy physics and also enable new sources of ultrafast, extreme brightness and precise x-rays for a wide variety of applications. In laser wake field acceleration, an electron bunch “surfs” on the electron plasma wave (the “wake field”) generated by the ponderomotive force of an intense laser. The plasma wave has a strong longitudinal electric field that stays in phase with the relativistic driver. A relativistic charged particle may, therefore, remain in phase with the accelerating field over long distances and gain ultra-relativistic energies. The accelerating electric field strength that the plasma wave can support can be many orders of magnitude higher than that of conventional accelerators, which makes laser wakefield acceleration an exciting prospect as an advanced accelerator concept. In this research project we have investigated the scaling of this mechanism to laser powers of 2 PW and have measured the x-ray emission and radio frequency emission resulting from the acceleration process. We have also performed theoretical investigation of mechanisms to scale laser driven accelerators to much higher energy using dephasingless acceleration processes.

43 PARTICLE ACCELERATORS↗

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↗

From Coherence to Function: Exploring the Connection in Chemical Systems

The role of quantum mechanical coherences or coherent superposition states in excited state processes has received considerable attention in the last two decades largely due to advancements in ultrafast laser spectroscopy. These coherence effects hold promise for enhancing the efficiency and robustness of functionally relevant processes, even when confronted with energy disorder and environmental fluctuations. Understanding coherence deeply drives us to unravel mechanisms and dynamics controlled by order and synchronization at a quantum mechanical level, envisioning optical control of coherence to enhance functions or create new ones in molecular and material systems. In this frontier, the interplay between electronic and vibrational dynamics, specifically the influence of vibrations in directing electronic dynamics, has emerged as the leading principle. Here, two energetically disparate quantum degrees of freedom work in-sync to dictate the trajectory of an excited state reaction. Moreover, with the vibrational degree being directly related to the structural composition of molecular or material systems, new molecular designs could be inspired by tailoring certain structural elements. In the realm of chemical kinetics, our understanding of the dynamics of chemical transformations is underpinned by fundamental theories, such as transition state theory, activated rate theory, and Marcus theory. These theories elucidate reaction rates by considering the energy barriers that must be overcome for reactants to transform into products. Those barriers are surmounted by the stochastic nature of energy gap fluctuations within reacting systems, emphasizing that the reaction coordinate, the pathway from reactants to products, is not rigidly defined by a specific vibrational motion but encompasses a diverse array of molecular motions. While less is known about the involvement of specific intramolecular vibrational modes, their significance in certain cases cannot be overlooked. In this Account, we summarize key experimental findings that offer deeper insights into the complex electronic–vibrational trajectories encompassing excited states afforded from state-of-the-art ultrafast laser spectroscopy in three exemplary processes: photoinduced electron transfer, singlet–triplet intersystem crossing, and intramolecular vibrational energy flow in molecular systems. We delve into the rapid decoherence, or loss of phase and amplitude correlations, of vibrational coherences along promoter vibrations during subpicosecond intersystem crossing dynamics in a series of binuclear platinum complexes. This rapid decoherence illustrates the vibration-driven reactive pathways from the Franck–Condon state to the curve crossing region. We also explore the generation of new vibrational coherences induced by impulsive reaction dynamics rather than by the laser pulse in these systems, which sheds light on specific energy dissipation pathways and thereby on the progression of the reaction trajectory in the vicinity of the curve crossing on the product side. Another property of vibrational coherences, amplitude, reveals how energy can flow from one vibration to another in the electronic excited state of a terpyridine–molybdenum complex hosting a nonreactive dinitrogen substrate. In conclusion, a slight change in vibrational energy triggers a quasi-resonant interaction, leading to constructive wavepacket interference and ultimately intramolecular vibrational redistribution from a Franck–Condon active terpyridine vibration to a dinitrogen stretching vibration, energizing the dinitrogen bond.

Electrical energy↗