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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

Design of a Magnetic Gear for NASA's Vertical Lift Quadrotor Concept Vehicle

Magnetic gears are an attractive alternative to mechanical gears for electrified aircraft drive systems due to their ability to transmit torque without mechanical tooth contact. Consequently, magnetic gears enable electrified aircraft to take advantage of the benefits of gearing without introducing most of the contact-related reliability concerns associated with mechanical gearing. Magnetic gears however, have not been shown to match the specific torque (torque/mass) and efficiency of their mechanical counterparts in an aerospace application to date. In this paper, the design of a concentric magnetic gear for a personal air transport NASA reference vehicle is presented to demonstrate the feasibility of a magnetic gear for aerospace applications.

Tallerico, Thomas F.↗

Design of a Magnetic Gear for NASA's Vertical Lift Quadrotor Reference Vehicle

Magnetic gears are an attractive alternative to mechanical gears for electrified aircraft drive systems due to their ability to transmit torque without mechanical tooth contact. Consequently, magnetic gears enable electrified aircraft to take advantage of the benefits of gearing without introducing most of the contact-related reliability concerns associated with mechanical gearing. Magnetic gears however, have not been shown to match the specific torque (torque/mass) and efficiency of their mechanical counterparts in an aerospace application to date. In this paper, the design of a concentric magnetic gear for a personal air transport NASA reference vehicle is presented to demonstrate the feasibility of a magnetic gear for aerospace applications.

Tallerico, Thomas↗

Dynamic Testing of a High-Specific-Torque Concentric Magnetic Gear

This paper presents initial measurements of the efficiency of NASA's 2nd magnetic gear prototype. A detailed discussion of the test rig's design and capabilities was presented, along with a thorough uncertainty analysis. The reported uncertainties are 95% confidence intervals that include the effects of temperature and parasitic loads. The prototype's response was measured at output speeds between 124 rpm and 744 rpm for a controlled output torque of 10 Nm (8% of the prototype's maximum torque). After correcting for tare losses, the prototype's efficiency was found to decrease from 90.0% to 83.0% as speed increased. If the efficiency is extrapolated to a typical operating condition (85% of maximum torque) using the good assumption that energy loss is approximately independent of the transmitted torque, the expected efficiency would be 99.0% to 98.4%, which exceeds the state of the art for these speeds.

magnetic gears↗

Control and Scaling Approach for the Emulation of Dynamic Subscale Torque Loads

Research and development of electrified aircraft propulsion powertrains is moving toward the use electro-mechanical systems to emulate the loads a system imparts on another. Replacing a prime mover with a model driving an electro-mechanical system capable of emulating loads that regulate the system to produce a desired response is a lower risk, lower cost alternative to using the traditional prime mover for control system verification. This paper outlines a control and scaling approach for emulating scaled dynamic torque loads using electric machine (EM) hardware for electrified aircraft propulsion research and development purposes. The approach, known as the Sliding Mode Impedance Controller with Scaling (SMICS), drives a mechanically coupled two-EM system that provides a scaled hardware representation of an electrified turbomachinery shaft. One EM reflects inertial dynamics and load of the shaft under steady-state and transient operation while the second EM represents a motor/generator connected to the shaft. This closed loop system applies impedance and sliding mode control schemes to match desired dynamics in real-time along with parameter scaling to effectively scale full scale torque inputs, a full-scale desired inertia, and sub-scale speed feedback. The result is a sub-scale hardware implementation of a coupled EM system that is command-able by a model and control system designed for a full-scale electrified aircraft propulsion powertrain. The paper elaborates on the need for closed loop control and scaling as well as impedance and sliding mode control theory, shows a derivation of the controller and scaling, its implementation, and presents a comparison of theoretical and actual simulation results acquired during hardware-in-the-loop testing of a partial turboelectric propulsion concept at the NASA Electric Aircraft Testbed (NEAT).

Santino J Bianco↗

Control and Scaling Approach for the Emulation of Dynamic Subscale Torque Loads

Research and development of electrified aircraft propulsion powertrains are relying on the use of electromechanical systems to emulate turbomachinery/rotor loads. Replacing a physical turbomachinery/rotor with a model driving a subscale electromechanical system capable of emulating subscale torque loads and responses is a lower risk, lower cost alternative to using the full-scale turbomachinery/rotor for initial control system verification. This paper outlines a novel control and scaling approach for emulating dynamic subscale torque loads using electric machine (EM) hardware for electrified aircraft propulsion research and development purposes. The approach, known as the Sliding Mode Impedance Controller with Scaling (SMICS), drives a mechanically coupled, two-EM system to behave like a subscale hardware representation of a hybrid-electric turbomachinery shaft. One EM reflects the inertial dynamics and torque load of the subscale turbomachinery under steady-state and transient operation while the second EM represents a motor/generator connected to the shaft, which is intended to hybridize the turbomachinery. This closed loop control and scaling algorithm applies impedance and sliding mode control schemes, along with parameter scaling, to match subscale, desired dynamics in real-time and to allow this system to be driven by a full-scale hybrid-electric turbomachinery model and control. The paper elaborates on the concept of the closed loop control and scaling approach and explains the significance of using impedance and sliding mode control. It shows a derivation of the closed loop control and scaling algorithm, its implementation, and presents a comparison of theoretical and actual simulation results acquired during hardware-in-the-loop testing of a partial turboelectric propulsion concept aircraft at the NASA Electric Aircraft Testbed (NEAT).The results show that the intended dynamic responses of the hardware and the aircraft model are achieved in both the time and frequency domain. Full scale propulsion control systems can be tested using this hardware and software approach.

Emulation↗

Turboelectric and Hybrid Electric Aircraft Drive Key Performance Parameters

NASA has been investigating electrified aircraft propulsion as a means of furthering its goals of reducing fuel burn, emissions, and noise. However, the electric drive components required introduce weight and efficiency penalties at odds with these goals. The purpose of this paper is to propose electric drive specific power, electric drive efficiency, and electrical propulsion fraction as the key performance parameters for fully turboelectric, partially turboelectric, and parallel hybrid electric aircraft power systems. The impacts of these parameters on overall aircraft performance are investigated. Range equations for each aircraft type are described. The benefits and costs that may result from the electrified propulsion systems are enumerated. A breakeven analysis is conducted to find the minimum allowable electric drive specific power and efficiency, for a given electrical propulsion fraction and battery specific energy, that can preserve the range, payload weight, input energy, and ratio of operating empty weight to initial weight of the conventional aircraft.

turboelectric aircraft propulsion↗

Turboelectric and Hybrid Electric Aircraft Drive Key Performance Parameters

NASA has been investigating electrified aircraft propulsion as a means of furthering its goals of reducing fuel burn, emissions, and noise. However, the electric drive components required introduce weight and efficiency penalties at odds with these goals. The purpose of this paper is to propose electric drive specific power, electric drive efficiency, and electric propulsion fraction as the key performance parameters for fully turboelectric, partially turboelectric, and parallel hybrid electric aircraft power systems. The impact of these parameters on overall aircraft performance are investigated. Range equations for each aircraft type are described. The benefits and costs that may result from the electrified propulsion systems are enumerated. A breakeven analysis is conducted to find the minimum allowable electric drive specific power and efficiency, for a given electrical propulsion fraction and battery specific energy, that can preserve the range, payload weight, input energy, and ratio of operating empty weight to initial weight of the conventional aircraft.

Duffy, Kirsten P.↗

Failure Modes and Mitigation Strategies for a Turboelectric Aircraft Concept with Turbine Electrified Energy Management

The electrification of gas turbine engines represents a major step-change in aircraft propulsion systems commonly known as Electrified Aircraft Propulsion (EAP). EAP involves the integration of electric machines potentially functioning as generators for large scale power extraction, as motors providing electrical augmentation of the engine spools, and even as a means of driving propulsors beyond the immediate scope of the engine. It may also include the use of energy storage. These and other characteristics of hybrid electric propulsion systems are relatively new to aircraft propulsion. The expanded propulsion architecture can be leveraged to improve propulsive efficiency and achieve better vehicle aerodynamics and controllability. It can also allow for additional benefits such as those enabled through Turbine Electrified Energy Management (TEEM). As the propulsion system and its functions expand, new failure modes are introduced. Due to the highly coupled nature of the propulsion system, failures could propagate throughout the system in ways that are unique to the new EAP architectures. To build confidence in the safety and practicality of EAP concepts, these failure modes need to be identified, explored, and addressed through mitigation strategies. This paper seeks to evaluate failure modes and failure mitigation strategies for the EAP concept known as the Single aisle Turboelectric AiRCaft with Aft Boundary Layer propulsor (STARC-ABL). The TEEM control concept is applied to improve transient operability. Several failure modes are considered and control based failure mitigation strategies are proposed with the goal of retaining operability and overall thrust. The results demonstrate the ability to maintain operability and a substantial amount of thrust in the event of various types of failures. Some challenges are also identified and discussed.

Turbine Electrified Energy Management↗

Core Losses in Co-Rich Inductors with Tunable Permeability

High frequency, low loss power systems enable electrified aircraft propulsion. Filter inductors that reduce noise in high current systems can account for 50% of the motor drive mass. Efficient inductor cores with tunable permeability reduce system mass by producing less heat, that removes heat sink mass. Requirements for filter inductors vary based on the chosen topology, but all inductor cores must operate below saturation levels. As the saturation flux density is limited (less than ~2 T), high differential current applications require cores with low relative permeabilities. The large induced anisotropies possible in Co-rich metal amorphous nanocomposite materials enables gapless inductors with relative permeabilities down to ~20. These materials have fine grain size ~8nm with a faulted, close packed structure. The impact of different processing methods on core losses are presented along with comparison to other low permeability soft magnetic materials.

Leary, Alex↗

Impedance Measurements of Motor Drives and Supply in SPEED Testbed

Many electrified aircraft configurations consist of a number of power components operating on the same shared electrical bus. Understanding the impedance performance of electrical loads and sources is key to understanding, and designing for, acceptable overall vehicle power quality and power system stability. To enable these measurements, personnel at NASA’s Glenn research Center have designed and built the Scaled Power ElEctrified Drivetrain (SPEED) Testbed. This paper will present data taken in the SPEED lab, including impedance measurements of a DC supply (source) and a motor drive and electric machine (load) under a number of conditions. Impacts of load power, drive controller tuning, and field weakening on load impedance are measured, presented, and discussed; as are source impedance data, and DC bus current spectra at different loading levels.

electrified aircraft propulsion↗

Impedance Measurements of Motor Drive and Supply in SPEED Testbed

Many electrified aircraft configurations consist of a number of power components operating on the same shared electrical bus. Understanding the impedance performance of electrical loads and sources is key to understanding, and designing for, acceptable overall vehicle power quality and power system stability. To enable these measurements, personnel at NASA’s Glenn Research Center have designed and built the Scaled Power ElEctrified Drivetrain (SPEED) Testbed. This paper will present data taken in the SPEED lab, including impedance measurements of a DC supply (source) and a motor drive and electric machine (load) under a number of conditions. Impacts of load power, drive controller tuning, and field-weakening on load impedance are measured, presented, and discussed; as are source impedance data, stability, and DC bus current spectra at different loading levels.

electrified aircraft propulsion↗

Impedance Measurements of Motor Drives and Supplies in NASA NEAT Facility

Many electrified aircraft configurations consist of a number of power components operating on the same shared electrical bus. Understanding the impedance performance of electrical loads and sources is key to understanding, and designing for, acceptable overall vehicle power quality and power system stability. This paper discusses impedance measurements made on the NASA Electric Aircraft Testbed (NEAT) Electrical Power System (EPS) at NASA Glenn Research Center. First, an overall discussion of the NEAT facility configuration during testing is presented; then details of the impedance measurement approach and the various testing configurations are discussed. Next, input impedance measurements at NEAT, including sources (DC supplies) and loads (multiple motor drives, electric machines, and resistive load banks, with long interconnecting cable leads), are performed under a number of conditions, and results, including load model comparisons and stability analysis, are presented and discussed.

electrified aircraft propulsion↗

Impedance Measurements of Motor Drives and Supplies in NASA NEAT Facility

Many electrified aircraft configurations consist of a number of power components operating on the same shared electrical bus. Understanding the impedance performance of electrical loads and sources is key to understanding, and designing for, acceptable overall vehicle power quality and power system stability. This paper discusses impedance measurements made on the NASA Electric Aircraft Testbed (NEAT) Electrical Power System (EPS) at NASA Glenn Research Center. First, an overall discussion of the NEAT facility configuration during testing is presented. Then, details of the impedance measurement approach and the various testing configurations are discussed. Next, input impedance measurements at NEAT, including sources (DC supplies) and loads (multiple motor drives, electric machines, and resistive load banks, with long interconnecting cable leads), are performed under a number of conditions, and results, including load model comparisons and stability analysis, are presented and discussed.

electrified aircraft propulsion↗

Subscale Hardware-In-The-Loop Results for Hybrid Electric Turbofan Controls Use Cases

NASA is investigating hybrid electric turbine engine systems for commercial transport aircraft due to the potentially significant improvements hybrid electric technology offers in performance, fuel consumption, and operational and design flexibility. Recently, the technology has been tested at full scale in partnership with industry and advanced to Technology Readiness Level 4. This presentation will focus on a recent subscale hardware-in-the-loop test of an open source turbofan engine model developed by NASA. The Advanced Geared Turbofan 30,000 lbf – electrified (AGTF30-e) engine is used as a reference model to demonstrate control system design and use cases for an example mild hybrid electric system with no large-scale energy storage. This model is run in real-time in NASA’s Hybrid Propulsion Emulation Rig (HyPER) and is used to drive an emulation of the turbomachinery system using subscale electric machines. This dynamic scaled shaft emulation interacts with a subscale (<100 kW) hybrid system consisting of electric machines, motor controllers, and a programmable electronic load. Specific use cases demonstrated include the use of Turbine Electrified Energy Management to improve operation during transients, megawatt-scale power extraction from the AGTF30-e, and power transfer between engine spools. Results related to the effectiveness of hybrid systems are qualitatively compared to results from industry testing.

Hybrid↗

Electrical Propulsive Fuselage Concept for Transonic Transport Aircraft

NASA is broadly engaged in Electrified Aircraft Propulsion (EAP) efforts across air vehicle sizes and electric aircraft propulsion approaches. EAP enables a wide range of propulsion airframe integration options as well as the use of rechargeable energy storage in an aircraft. This paper is limited to a discussion of boundary layer ingestion (BLI) systems which are located on the fuselage of the aircraft and use electrical drive systems. We term that combination an "electrical propulsive fuselage". The benefits, challenges, and design parameters of an electrically driven fuselage BLI system are considered. Five existing types of fuselage BLI implementation approaches which can be implemented using either electrical or mechanical drive systems are reviewed. An overview of boundary layer types, fan response to boundary layer, and electrical system for aircraft propulsion is presented. An idea distributed electric propulsive fuselage is proposed.

Electrified Aircraft Propulsion↗

A Summary of NASA Rotary Wing Research: Circa 2008–2018

The general public may not know that the first “A” in NASA stands for Aeronautics. If they do know, they will very likely be surprised that in addition to airplanes, the “A” includes research in helicopters, tiltrotors, and other vehicles adorned with rotors. There is, arguably, no subsonic air vehicle more difficult to accurately analyze than a vehicle with lift-producing rotors. No wonder that NASA has conducted rotary wing research since the days of the NACA and has partnered, since 1965, with the U.S. Army in order to overcome some of the most challenging obstacles to understanding the behavior of these vehicles. Since 2006, NASA rotary wing research has been performed under several different project names [Gorton et al., 2015]: Subsonic Rotary Wing (SRW) (2006–2012), Rotary Wing (RW) (2012–2014), and Revolutionary Vertical Lift Technology (RVLT) (2014–present). In 2009, the SRW Project published a report that assessed the status of NASA rotorcraft research; in particular, the predictive capability of NASA rotorcraft tools was addressed for a number of technical disciplines. A brief history of NASA rotorcraft research through 2009 was also provided [Yamauchi and Young, 2009]. Gorton et al. [2015] describes the system studies during 2009–2011 that informed the SRW/RW/RVLT project investment prioritization and organization. The authors also provided the status of research in the RW Project in engines, drive systems, aeromechanics, and impact dynamics as related to structural dynamics of vertical lift vehicles. Since 2009, the focus of research has shifted from large civil VTOL transports, to environmentally clean aircraft, to electrified VTOL aircraft for the urban air mobility (UAM) market. The changing focus of rotorcraft research has been a reflection of the evolving strategic direction of the NASA Aeronautics Research Mission Directorate (ARMD). By 2014, the project had been renamed the Revolutionary Vertical Lift Technology Project. In response to the 2014 NASA Strategic Plan, ARMD developed six Strategic Thrusts. Strategic Thrust 3B was defined as the “Ultra-Efficient Commercial Vehicles—Vertical Lift Aircraft.” Hochstetler et al. [2017] uses Thrust 3B as an example for developing metrics usable by ARMD to measure the effectiveness of each of the Strategic Thrusts. The authors provide near-, mid-, and long-term outcomes for Thrust 3B with corresponding benefits and capabilities. The importance of VTOL research, especially with the rapidly expanding UAM market, eventually resulted in a new Strategic Thrust (to begin in 2020): Thrust 4—Safe, Quiet, and Affordable Vertical Lift Air Vehicles. The underlying rotary wing analysis tools used by NASA are still applicable to traditional rotorcraft and have been expanded in capability to accommodate the growing number of VTOL configurations designed for UAM. The top-level goal of the RVLT Project remains unchanged since 2006: Develop and validate tools, technologies and concepts to overcome key barriers for vertical lift vehicles. In 2019, NASA rotary wing/VTOL research has never been more important for supporting new aircraft and advancements in technology. 2 A decade is a reasonable interval to pause and take stock of progress and accomplishments. In 10 years, digital technology has propelled progress in computational efficiency by orders of magnitude and expanded capabilities in measurement techniques. The purpose of this report is to provide a compilation of the NASA rotary wing research from ~2008 to ~2018. Brief summaries of publications from NASA, NASA-funded, and NASA-supported research are provided in 12 chapters: Acoustics, Aeromechanics, Computational Fluid Dynamics (External Flow), Experimental Methods, Flight Dynamics and Control, Drive Systems, Engines, Crashworthiness, Icing, Structures and Materials, Conceptual Design and System Analysis, and Mars Helicopter. We hope this report serves as a useful reference for future NASA vertical lift researchers.

Yamauchi, Gloria K.↗

Reversionary Control Modes for the Mitigation of Failures in a Partially Turboelectric Aircraft Propulsion System

In support of emission and fuel burn reduction goals, the aviation industry is actively pursuing the advancement of electrified aircraft propulsion (EAP) technology. This includes turboelectric and hybrid electric propulsion designs that combine gas turbine engine and electrical system hardware. Such architectures exhibit a high degree of coupling between subsystems. This drives the need for system-level control strategies to ensure the safe, coordinated, and efficient operation of all subsystems. The design and certification of any aircraft propulsion system requires that all potential subsystem failures are identified, and the hazards posed by these failures are appropriately mitigated. This requirement is particularly challenging for EAP systems due to their integrated nature. One approach to assist in EAP failure mitigation is the inclusion of automated reconfiguration capabilities within the propulsion control system. Such control modes, referred to as reversionary control modes, are designed to automatically detect failures and activate backup control modes upon failure detection. This paper covers the design and evaluation of reversionary control mode logic developed for a partially turboelectric propulsion concept. Test results from a real-time hardware-in-the-loop evaluation of the concept are also presented and discussed. The results show that the developed reversionary control logic can successfully detect and mitigate subsystem failures in a representative environment that includes actual electrical system hardware.

Electrified Aircraft Propulsion↗

Reversionary Control Modes for the Mitigation of Failures in a Partially Turboelectric Aircraft Propulsion System

In support of emission and fuel burn reduction goals, the aviation industry is actively pursuing the advancement of electrified aircraft propulsion (EAP) technology. This includes turboelectric and hybrid electric propulsion designs that combine gas turbine engine and electrical system hardware. Such architectures exhibit a high degree of coupling between subsystems. This drives the need for system-level control strategies to ensure the safe, coordinated, and efficient operation of all subsystems. The design and certification of any aircraft propulsion system requires that all potential subsystem failures are identified, and the hazards posed by these failures are appropriately mitigated. This requirement is particularly challenging for EAP systems due to their integrated nature. One approach to assist in EAP failure mitigation is the inclusion of automated reconfiguration capabilities within the propulsion control system. Such control modes, referred to as reversionary control modes, are designed to automatically detect failures and activate backup control modes upon failure detection. This paper covers the design and evaluation of reversionary control mode logic developed for a partially turboelectric propulsion concept. Test results from a real-time hardware-in-the-loop evaluation of the concept are also presented and discussed. The results show that the developed reversionary control logic can successfully detect and mitigate subsystem failures in a representative environment that includes actual electrical system hardware.

Electrified Aircraft Propulsion↗