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Results for “high torque”

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 OSTI2018

Advanced High Torque Density Magnetically Geared Generator

The objective of this research project was to investigate the fundamental torque density limitations of multistage flux focusing magnetic gears and magnetically geared direct-drive generators for wind turbines. Magnetic gears create non-contact speed amplification by modulating the air-gap magnetic field harmonics created by magnetic rotors. By integrating a stator into the magnetic gear structure a very high torque density direct-drive generator can be created. Magnetic geared systems offer unique capabilities that are currently not available using existing mechanically geared systems, such as overload protection. Magnetic gears also offer the potential for higher reliability, higher efficiency and quieter operation than is currently achievable using a mechanically geared generator. By increasing reliability and design life magnetic gears could decrease the overall life-cycle costs when compared with equivalent mechanical or direct-drive drivetrains. This research project investigated and experimentally testing two sub-scale magnetic gearboxes (0.12 m diameter) and two large diameter magnetic gearboxes (0.56m and 0.63m diameter). The goal of the project was to demonstrate a torque density >300Nm/L for a multistage magnetic gearbox with integrated stator. A nested multistage magnetic gear structure was first proposed and studied. However, it was shown that the nested design greatly increased mechanical complexity and therefore a two-stage series typology was utilized. A multi-stage magnetic gear with a 59:1 gear ratio was successfully experimentally tested. A peak torque of 4.25 kN·m was measured and this resulted in an overall active region torque density of 141 N·m/L (when including support rings). The torque density was significantly reduced from what was computed using 2-D electromagnetic analysis. This reduction was due to the 3-D edge effects, increased power losses and the inclusion of additional mechanical support rings as well as other mechanical assembly design changes. At large diameters contiguous lamination parts could not be fabricated and so a segmented laminated rotor design had to be used. This reduced the mechanical strength of the design when compared to small diameter magnetic gears and resulted in the need for the addition of mechanical support rings to prevent deflection. The final experimentally tested design also had a high torque ripple and the power loss within the magnetic gear did not change significantly with load. This therefore resulted in the efficiency being high only at peak loads. Despite not experimentally achieving the 2-D calculated high torque density the analysis has shown that the problems encountered with the scaling can be overcome with careful design changes. For example, understanding the unique mechanical deflection requirements during the electromagnetic design of the large diameter magnetic gears is key to achieving both a high torque density based on the electromagnetic analysis and a high torque density based on the mechanical support needs. Furthermore, ensuring that end plates are made of non-conductive material and minimizing other conductive support elements within the magnetic structure is a key requirement for reducing eddy current losses. In summary, if the mechanical design can be made more robust and eddy current loss mitigation strategies are used in the mechanical design phase then the magnetic gear is capable of being scaled up whilst operating at a very high torque density. This will then enable it to be potentially performance and cost competitive with alternative direct-drive and mechanically geared wind turbine drivetrains.

17 WIND ENERGY↗
NASA NTRS1972

High torque CMG rotary actuator

A high torque rotary actuator was designed, fabricated and tested. Exacting requirements were placed on performance and physical characteristics of the actuator, particularly in the area of stiffness, backlash, torque ripple, power and size and weight. A brushless dc motor was designed utilizing rare earth magnets to meet power and weight requirements. A 26-to-1 planetary roller gear transmission was selected to best meet overall requirements. The transmission utilizes parallel gear and roller paths to minimize backlash and breakaway torque.

Source record↗
NASA NTRS1968

High-torque power wrench, a concept

High-torque power wrench is small enough to be handled by one or two men yet has sufficient torque to remove 1-1/2- to 4-inch nuts from high-pressure tanks and valves. The action can be made automatic by use of solenoid-operated valves and suitable switches.

Cox, E. F.↗
NASA NTRS1972

High torque bellows seal rotary drive

Bellows seal rotary drive device was developed which allows high torque transmission through sealed compartments. Bearing friction which would normally be carried by sealing bellows in comparable devices is absorbed by universal-gimbal joint. It can be used to transmit high torque, low speed, rotary motion through sealed barriers to prevent contamination or escape of fluids.

Diaguila, A. J.↗
NASA NTRS1976

High torque DC motor fabrication and test program

The testing of a standard iron and standard alnico permanent magnet two-phase, brushless dc spin motor for potential application to the space telescope has been concluded. The purpose of this study was to determine spin motor power losses, magnetic drag, efficiency and torque speed characteristics of a high torque dc motor. The motor was designed and built to fit an existing reaction wheel as a test vehicle and to use existing brass-board commutation and torque command electronics. The results of the tests are included in this report.

Makus, P.↗
NASA NTRS1978

High-torque open-end wrench

A wrench is described that is usable where limited access normally requires an open-end wrench, but which has substantially the high-torque capacity and small radial clearance characteristics of a closed-end wrench. The wrench includes a sleeve forming a nut-engageable socket with a gap in its side, and an adaptor forming a socket with a gap in its side, the adaptor closely surrounding the sleeve and extending across the gap in the sleeve. The sleeve and adaptor have surfaces that become fully engaged when a wrench handle is applied to the adaptor to turn it so as to tighten a nut engaged by the sleeve.

Giandomenico, A.↗
DOE OSTI2021

MADE3D: Enabling the next generation of high-torque density wind generators by additive design and 3D printing

Direct-drive wind turbine generators are increasing in popularity, thanks to recent project developments—especially offshore, where reliability and efficiency are major cost drivers. Yet, high capital costs are forcing many original equipment manufacturers to consider lightweight, high-torque density generators for next-generation multi-megawatt turbines that may be difficult to realize by traditional design or manufacturing methods. In this study, we present a new design framework enabled by advanced machine learning and multimaterial additive manufacturing to perform a magnetic topology optimization that maximizes the torque per rotor active mass for a 15-megawatt direct-drive permanent magnet wind generator. A comparison of the proposed approach against conventional topology optimization demonstrated a significant increase in computational efficiency and accuracy in performance predictions. Results using single and multimaterial compositions for rotor core and magnets identify a wider choice of 3D printable designs for a given specification. A hybrid combination of sintered and dysprosium-free polymer-bonded magnets shows good potential for torque performance by saving material costs up to 8.75%. More than 30% improvement in rotor torque densities is identified which can marginally improve the overall generator torque density. With the rapid evolution of multipowder deposition technolgies, this study can greatly inspire a new paradigm for design-driven manufacturing with novel material compositions and lightweight, low-cost, high-strength multimaterial geometries that were previously unexplored for direct-drive generators.

17 WIND ENERGY↗
DOE OSTI2021

MADE3D: Enabling the Next-Generation High-Torque- Density Wind Generators by Additive Design and 3D Printing

Direct-drive wind turbine generators are increasing in popularity, thanks to recent project developments - especially offshore, where reliability and efficiency are major cost drivers. Yet, high capital costs are forcing many original equipment manufacturers to consider lightweight, high-torque density generators for next-generation multi-megawatt turbines that may be difficult to realize by traditional design or manufacturing methods. In this study, we present a new design framework enabled by advanced machine learning and multimaterial additive manufacturing to perform a magnetic topology optimization that maximizes the torque per rotor active mass for a 15-megawatt direct-drive permanent magnet wind generator. A comparison of the proposed approach against conventional topology optimization demonstrated a significant increase in computational efficiency and accuracy in performance predictions. Results using single and multimaterial compositions for rotor core and magnets identify a wider choice of 3D printable designs for a given specification. A hybrid combination of sintered and dysprosium-free polymer-bonded magnets shows good potential for torque performance by saving material costs up to 8.75%. More than 30% improvement in rotor torque densities is identified which can marginally improve the overall generator torque density. With the rapid evolution of multipowder deposition technologies, this study can greatly inspire a new paradigm for design-driven manufacturing with novel material compositions and lightweight, low-cost, high-strength multimaterial geometries that were previously unexplored for direct-drive generators.

3D printing↗
DOE OSTI2019

Shaping of Cams for High-Torque Variable-Speed Drives

Attention focuses on the calculation of the working profile for three-dimensional cams in an oscillatory lever mechanism with a contacting spherical roller. That permits the creation of 3D surfaces for milling of the cams on CNC machine tools. Methods are proposed for determining the pressure angle and selecting the optimal parameters of the oscillatory mechanism in a nonfrictional high-torque variable-speed drive.

42 ENGINEERING↗
NASA NTRS1995

Special-Purpose High-Torque Permanent-Magnet Motors

Permanent-magnet brushless motors that must provide high commanded torques and satisfy unusual heat-removal requirement are developed. Intended for use as thrust-vector-control actuators in large rocket engines. Techniques and concepts used to design improved motors for special terrestrial applications. Conceptual motor design calls for use of rotor containing latest high-energy-product rare-earth permanent magnets so that motor produces required torque while drawing smallest possible currents from power supply. Torque generated by electromagnetic interaction between stator and permanent magnets in rotor when associated electronic circuits applied appropriately temporally and spatially phased currents to stator windings. Phase relationships needed to produce commanded torque computed in response to torque command and to electronically sensed angular position of rotor relative to stator.

Doane, George B., III↗
DOE OSTI2026

High-Torque Heavy-Rare-Earth-Free Electric Motor Thermal Management

This project is part of a multi-lab Next-Generation Reliable Electric Drive Systems for Medium and Heavy-Duty Vehicles (NEXT-DRIVE) project led by Oak Ridge National Laboratory (ORNL), and including NREL, Sandia National Laboratories (SNL), and Ames Laboratory that leverages research expertise and facilities of these national labs to develop tools and approaches for reducing the design and development time of new electric drive technologies for medium and heavy-duty vehicles (MHDVs) and their associated costs while increasing reliability and asset utilization. The Next-Drive project aligns with the DOE's goals by introducing high-fidelity multi-physics and AI/ML-based modeling to design low-cost, highly reliable, and longer-lifetime drivetrains, aiming to achieve 25 years of progress in 5 years. The efforts of this project will focus on NEXT-DRIVE Task 4 (led by ORNL, NREL, and AMES) - developing high-fidelity modeling framework and identifying technologies enabling heavy-rare-earth-free electric motors for medium- and heavy-duty vehicles to achieve 1 million miles of operation. Contrary to conventional approaches that optimize the motor for power density, the focus will be to identify motor designs that achieve the best trade-off between motor power density and durable operation. NREL tasks include development of high-fidelity motor thermal models incorporating rotor windage losses and identification, evaluation and measurement of motor interface materials in key thermal pathways. The poster summarizes NREL's accomplishments for the first half of FY 2025 and outlines future plans.

33 ADVANCED PROPULSION SYSTEMS↗
NASA NTRS1968

High-torque precision stepping drive

Stepping drive has been designed for precise incremental angular positioning of scale models of spacecraft about a horizontal axis in order to accurately measure antenna receiving and transmitting characteristics. Positioning is insured by spring-loaded, self-locking plungers.

Kaspareck, W. E.↗
NASA NTRS1986

Evaluation of a high-torque backlash-free roller actuator

The results are presented of a test program that evaluated the stiffness, accuracy, torque ripple, frictional losses, and torque holding capability of a 16:1 ratio, 430 N-m (320 ft-lb) planetary roller drive for a potential space vehicle actuator application. The drive's planet roller supporting structure and bearings were found to be the largest contributors to overall drive compliance, accounting for more than half of the total. In comparison, the traction roller contacts themselves contributed only 9 percent of the drive's compliance based on an experimentally verified stiffness model. The drive exhibited no backlash although 8 arc sec of hysteresis deflection were recorded due to microcreep within the contact under torque load. Because of these load-dependent displacements, some form of feedback control would be required for arc second positioning applications. Torque ripple tests showed the drive to be extremely smooth, actually providing some damping of input torsional oscillations. The drive also demonstrated the ability to hold static torque with drifts of 7 arc sec or less over a 24 hr period at 35 percent of full load.

Steinetz, Bruce M.↗
NASA NTRS1988

Evaluation of a high-torque backlash-free roller actuator

The results are presented of a test program that evaluated the stiffness, accuracy, torque ripple, frictional losses, and torque holding capability of a 16:1 ratio, 430 N-m (320 ft-lb) planetary roller drive for a potential space vehicle actuator application. The drive's planet roller supporting structure and bearings were found to be the largest contributors to overall drive compliance, accounting for more than half the total. In comparison, the traction roller contacts themselves contributed only 9 percent of the drive's compliance based on an experimentally verified stiffnesss model. Torque ripple tests showed the drive to be extremely smooth, actually providing some damping of input torsional oscillations. The drive also demonstrated the ability to hold static torque with drifts of 7 arc sec or less over a 24-hour period at 35 percent of full load.

Steinetz, Bruce M.↗
NASA NTRS1995

High-Torque, Lightweight, Pneumatically Driven Wrench For Small Spaces

Pneumatically driven wrench provides torque up to 3,000 lb. per ft. in small space. Designed to reach into 2.6 x 2.75 x 6 in. pocket. Weighs approximately 25 lbs. Includes reversible pneumatic motor (electric motor could be used instead) and slip clutch. Also includes device indicating total angle through which wrench turned bolt or nut. This feature used for turn-of-the-nut tightening method.

Miller, Thomas W.↗
NASA NTRS1986

Evaluation of a High-Torque Backlash-Free Roller Actuator

The results are presented herein of a test program that evaluated the stiffness, accuracy, torque ripple, frictional losses, and torque holding capability of a 16:1 ratio, 430 N-m (320 ft-lb) planetary roller drive for a potential space vehicle actuator application. The drive's planet roller supporting structure and bearings were found to be the largest contributors to overall drive compliance, accounting for more than half of the total. In comparison, the traction roller contacts themselves contributed only nine percent of the drive's compliance based on an experimentally verified stiffness model. The drive exhibited no backlash although 8 arc sec of hysteresis deflection were recorded due to microcreep within the contact under torque load. Because of these load-dependent displacements, some form of feedback control would be required for arc second positioning applications. Torque ripple tests showed the drive to be extremely smooth, actually providing some damping of input torsional oscillations. The drive also demonstrated the ability to hold static torque with drifts of 7 arc sec or less over a 24 hr period at 35 percent of full load.

Steinetz, Bruce M.↗
DOE OSTI2015

System and method to allow a synchronous motor to successfully synchronize with loads that have high inertia and/or high torque

A mechanical soft-start type coupling is used as an interface between a line start, synchronous motor and a heavy load to enable the synchronous motor to bring the heavy load up to or near synchronous speed. The soft-start coupling effectively isolates the synchronous motor from the load for enough time to enable the synchronous motor to come up to full speed. The soft-start coupling then brings the load up to or near synchronous speed.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗