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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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9 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Fully Integrated High Speed Megawatt Class Motor and High Frequency Variable Speed Drive System

This project involved developing a fully integrated high speed megawatt class motor and high frequency variable speed drive system that serve as a commercially viable and technically sound methodology for high speed industrial system applications. The project team organizations consist of Clemson University and TECO Westinghouse Motor Company (TWMC) formed an academic and industrial collaboration that combines the design, analysis, manufacturing and testing experience required for a large research project of this magnitude. The project resulted in an integrated high speed megawatt class medium voltage motor drive system that is at a TRL 6 with a clear path for commercialization. The fully integrated prototype system has been manufactured by TWMC in its Round Rock, Texas facility and tested at full power on a dynamometer at the Clemson University’s eGRID Center in North Charleston, South Carolina.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
NASA NTRSDate not supplied

Design Optimization Studies of Partially Superconducting Machines based on NASA’s High Efficiency Megawatt Motor

Single aisle class electric aircraft require high power density and efficiency megawatt electric machines to be competitive with their tradition turbofan counterparts. Superconducting machines are seen as a key enabling technology for achieving the electric motor power density and efficiency needed by single aisle class electric aircraft. NASA’s High Efficiency Megawatt Motor (HEMM) is a partially superconducting machine being developed at NASA Glenn Research Center as a technology demonstration of a practical near-term superconducting machine. HEMM is being developed to meet the requirements of the generators on NASA’s STARC-ABL reference aircraft. HEMM is expected to achieve greater than 16 kW/kg electromagnetic specific power and greater than 98% efficiency at a nominal operating condition of 1.4 MW and 6800 RPM. In this paper, a design optimization algorithm for partially superconducting machines based on HEMM’s technologies is used to explore the possible performance of HEMM technology at other machine power levels and operating conditions. The design optimization algorithm is detailed in full and results for achievable geared and direct drive machine performance are presented.

Thomas F Tallerico↗
NASA NTRS2024

AC and DC Fault Management for Megawatt Electrified Aircraft Electrical Powertrains - Task 2: Power Quality Filtering Using Nanocrystalline Soft Magnetic Inductor

The NASA RTAPS program on AC and DC Fault Management for Megawatt Electrified Power Train is a multi-year joint project with Pratt & Whitney (P&W), Collins Aerospace (CA), and RTX Technology Research Center (RTRC). This research program focuses on the high-voltage distribution issues that present a significant technological obstacle in the adoption of Electrified Aviation Propulsion (EAP) systems. One challenge to the adoption of high-voltage distribution systems with power electronic converters is the need for filter elements to limit the generation and propagation of noise, protect the cable systems from premature aging and prevent against excessive heating within subcomponents due to high-frequency induced currents. While increased distribution voltages aide in reducing the cable mass for a fixed power system, the associated mass with the filtering elements for power electronic converter can grow with increasing distribution voltages – thereby mitigating any benefit associated with increasing the distribution system voltage. To enable high-voltage distribution systems with high system specific power densities, new magnetic materials must be developed. Therefore, the second task of the NASA RTAPS program is associated with the design and application of advanced soft magnetic components for Megawatt class electric propulsion systems, specifically the motor drive system. This report covers the collaborative work between NASA Glenn Research Center (GRC), RTRC, P&W and CA in the development of three types of magnetic components over the span of the three-year program. These critical magnetic components are the DC side EMI filter, which limits the propagation of harmful electromagnetic noise to the rise of the distribution system, and the AC side damping with the dv/dt filter, which limits the fast rise time of the power electronic converter output voltage to limit the degradation on the cable/motor insulation systems. Each of these components are investigated from component level design and are optimized at the system level with a combined modelling and testing effort. In the final experimental evaluation of the NASA developed soft magnetic material with a dv/dt filter, a commercial-off-the-shelf (COTS) magnetic core and the GRC magnetic core are optimized and loaded at 320Arms to evaluate their difference in performance. After a run time of 30 minutes in a MW-class motor driver at RTRC, the NASA GRC cores were found to not only offer a lower temperature rise of nearly 25°𝐶, but also a reduction in measured core loss of 25% (12.75W to 9.5W).

Elecrified Aircraft Propulsion↗
NASA NTRSDate not supplied

Electromagnetic Redesign of NASA’s High Efficiency Megawatt Motor

NASA’s High Efficiency Megawatt Motor (HEMM) is being developed to achieve the performance needed by single aisle class electrified aircraft. It is a 1.4 MW electric machine designed as a generator for NASA’s STARC-ABL concept vehicle. It has performance objectives of greater than 16 kW/kg electromagnetic specific power and efficiency of greater than 98%. A significant flaw in the preliminary electromagnetic design of HEMM was recently discovered. The stator teeth in the preliminary design cause the magnetic flux in the rotating components of HEMM to oscillate at a very high frequency (12,240 Hz). Two independent energy loss analyses are presented to show that the frequency is high enough to cause eddy current losses that significantly exceed the rotor’s loss limit (50 W), despite the very small magnitude of this flux oscillation (<0.01 T). To eliminate these rotor losses, while continuing to meet the target performance, it was determined that the stator teeth needed to be removed and the electromagnetic geometry of the motor needed to be revised. The revised, slotless HEMM motor design is summarized. Sensitivity of the new design to key unknown variables such as the temperature of and number of turns in the superconducting rotor coils and the stator winding’s average temperature.

Thomas T Tallerico↗
NASA NTRSDate not supplied

Combined Analysis of NASA's High Efficiency Megawatt Motor and Its Converter

NASA’s High Efficiency Megawatt Motor (HEMM) is being developed to achieve the performance needed by single aisle class electrified aircraft. It is a 1.4 MW electric machine designed as a generator for NASA’s STARC-ABL concept vehicle. It has performance objectives of greater than 16 kW/kg electromagnetic specific power and efficiency of greater than 98%. The key enabling technology for HEMM’s high performance metrics is a superconducting rotor cooled by an integrated cryocooler. HEMM’s integrated cryocooler is being designed to only lift 50 W of heat at its target 50 K cold tip operating temperature. HEMM’s superconducting rotor therefore needs to have essentially zero electromagnetic losses in order to stay below the 50 W heat rejection limit of the cryocooler. This paper presents the combined analysis of HEMM and a preliminarily designed HEMM converter to analyze the rotor loss impact of several potential converter filter topologies. The analysis results point to interleaving and series inductance filters not being sufficient to suppress switching harmonic caused rotor loss. Paths forward to develop a converter to eliminate rotor loss are discussed.

Matthew Granger↗
NASA NTRSDate not supplied

Combined Analysis of NASA's High Efficiency Megawatt Motor and Its Converter

NASA’s High Efficiency Megawatt Motor (HEMM) is being developed to achieve the performance needed by single aisle class electrified aircraft. It is a 1.4 MW electric machine designed as a generator for NASA’s STARC-ABL concept vehicle. It has performance objectives of greater than 16 kW/kg electromagnetic specific power and efficiency of greater than 98%. The key enabling technology for HEMM’s high performance metrics is a superconducting rotor cooled by an integrated cryocooler. HEMM’s integrated cryocooler is being designed to only lift 50 W of heat at its target 50 K cold tip operating temperature. HEMM’s superconducting rotor therefore needs to have essentially zero electromagnetic losses in order to stay below the 50 W heat rejection limit of the cryocooler. This paper presents the combined analysis of HEMM and a preliminarily designed HEMM converter to analyze the rotor loss impact of several potential converter filter topologies. The analysis results point to interleaving and series inductance filters not being sufficient to suppress switching harmonic caused rotor loss. Paths forward to develop a converter to eliminate rotor loss are discussed.

Matthew Granger↗
NASA NTRSDate not supplied

Thermal, Structural, and Rotordynamics Refinements to the Superconducting Rotor of A 1.4 Mw Partially Superconducting Machine for Electrified Aircraft

NASA is developing the high efficiency megawatt motor (HEMM), a 1.4 MW partially superconducting machine, to ad-dress the need for highly efficient, lightweight, MW-class ma-chines to support aviation sustainability efforts. This paper presents progress on the thermal, structural, and rotordynamics aspects of HEMM’s superconducting rotor. Emissivity measurements of gold coated cobalt iron and titanium parts are presented and then used to correlate a thermal model of the rotor to existing data from a thermo-electrical test of the full-scale rotor. Lessons learned from the correlated model are presented, including a rank ordering of the contributors to the temperature of the superconducting coils. An updated structural design of the HEMM rotor is presented and compared to the prior design. Finite element analysis demonstrates that the updated design improves stress margins while reducing magnetic flux leakage and retaining thermal performance. The key conclusions of the rotordynamics design are presented.

electrified aircraft propulsion↗
NASA NTRSDate not supplied

Parallel Hybrid Turboprop Performance Modeling and Optimization

NASA’s Electrified Powertrain Flight Demonstration (EPFD) project conducts ground and flight tests of integrated Megawatt (MW) class hybrid-electric powertrain systems on regional turboprop aircraft demonstrators. To meet the increased demand for assessment of potential capabilities and benefits from these novel vehicle configurations, NASA is developing tooling and models to estimate the performance of hybridized regional turboprops. This paper covers the development of a parametrically driven performance model for a De Havilland Canada Dash 8-400 (Q400) regional turboprop integrated with a novel parallel hybrid architecture using the Gascon framework. Gascon is a modern reimplementation of the General Aviation Synthesis Program (GASP) built using the Condor mathematical modeling framework in Python. Within Gascon, a parametric representation of the parallel hybrid architecture was synthesized, which features the electric motor coupled to the power turbine. This capability allows for in-the-loop optimization of the parametric parallel hybrid architecture to characterize the mission capabilities and fuel savings of the design and determine optimal power scheduling strategies for efficient electric power management for a given mission. The study shows that a fuel savings of up to 20% can be achieved, but that increased fuel savings comes at the expense of payload capacity.

Gascon↗
NASA NTRSDate not supplied

Parallel Hybrid Turboprop Performance Modeling and Optimization

NASA’s Electrified Powertrain Flight Demonstration (EPFD) project conducts ground and flight tests of integrated Megawatt (MW) class hybrid-electric powertrain systems on regional turboprop aircraft demonstrators. To meet the increased demand for assessment of potential capabilities and benefits from these novel vehicle configurations, NASA is developing tooling and models to estimate the performance of hybridized regional turboprops. This paper covers the development of a parametrically driven performance model for a De Havilland Canada Dash 8-400 (Q400) regional turboprop integrated with a novel parallel hybrid architecture using the Gascon framework. Gascon is a modern reimplementation of the General Aviation Synthesis Program (GASP) built using the Condor mathematical modeling framework in Python. Within Gascon, a parametric representation of the parallel hybrid architecture was synthesized, which features the electric motor coupled to the power turbine. This capability allows for in-the-loop optimization of the parametric parallel hybrid architecture to characterize the mission capabilities and fuel savings of the design and determine optimal power scheduling strategies for efficient electric power management for a given mission. The study shows that a fuel savings of up to 20% can be achieved, but that increased fuel savings comes at the expense of payload capacity.

Gascon↗