Results for “misalignment tolerance”

DOE OSTI2021

A Field Enhancement Integration Design Featuring Misalignment Tolerance for Wireless EV Charging Using LCL Topology

This article proposes a magnetic integration design for EV wireless power transfer (WPT) systems, where the compensation and transmitting coils overlap one on top of the other to share the ferrite layer without any decoupling consideration. The magnetic field generated by both the compensation and transmitting coils are exploited to transfer power. To this end, a compensation method is proposed to enable magnetic field enhancement without any reactive power flow between the compensation and the transmitting coils, and to achieve input zero phase angle and constant current output. In addition, an efficient finite element analysis-based coil optimization algorithm is proposed to improve the coil misalignment tolerance on the horizontal plane, in which a reversely connected inner coil is used to stabilize the system output under misalignment conditions. Analytical and simulation results confirm transmission flux density enhancement and reduced leakage field characteristics of the proposed coil design. Finally, a scaled-down WPT prototype is built and tested to verify the performance and effectiveness of the design. The proposed design achieves 91.17% efficiency and misalignment tolerance up to 200 mm in any XY-direction while maintaining the power transfer and its efficiency. The results of this work provide insights into magnetic integration design of high-order compensation topologies featuring higher compactness, less ferrite usage, magnetic field enhancement, and misalignment tolerance for WPT systems.

42 ENGINEERING↗

NASA NTRS2016

Study of Lateral Misalignment Tolerance of a Symmetric Free-Space Optical Link for Intra International Space Station Communication

This paper describes the study of lateral misalignment tolerance of a symmetric high-rate free-space optical link (FSOL) for use between International Space Station (ISS) payload sites and the main cabin. The link will enable gigabit per second (Gbps) transmission of data, which is up to three orders of magnitude greater than the current capabilities. This application includes 10-20 meter links and requires minimum size, weight, and power (SWaP). The optical power must not present an eye hazard and must be easily integrated into the existing ISS infrastructure. On the ISS, rapid thermal changes and astronaut movement will cause flexure of the structure which will potentially misalign the free space transmit and receive optics 9 cm laterally and 0.2 degrees angularly. If this misalignment is not accounted for, a loss of the link or degradation of link performance will occur. Power measurements were collected to better understand the effect of various system design parameters on lateral misalignment. Parameters that were varied include: the type of small form pluggable (SFP) transceivers, type of fiber, and transmitted power level. A potential solution was identified that can reach the lateral misalignment tolerance (decenter span) required to create an FSOL on the ISS by using 105 m core fibers, a duplex SFP, two channels of light, and two fiber amplifiers.

optical communications↗

NASA NTRS2016

Study of Lateral Misalignment Tolerance of a Symmetric Free-Space Optical Link for Intra International Space Station Communication

This paper describes the study of lateral misalignment tolerance of a symmetric high-rate free-space optical link (FSOL) for use between International Space Station (ISS) payload sites and the main cabin. The link will enable gigabit per second (Gbps) transmission of data, which is up to three orders of magnitude greater than the current capabilities. This application includes 10-20 meter links and requires minimum size, weight, and power (SWaP). The optical power must not present an eye hazard and must be easily integrated into the existing ISS infrastructure. On the ISS, rapid thermal changes and astronaut movement will cause flexure of the structure which will potentially misalign the free space transmit and receive optics 9 cm laterally and 0.2 degrees angularly. If this misalignment is not accounted for, a loss of the link or degradation of link performance will occur. Power measurements were collected to better understand the effect of various system design parameters on lateral misalignment. Parameters that were varied include: the type of small form pluggable (SFP) transceivers, type of fiber, and transmitted power level. A potential solution was identified that can reach the lateral misalignment tolerance (decenter span) required to create an FSOL on the ISS by using 105 m core fibers, a duplex SFP, two channels of light, and two fiber amplifiers.

free space↗

DOE OSTI2025

A Misalignment Tolerant Magnetic Coupler Design and Implementation for Wireless Charging of Unmanned Aerial Vehicles (UAVs)

Wireless power transfer technology is getting more attention these days as a part of expanded battery charging infrastructure and network at a wide range of power levels. Charging Unmanned aerial vehicles (UAVs) is one wireless charging application, and charging their batteries can be challenging because they have short flight times and are frequently charged. For wireless charging of UAVs, the misalignment performance of the magnetic coupler pads is critical because landing on a charging pad at a perfectly aligned position is difficult and can be time-consuming. Different coil shapes and system structures have been proposed in the literature to overcome this challenge. A new design with a high misalignment tolerance is needed; therefore, to fill this gap, a wireless power transfer system has been designed for a 250 W UAV battery charging system with a new magnetic coupler design. A 3D model of the proposed design was created, and finite element simulations were performed. To prove the proposed design, the magnetic coupler prototypes were developed, and experimental results are presented herein. The misalignment tolerance of the proposed system was observed for various rotational positions of the secondary coil, from 0° to 360°. The results demonstrate that DC–DC efficiency varies between 80% and 85% within full 360° rotation of the receiver coil. This result enables the proposed system to address the misalignment problem for wireless charging of UAVs.

UAVs↗

DOE OSTI2020

A Modular Integration Design of LCL Circuit Featuring Field Enhancement and Misalignment Tolerance for Wireless EV Charging

One of the major challenges of high-order wireless charging circuit is to reduce the system volume and cost induced by its additional components. Based on an LCL-S circuit, this paper proposes a modular integration design, in which an identical compensation inductor and transmitter are closely coupled. A new compensation method is derived to enable zero phase angle (ZPA) and constant current (CC) output. Identical currents are fed into the same reference terminals of both inductors to enable transmission field enhancement and to eliminate reactive power flow between the inductors. A misalignment tolerant coil is used to improve the output power stability under random parking imperfection. The proposed integration design achieves enhanced transmission capacity. Experiments are carried out to verify the proposed design.

Zhang, Pengcheng↗

DOE OSTI2026

Design and Performance Assessment of Intermediary Coils for Misalignment Tolerance Improvement in Wireless Power Transfer Systems

This paper investigates the use of intermediate coils positioned between the primary and secondary coils in Wireless Power Transfer (WPT) systems for electric vehicle (EV) charging, with the objective of improving power transfer efficiency and robustness under misalignment conditions. An optimized 1 kW power system that operates at 85 kHz is developed and the misalignment performance was analyzed and compared with and without intermediate coils. A preliminary increase in efficiency of 2.3% at a misalignment of 52% of the coil radius is shown to be possible for a passive intermediate coil. An experimental prototype is built for design verification.

Sivka, Gozde [ORNL]↗

DOE OSTI2024

Misalignment Tolerant Three-phase Wireless Fast Charging System for Electric Vehicles

This project proposes improving the technology level of the three-phase wireless charging technology developed at Oak Ridge National Laboratory (ORNL). Successful commercialization of wireless charging systems require that they meet strict safety standards for electromagnetic field emissions and interoperability with other wireless charging technology. ORNL has previously demonstrated a 50kW three-phase wireless power transfer system with 95% efficiency. This prototype system weighed less than 50% of similar high-power wireless charging system while simultaneously exhibiting better safety characteristics. Due to better material utilization, the reduction in mass is expected to translate into similar cost reduction for the magnetic coupler. Additionally, the smaller footprint of the system can ease vehicle integration difficulties that would be encountered using other technology. Furthermore, the three-phase design can be made to operate with existing single-phase coupler design more easily and without intentional physical misalignment which would otherwise pose safety issues.This project developed ORNL’s WPT technology to satisfy the specifications and requirements for electric vehicle (EV) charging. The result of the project will be a prototype and reference design for a high-power wireless charging system—including magnetics, power electronics, and controls—serving as a baseline for product development.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2024

Misalignment Tolerant Three-phase Wireless Fast Charging System for Electric Vehicles

This project proposes improving the technology level of the three-phase wireless charging technology developed at Oak Ridge National Laboratory (ORNL). Successful commercialization of wireless charging systems require that they meet strict safety standards for electromagnetic field emissions and interoperability with other wireless charging technology. ORNL has previously demonstrated a 50kW three-phase wireless power transfer system with 95% efficiency. This prototype system weighed less than 50% of similar high-power wireless charging system while simultaneously exhibiting better safety characteristics. Due to better material utilization, the reduction in mass is expected to translate into similar cost reduction for the magnetic coupler. Additionally, the smaller footprint of the system can ease vehicle integration difficulties that would be encountered using other technology. Furthermore, the three-phase design can be made to operate with existing single-phase coupler design more easily and without intentional physical misalignment which would otherwise pose safety issues. This project developed ORNL’s WPT technology to satisfy the specifications and requirements for electric vehicle (EV) charging. The result of the project will be a prototype and reference design for a high-power wireless charging system—including magnetics, power electronics, and controls—serving as a baseline for product development.

33 ADVANCED PROPULSION SYSTEMS↗

NASA NTRS1991

Optoelectronic Shaft-Angle Encoder Tolerates Misalignments

Optoelectronic shaft-angle encoder measures angle of rotation of shaft with high precision while minimizing effects of eccentricity and other misalignments. Grooves on disk serve as reference marks to locate reading heads and measure increments of rotation of disk. Shaft-angle encoder, resembling optical compact-disk drive, includes two tracking heads illuminating grooves on disk and measures reflections from them.

Osborne, Eric P.↗

NASA NTRS1966

Fluid pressure balanced seal

A seal which increases in effectiveness with increasing pressure is presented. The seal's functional capability throughout both static and dynamic operation makes it particularly useful for sealing ball valve ports. Other features of the seal include the ability to seal two opposed surfaces simultaneously, tolerance of small misalignments, tolerance of wide temperature ranges, ability to maintain positive sealing contact under conditions of internal or external pressurization, and ability to conform to slight irregularities in seal or surface contours.

Marsh, H. W.↗

DOE OSTI2023

A Novel Honeycomb-DD Multi Coil Design for Wireless Power Transfer Systems

Wireless power transfer (WPT) technology has received significant attention recently as an alternative charging method for batteries in a wide range of power levels. In the literature, many types of coil structures have been well-studied. Honeycomb coil arrays, which have been used mostly for low-power applications, have not been well-studied for high-power-level applications. In this paper, a novel honeycomb-DD coil design is proposed for high-power wireless battery charging systems. The proposed coil design with step by step design process is given and Finite Element Analysis (FEA) was performed to observe the full performance characteristics of the system for a 100 kW system. In addition, the misalignment tolerance of the proposed system was observed by shifting the secondary side charging pad at different misalignment positions, and the electromagnetic compatibility to the standards was investigated. The core and strand losses were obtained. The results show that the honeycomb coil array provides high coupling coefficient and better misalignment tolerance, making it a potential coil topology for WPT applications.

Aydin, Emrullah↗

NASA NTRS2018

Exploration of Double Clad Fibers for Increased Stability of Bidirectional Free Space Optical Links

Bidirectional, high data rate, low size, weight, and power (SWaP), and low cost free space optical links are needed for space communication applications to send and receive large volumes of data. We are exploring design strategies for optical transceivers to reduce SWaP and cost through increased misalignment tolerance (pointing requirement reduction) and sharing the optical transmit and receive paths (imposing optical symmetry). In applications where the detector is fiber coupled, the fiber numerical aperture is the main driver of the pointing accuracy requirement. Unfortunately, reducing the pointing requirement by increasing the fiber numerical aperture symmetrically causes instability in received power over small environmental changes. This paper explores double clad fibers as a solution to both reduce the power instability and increase the pointing accuracy tolerance. Double clad fibers can transmit a Gaussian beam from a single mode fiber and receive in a multi-mode aperture. Results show that double clad fiber have an improved misalignment tolerance and a higher stability for small changes in temperature when compared to single mode fibers and multimode fibers. Also, double clad fibers are shown to match the performance of an asymmetrical link design with a single mode transmit fiber and a multimode receive fiber.

Double Clad fibers↗

NASA NTRS2018

Exploration of Double Clad Fibers for Increased Stability of Bidirectional Free Space Optical Links

Bidirectional, high data rate, low size, weight, and power (SWaP), and low cost free space optical links are needed for space communication applications to send and receive large volumes of data. We are exploring design strategies for optical transceivers to reduce SWaP and cost through increased misalignment tolerance (pointing requirement reduction) and sharing the optical transmit and receive paths (imposing optical symmetry). In applications where the detector is fiber coupled, the fiber numerical aperture is the main driver of the pointing accuracy requirement. Unfortunately, reducing the pointing requirement by increasing the fiber numerical aperture symmetrically causes instability in received power over small environmental changes. This paper explores double clad fibers as a solution to both reduce the power instability and increase the pointing accuracy tolerance. Double clad fibers can transmit a Gaussian beam from a single mode fiber and receive in a multi-mode aperture. Results show that double clad fiber have an improved misalignment tolerance and a higher stability for small changes in temperature when compared to single mode fibers and multimode fibers. Also, double clad fibers are shown to match the performance of an asymmetrical link design with a single mode transmit fiber and a multimode receive fiber.

Double Clad fibers↗

DOE OSTI2023

Effects of Size and Shape on the Tolerances for Misalignment and Probabilities for Successful Oriented Attachment of Nanoparticles

Oriented attachment (OA) of nanoparticles is an important pathway of crystal growth, but tools for quantitatively modeling OA are lacking. Here we present several simple models that relate the probability of achieving OA to basic geometric parameters such as particle size, shape, and lattice periodicity. A Moiré-domain model is applied to understand twist-misorientations between parallel surfaces, and it predicts that the range of twist angles yielding perfect OA is inversely related to the width of the contact area. This is confirmed and further developed using a surface functional model, which predicts how crystallographic registration forces drive the emergence of complex orientational energy landscapes. The energy landscapes are predicted to possess local minima that can trap particles in imperfect alignments, and these local minima become deeper and more numerous as the contact area increases, making OA more challenging for large particles. Further, a second set of models is presented to understand the sequence of events by which two crystallographic faces become co-planer after collision. We use a ‘central force approximation’ to quantitatively predict the odds of attaining coalignment between various faces when particles collide with random misalignments, and we show that in the absence of biasing forces, the probability of attaining alignment on a given face is roughly proportional to its solid angle as viewed from the center of the particle. The model predicts that OA is most favorable between well-faceted particles and becomes exceedingly unlikely for large spherical particles that express many microfacets.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2025

Multi-phase Wireless Power Transfer with High Power Density Inductive Coils for Electric Drone Charging

Wireless charging of unmanned ground vehi-cles and aircraft has been proposed to increase charging reliability and security, allow for autonomous functionality, and either reduce battery size or increase continuous flight time. This paper proposes a three-phase Litz wire primary and a two-phase PCB secondary for high secondary-side power density considering misalignment tolerances, surface and volumetric power density, and coil sizing. Elec-tromagnetic 3D finite element analysis (FEA) simulations are conducted to study variation in mutual inductance and coupling coefficient with different secondary coil sizes and number of turns, horizontal and vertical misalignment between the primary and secondary, and a combination of both for a set of designs with the same rated power. Results indicate that receiver coils of reduced size relative to the primary can deliver rated power for increased power density and higher tolerance to misalignment.

Gastineau, Lucas [University of Kentucky]↗

NASA NTRS1991

Guideline requirements for serviceable spacecraft grasping/berthing/docking interfaces based on simulations and flight experience (survey paper)

As space vehicles and structures become larger and more complex, the development of systems to assist humans in assembling, operating, maintaining, and performing space rescue or retrieval of these vehicles and structures becomes increasingly important. With the diversity of international spacecraft, both manned and unmanned, planned to be in orbit in the future, a set of guidelines for berthing and docking subsystems is mandatory if servicing, resupply, and retrieval is to become practical on an international level. Successful interaction between these space systems and ground and/or space-based humans requires standardized and effective operational interface designs, particularly with respect to space grasping/berthing/docking interface mechanisms. This paper defines the spacecraft mechanical interfaces necessary to create a standard dynamic envelope for joining two free-flying spacecraft in a 'hard' berth or dock with each other in space. A review was made of past space flights and dynamics simulations dating back to 1962 to obtain necessary parameters and their values for successful manually controlled and autonomous spacecraft docking/berthing. The various spacecraft docking/berthing mechanisms and concepts are illustrated along with their dynamic capture and impact tolerances including maximum contact velocity along the approach axis and in the y-z plane; capture linear misalignment tolerances; and maximum capture roll, pitch, and yaw angles. From this data sets of recommended guidelines parameters were developed for autonomous and manual impact docking tolerances, non-impact grasping/berthing tolerances (end effectors), berthing contact conditions, and alignment tolerances after rigidizing. Also, detailed requirements were developed for mechanical design interface features, as well as latching, unlatching, and separation tolerances. This data was drafted in the form of a proposed ANSI Standard guideline, reviewed, and added to by members of the committee representing several spacecraft manufacturers, NASA, and the USAF, and a consensus was reached.

Thompson, Allen B.↗

NASA NTRS2008

Misalignment in Gas Foil Journal Bearings: An Experimental Study

As gas foil journal bearings become more prevalent in production machines, such as small gas turbine propulsion systems and microturbines, system-level performance issues must be identified and quantified in order to provide for successful design practices. Several examples of system-level design parameters that are not fully understood in foil bearing systems are thermal management schemes, alignment requirements, balance requirements, thrust load balancing, and others. In order to address some of these deficiencies and begin to develop guidelines, this paper presents a preliminary experimental investigation of the misalignment tolerance of gas foil journal bearing systems. Using a notional gas foil bearing supported rotor and a laser-based shaft alignment system, increasing levels of misalignment are imparted to the bearing supports while monitoring temperature at the bearing edges. The amount of misalignment that induces bearing failure is identified and compared to other conventional bearing types such as cylindrical roller bearings and angular contact ball bearings. Additionally, the dynamic response of the rotor indicates that the gas foil bearing force coefficients may be affected by misalignment.

Howard, Samuel A.↗

DOE OSTI2024

Fourier Analysis and Loss Modeling for Inductive Wireless Electric Vehicle Charging with Reduced Stray Field

With the growth of electric vehicle (EV) popularity, different charging options to increase user convenience and reduce charging times are being considered and researched. Among these, inductive wireless power transfer (WPT) systems for EVs are being designed to meet specifications such as stray field, power level, efficiency, misalignment tolerance, and ground clearance, which are all heavily influenced by the coil geometry. The proposed Fourier Analysis Method (FAM) is an analytical method to directly design coil geometries to meet stray field and power level requirements through an optimization of Fourier basis function coefficients. The outputs of the optimization are complex, planar coil geometries that meet the power level and stray field constraints with minimized loss factors. Contours of these potentials determine the coil conductor paths and loss models predict the system efficiency and performance over misalignment. The Fourier representation of the geometry is used to conveniently calculate the coupling over misalignment, external proximity effect loss, and ferrite loss. A 6.6 kW prototype WPT system with low stray field and high efficiency is built from the optimization results to validate the models and showcase the usefulness of the FAM design approach.

33 ADVANCED PROPULSION SYSTEMS↗