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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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14 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2016

Power Converter Control Algorithm Design and Simulation for the NREL Next-Generation Drivetrain: July 8, 2013 - January 7, 2016

The National Renewable Energy Laboratory (NREL) and NREL Next-Generation Drivetrain Partners are developing a next-generation drivetrain (NGD) design as part of a Funding Opportunity Announcement award from the U.S. Department of Energy. The proposed NGD includes comprehensive innovations to the gearbox, generator, and power converter that increase the gearbox reliability and drivetrain capacity, while lowering deployment and operation and maintenance costs. A key task within this development effort is the power converter fault control algorithm design and associated computer simulations using an integrated electromechanical model of the drivetrain. The results of this task will be used in generating the embedded control software to be utilized in the power converter during testing of the NGD in the National Wind Technology Center 2.5-MW dynamometer. A list of issues to be addressed with these algorithms was developed by review of the grid interconnection requirements of various North American transmission system operators, and those requirements that presented the greatest impact to the wind turbine drivetrain design were then selected for mitigation via power converter control algorithms.

17 WIND ENERGY↗
DOE OSTI2016

NREL-Prime Next-Generation Drivetrain Dynamometer Test Report

Advances in wind turbine drivetrain technologies are necessary to improve reliability and reduce the cost of energy for land-based and offshore wind turbines. The NREL-Prime Next-Generation Drivetrain team developed a geared, medium-speed drivetrain that is lighter, more reliable and more efficient than existing designs. One of the objectives of Phase II of the project was to complete the detailed design, fabrication, and dynamometer testing of a 750 kilowatt (kW) drivetrain that includes the key gearbox innovations designed by Romax Technology and power converter innovations designed by DNV Kema Renewables. The purpose of this document is to summarize these tests completed in NREL's National Wind Technology Center 2.5 megawatt (MW) dynamometer.

16 TIDAL AND WAVE POWER↗
DOE OSTI2016

The DOE Next-Generation Drivetrain for Wind Turbine Applications: Gearbox, Generator, and Advanced Si/SiC Hybrid Inverter System: Preprint

This paper reports on the design and testing results from the U.S. Department of Energy Next-Generation Wind Turbine Drivetrain Project. The drivetrain design reduces the cost of energy by increasing energy capture through drivetrain efficiency improvements; by reducing operation and maintenance costs through reducing gearbox failures; and by lowering capital costs through weight reduction and a series of mechanical and electronic innovations. The paper provides an overview of the drivetrain gearbox and generator and provides a deeper look into the power converter system. The power converter has a number of innovations including the use of hybrid silicon (Si)/silicon carbide (SiC) isolated baseplate switching modules. Switching energies are compared between SiC and Si PIN diodes. The efficiency improvement by use of the SiC diode in a three-level converter is also described. Finally, a brief discussion covering utility interconnect requirements for turbines is provided with a particular focus on utility events that lead to high transient torque loads on drivetrain mechanical elements.

17 WIND ENERGY↗
DOE OSTI2015

Next Generation Drivetrain Development and Test Program

This presentation was given at the Wind Energy IQ conference in Bremen, Germany, November 30 through December 2, 2105. It focused on the next-generation drivetrain architecture and drivetrain technology development and testing (including gearbox and inverter software and medium-voltage inverter modules.

17 WIND ENERGY↗
DOE OSTI2016

Torsional Vibration in the National Wind Technology Center’s 2.5-Megawatt Dynamometer

This report documents the torsional drivetrain dynamics of the NWTC's 2.5-megawatt dynamometer as identified experimentally and as calculated using lumped parameter models using known inertia and stiffness parameters. The report is presented in two parts beginning with the identification of the primary torsional modes followed by the investigation of approaches to damp the torsional vibrations. The key mechanical parameters for the lumped parameter models and justification for the element grouping used in the derivation of the torsional modes are presented. The sensitivities of the torsional modes to different test article properties are discussed. The oscillations observed from the low-speed and generator torque measurements were used to identify the extent of damping inherently achieved through active and passive compensation techniques. A simplified Simulink model of the dynamometer test article integrating the electro-mechanical power conversion and control features was established to emulate the torque behavior that was observed during testing. The torque response in the high-speed, low-speed, and generator shafts were tested and validated against experimental measurements involving step changes in load with the dynamometer operating under speed-regulation mode. The Simulink model serves as a ready reference to identify the torque sensitivities to various system parameters and to explore opportunities to improve torsional damping under different conditions.

17 WIND ENERGY↗
NASA NTRS1990

Advanced Rotorcraft Transmission Program

The U.S. Army/NASA Advanced Rotorcraft Transmission (ART) program is charged with developing and demonstrating a light, quiet, and durable drivetrain for next-generation rotorcraft in two classes: a 10,000-20,000 Future Attack Air Vehicle capable of both tactical ground support and air-to-air missions, and a 60,000-80,000 lb Advanced Cargo Aircraft, for heavy-lift field-support operations. Specific ART objectives encompass a 25-percent reduction in drivetrain weight, a 10-dB noise level reduction at the transmission source, and the achievement of a 5000-hr MTBF. Four candidate drivetrain systems have been carried to a conceptual design stage, together with projections of their mission performance and life-cycle costs.

Bill, Robert C.↗
NASA NTRS1992

Summary highlights of the Advanced Rotorcraft Transmission (ART) program

The NASA/U.S. Army Advanced Rotorcraft Transmission (ART) program is charged with the development and demonstration of lightweight, durable drivetrains for next-generation rotorcraft: (1) a Future Air Attack Vehicle for tactical ground-support and air-to-air missions, and (2) an Advanced Cargo Aircraft for heavy-lift field-support operations. Both tilt-rotor and more conventional helicopter configurations have been studied by the ART program. ART performance goals are sought through the use of advanced component materials and lubrication systems, transmission and geartrain configurations, and airframe/drivetrain integrations.

Bill, Robert C.↗
DOE OSTI2016

Clemson University Wind Turbine Drivetrain Test Facility

In November of 2009, Clemson University was awarded a competitive grant from the U.S. Department of Energy to design, build and operate a facility for full-scale, highly accelerated mechanical testing of next-generation wind turbine drivetrain technologies. The primary goal of the project was to design, construct, commission, and operate a state-of-the-art sustainable facility that permits full-scale highly accelerated testing of advanced drivetrain systems for large wind turbines. The secondary goal was to meet the objectives of the American Recovery and Reinvestment Act of 2009, especially in job creation, and provide a positive impact on economically distressed areas in the United States, and preservation and economic recovery in an expeditious manner. The project was executed according to a managed cooperative agreement with the Department of Energy and was an extraordinary success. The resultant new facility is located in North Charleston, SC, providing easy transportation access by rail, road or ship and operates on an open access model such that it is available to the U.S. Wind Industry for research, analysis, and evaluation activities. The 72 m by 97 m facility features two mechanical dynamometer test bays for evaluating the torque and blade dynamic forces experienced by the rotors of wind turbine drivetrains. The dynamometers are rated at 7.5 MW and 15 MW of low speed shaft power and are configured as independent test areas capable of simultaneous operation. All six degrees of freedom, three linear and three rotational, for blade and rotor dynamics are replicated through the combination of a drive motor, speed reduction gearbox and a controllable hydraulic load application unit (LAU). This new LAU setup readily supports accelerated lifetime mechanical testing and load analysis for the entire drivetrain system of the nacelle and easily simulates a wide variety of realistic operating scenarios in a controlled laboratory environment. The development of these two dynamometer test rigs is the first significant achievement for the project. These test rigs embody a new manner of test due to the system configuration and completely new design with a free floating loading hub in the LAU. This project provided the catalyst for the advancement to this new test rig configuration that has been adopted by every significant wind turbine test rig constructed since the inception of this project. There are currently two different vendors supplying these new systems. Catalyzing this new design is the second major success of the project. With the increased market penetration of wind energy over the past decade, many regions and countries have developed specific electrical grid specifications and performance codes for large wind farms to ensure operational reliability and stability. These grid codes provide requirements for interconnection with the grid during low or high voltage phenomena, typically encountered during and after system fault events. Given the installed infrastructure of the Wind Turbine Drivetrain Testing Facility (WTDTF), a natural expansion of facility capability was to include the necessary equipment for performing fault ride-through evaluations of wind turbines to the Low Voltage Ride Through (LVRT) codes. Once the decision was made to expand the scope of the original grant into fault ride-through testing, it was clear that there are several markets, not just wind, which could benefit from this type of test and that simple fault ride-through testing could be extended into a broader scope of electrical testing capabilities. It was at this point that Clemson University was awarded a second grant to build a 15 MW Hardware-In-the-Loop (HIL) Grid Simulator in order to establish world class electrical testing capabilities to compliment the mechanical testing at the WTDTF. This third significant achievement resulted in the 15 MW HIL Grid Simulator as the corner stone of the Duke Energy eGRID Center and is collocated with the WTDTF in the SCE&G Energy Innovation Center at the new Facility in North Charleston, SC, USA. Before the eGRID was completed, it was recognized that the ability to test solar farm equipment was but a small step away thru the addition of enhanced equipment to provide for DC testing. In yet another expansion/success, a 2.5 MW rectifier system was designed and implemented by Clemson staff to enhance the Center’s capabilities. The program required over 250,000 man-hours of on-site construction labor reworking the brownfield facility on the former Navy Base, clearly satisfying one of the major goals of the Reinvestment Act. This was done while winning numerous awards for design and construction of the facility, including the Top US Project for 2014 from the Trade Journal Engineering News Record. The project was a major collaborative developmental activity managed by Clemson University staff that involved the DOE and many partners and organizations.

17 WIND ENERGY↗
DOE OSTI2024

Next-Generation, High-temperature, High-frequency, High-efficiency, High-power-density Traction System

To meet performance and reliability requirements necessary for broader adoption of electric drive vehicles, the Electrical and Electronics Technical Team of the U.S. Drive partnership has established aggressive design goals for next-generation electric vehicle drivetrains. Specifically, the 2025 roadmap stipulates a 100 kW/L power density target and a $\$$2.7/kW cost target for power electronics, in addition to high-voltage operation (i.e., greater than 800 VDC). The additional targets for traction motor and the overall system performance impose further challenges on the power electronics design. For example, many high specific power machines have reduced iron content, and therefore reduced intrinsic filtering, thus requiring the inverter to supply a low-distortion drive current. These machines also typically have a high pole count, thus requiring drive current at a higher electrical frequency. Other motors, such as brush-less dc and switch reluctance machines, require a carefully-shaped, non-sinusoidal drive current (Yang, Shang, Brown, & Krishnamurthy, 2015), (Zhang, Bowman, O'Connel, & Haran, 2018), (Anderson, et al., 2018). Two- and three-level inverter topologies are the conventional framework for the power electronics design of the drivetrain, and some demonstrations have shown recent progress towards addressing cost, power density and efficiency goals (Gurpinar & Ozpineci, 2018), (Zhu, Kim, Chen, Erickson, & Maksimović, 2018), (Deshpande, Chen, Narayanasamy, Sathyanarayanan, & Luo, 2018), (Alizadeh, et al., 2019). However, an unconventional approach may be necessary to take the dramatic leap in power density necessitated by the roadmap—while simultaneously addressing the other system needs. Therefore, this project leverages the flying capacitor multilevel (FCML) topology, together with a scalable, modular approach, to address these needs. This type of hybrid converter has several advantages: lower voltage (i.e., less than 300 V) transistors can be used, energy-dense capacitors process most of the power, and the output current waveform is multilevel and exhibits a frequency multiplying effect—in other words, the output has reduced dv/dt and filtering requirements for the same high voltage dc bus. For example, in an electric vehicle with an 800 V bus, a 10-level FCML could leverage 100 V, commercially available GaN devices switching at 115 kHz to produce a ~1 MHz switching waveform (modulated according to the motor drive requirements) with one ninth of the dv/dt of a two-level converter. Prior work has already demonstrated promising performance and gravimetric power density figures for more electric aircraft applications (Pallo, Foulkes, Modeer, Coday, & Pilawa-Podgurski, 2018). This project leverages lessons learned to achieve the volumetric power density of 100 kW/L by employing advanced liquid cooling, address the 300,000 mile reliability challenge with redundant design, topology failure studies and online health monitoring, and reduce costs to $\$$2.7/kW through the use of low-cost GaN devices, modular converter assemblies, and modest modifications to traditional manufacturing methods. The project involved several hardware designs, each achieving increasing performance. At the conclusion of the project, a volumetric power density of 380 kW/L was achieved, in a 800V dc-ac converter, greatly surpassing even the aggressive target goal.

33 ADVANCED PROPULSION SYSTEMS↗
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↗