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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
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Advanced Permanent Magnet Generator Topologies Using Multimaterial Shape Optimization and 3D Printing: Preprint

A vast majority of utility-scale wind turbine generators in the United States are dependent on foreign- sourced rare-earth permanent magnets that are vulnerable to supply chain uncertainties. Many small wind original equipment manufacturers are motivated to pursue continuous improvements to the generator design to lower the material and production costs and improve performance by lowering cogging torque and increasing the efficiency. Traditional design and manufacturing offer limited opportunities. In this work, we demonstrate advanced design approaches for a 15-kW baseline wind turbine generator by making use of recent progress in three-dimensional (3D) printing of polymer- bonded magnets and, electrical and structural steel. We explore three methods of magnet parametrization using Bezier curves resulting in symmetric, asymmetric and multimaterial magnet designs. We employ a multiphysics approach combining parametric computer-aided design modeling, finite- element analysis and targeted sampling to identify novel designs with more opportunities for reducing rare-earth material, improving efficiency and minimizing cogging torque. The results show that asymmetric-pole design and multimaterial-pole designs offer a greater opportunity to minimize rare-earth magnet materials by up to 35% with similar performance as the baseline generator, suggesting newer opportunities with design freedom beyond traditional limits of symmetry and as allowed by 3D printing.

Bezier curves↗
DOE OSTI2015

Demonstration of variable speed permanent magnet generator at small, low-head hydro site

Small hydro developers face a limited set of bad choices when choosing a generator for a small low-head hydro site. Direct drive synchronous generators are expensive and technically complex to install. Simpler induction generators are higher speed, requiring a speed increaser, which results in inefficiencies and maintenance problems. In addition, both induction and synchronous generators turn at a fixed speed, causing the turbine to run off its peak efficiency curve whenever the available head is different than the designed optimum head.The solution to these problems is the variable speed Permanent Magnet Generators (PMG). At the Weisenberger Mill in Midway, KY, a variable speed Permanent Magnet Generator has been installed and demonstrated. This new PMG system replaced an existing induction generator that had a HTD belt drive speed increaser system. Data was taken from the old generator before it was removed and compared to data collected after the PMG system was installed. The new variable speed PMG system is calculated to produce over 96% more energy than the old induction generator system during an average year. This significant increase was primarily due to the PMG generator operating at the correct speed at the maximum head, and the ability for the PMG generator to reduce its speed to lower optimum speeds as the stream flow increased and the net head decreased.This demonstration showed the importance of being able to adjust the speed of fixed blade turbines. All fixed blade turbines with varying net heads could achieve higher efficiencies if the speed can be matched to the optimum speed as the head changes. In addition, this demonstration showed that there are many potential efficiencies that could be realized with variable speed technology at hydro sites where mismatched turbine and generator speeds result in lower power output, even at maximum head. Funding for this project came from the US Dept. of Energy, through Award Number DE-EE0005429.

13 HYDRO ENERGY↗
DOE OSTI2025

Design and performance validation of a high-temperature downhole permanent magnet generator used for an electro-pulse boring system in geothermal energy applications

Novel, direct-energy drilling technologies such as electro-pulse boring, have the potential to significantly increase the speed and depth of geothermal drilling but have not achieved widespread adoption due to several economic and technical barriers. One major challenge is that these drilling systems require electric power downhole. The current practice is to supply power to the drill string components by running electric cables down the geothermal well, but at the targeted well depths, this practice is cost-inhibitive, inefficient in terms of power consumption, and adds an additional failure point with the long cabling going through a highly corrosive, high-temperature environment. A solution to this problem is to develop high-temperature electric generator technology that can generate the required power downhole. Such a generator must also operate with high efficiency at the target downhole ambient temperature of 250 °C. In this paper, we investigate the various design considerations for this concept and subsequently design the downhole electric generator using a multi-objective design optimization approach. Through electromagnetic-, thermal- and short-circuit fault condition analysis, it is demonstrated that the optimized downhole electric generator concept presented in this paper can meet the performance requirements within this extreme drilling environment. Most remarkably, it is shown that a generator efficiency of 90% is achieved. In conclusion, to validate the results presented in this paper, a prototype generator is built and its performance is measured at 250 °C using a test bench uniquely developed for this application.

15 GEOTHERMAL ENERGY↗
DOE OSTI2016

Improved inertial control for permanent magnet synchronous generator wind turbine generators

With increasing integrations of large‐scale systems based on permanent magnet synchronous generator wind turbine generators (PMSG‐WTGs), the overall inertial response of a power system will tend to deteriorate as a result of the decoupling of rotor speed and grid frequency through the power converter as well as the scheduled retirement of conventional synchronous generators. Thus, PMSG‐WTGs can provide value to an electric grid by contributing to the system's inertial response through the inherent kinetic energy stored in their rotating masses and fast power converter control. In this study, an improved inertial control method based on the maximum power point tracking operation curve is introduced to enhance the overall frequency support capability of PMSG‐WTGs in the case of large supply–demand imbalances. Moreover, this method is implemented in the CART2‐PMSG integrated model in MATLAB/Simulink to investigate its impact on the wind turbine's structural loads during the inertial response process. Simulation results indicate that the proposed method can effectively reduce the frequency nadir, arrest the rate of change of frequency, and alleviate the secondary frequency dip while imposing no negative impact on the major mechanical components of the wind turbine.

Wu, Ziping↗
NASA NTRS2008

Preliminary Results of Performance Measurements on a Cylindrical Hall-Effect Thruster with Magnetic Field Generated by Permanent Magnets

The performance of a low-power cylindrical Hall thruster, which more readily lends itself to miniaturization and low-power operation than a conventional (annular) Hall thruster, was measured using a planar plasma probe and a thrust stand. The field in the cylindrical thruster was produced using permanent magnets, promising a power reduction over previous cylindrical thruster iterations that employed electromagnets to generate the required magnetic field topology. Two sets of ring-shaped permanent magnets are used, and two different field configurations can be produced by reorienting the poles of one magnet relative to the other. A plasma probe measuring ion flux in the plume is used to estimate the current utilization for the two magnetic configurations. The measurements indicate that electron transport is impeded much more effectively in one configuration, implying a higher thrust efficiency. Preliminary thruster performance measurements on this configuration were obtained over a power range of 100-250 W. The thrust levels over this power range were 3.5-6.5 mN, with anode efficiencies and specific impulses spanning 14-19% and 875- 1425 s, respectively. The magnetic field in the thruster was lower for the thrust measurements than the plasma probe measurements due to heating and weakening of the permanent magnets, reducing the maximum field strength from 2 kG to roughly 750-800 G. The discharge current levels observed during thrust stand testing were anomalously high compared to those levels measured in previous experiments with this thruster.

Polzin, K. A.↗
NASA NTRS2008

Performance of a Cylindrical Hall-Effect Thruster with Magnetic Field Generated by Permanent Magnets

While Hall thrusters can operate at high efficiency at kW power levels, it is difficult to construct one that operates over a broad envelope down to 100W while maintaining an efficiency of 45- 55%. Scaling to low power while holding the main dimensionless parameters constant requires a decrease in the thruster channel size and an increase in the magnetic field strength. Increasing the magnetic field becomes technically challenging since the field can saturate the miniaturized inner components of the magnetic circuit and scaling down the magnetic circuit leaves very little room for magnetic pole pieces and heat shields. An alternative approach is to employ a cylindrical Hall thruster (CHT) geometry. Laboratory model CHTs have operated at power levels ranging from the order of 50 Watts up to 1 kW. These thrusters exhibit performance characteristics which are comparable to conventional, annular Hall thrusters of similar size. Compared to the annular Hall thruster, the CHT has a lower insulator surface area to discharge chamber volume ratio. Consequently, there is the potential for reduced wall losses in the channel of a CHT, and any reduction in wall losses should translate into lower channel heating rates and reduced erosion. This makes the CHT geometry promising for low-power applications. Recently, a CHT that uses permanent magnets to produce the magnetic field topology was tested. This thruster has the promise of reduced power consumption over previous CHT iterations that employed electromagnets. Data are presented for two purposes: to expose the effect different controllable parameters have on the discharge and to summarize performance measurements (thrust, Isp, efficiency) obtained using a thrust stand. These data are used to gain insight into the thruster's operation and to allow for quantitative comparisons between the permanent magnet CHT and the electromagnet CHT.

Polzin, Kurt A.↗
DOE OSTI2013

Investigating Short Circuit Models for Wind Turbine Generators

Short circuit study needs to be performed at the planning stage before connecting large gen erators with the electric grid. This study will reveal the impact of new generation on the fault levels of the grid. The fault levels will determine the rating of nearby equipment and setting of relays. However, a short circuit model of the new generation is required for this study. This report investigates and quantifies the short circuit models of different wind turbine generators (WTGs) and of wind farms, and using these models, explores the effects of the wind farms on the nearby switchgear. WTGs, commonly classified as Type 1, Type 2, Type 3, and Type 4, exhibit different short circuit behavior depending upon their architecture and controls. The short circuit model (synonymous to Thevenin model) of Type 1 WTG is well known; it comprises of a voltage source behind a transient reactance, X'. The transient reactance X' is derived using the reactance of stator, rotor and the magnetizing reactance. In case of Type 2 WTG, an external rotor resistance is used to increase the range of operating slips. The value of the external rotor resistance increases at higher operating slips. The effect of the external rotor resistance on the fault current response is analyzed by simulating a validated model of Type 2 WTG. The validation is performed using the field data from an actual 67-machine Type 2 wind farm located in Wyoming, USA. The results shows that the external rotor resistance should be considered in its Thevenin impedance for better accuracy. A wind farm contains a large number of WTGs, pad mounted transformers, and cables typically connected in a ‘daisy chain” configuration. The effect of these cable impedances on the short circuit model of Type 2 wind farm is examined using the validated models. It is found that the collector circuit cables inside the farm do not have a significant effect on the short circuit model of the farm. Based on this finding, a simple equivalencing procedure for the wind farm is proposed and validated. Faults inside and outside the wind farm are analyzed and recommendations to select main circuit breakers and generator circuit breakers are made. Type 3 WTG, also known as Doubly Fed Asynchronous Generator (DFAG), uses back to back converters in the rotor circuit to inject slip frequency voltage into the rotor circuit. Until recently, these machines used crowbar to short the rotor circuit during faults to protect the converter com ponents form high rotor currents resulting from faults. This type of WTG is simulated and the model is validated using field data from a 66-machine Type 3 wind farm in Wyoming, USA. The simulation study reveals that the crowbar feature is activated almost immediately after the fault takes place, and remains activated throughout the fault-period. This confirms that the short circuit model for Type 3 WTG with crowbar is similar to the model for Type 2 WTG. In the past, wind farms were allowed to disconnect during faults. However, recent grid codes around the world and in the United States demand that the wind farms be kept connected to the grid during faults, and provide certain reactive power quantified based on the voltage dip at the point of interconnection. This requirement, also called low voltage ride through (LVRT), can be accomplished by using Type 4 WTGs that employ full back to back converter interface between generators (permanent magnet synchronous generators are typically used) and the grid. However, the controls are proprietary, and hence the short circuit models are not well defined. This report proposes controls that enable the WTG to comply with the strictest grid codes, and based on this model, proposes a short circuit model of the Type 4 WTG. This model is not validated due to lack of validation data, but the use of grid code requirements as control objectives lends good credibility to the model. PSCAD/EMTDC ® , a powerful and time-tested time-domain simulation software is used to implement all models. This software is capable of modeling in detail all components of wind farms, and all components and controls of converters in time domain.

17 WIND ENERGY↗
DOE OSTI2023

An Assessment of Additively Manufactured Bonded Permanent Magnets for a Distributed Wind Generator

In this paper, we examine and compare the performance of a generator design optimized using additively manufactured NdFeB-SmFeN in nylon-polymer-bonded permanent magnets (PMs) against a generator design with conventional NdFeB sintered PMs. To realize this, a commercially available 15-kW wind generator's rotor is re-optimized using both additively manufactured and sintered NdFeB magnets using simple geometric parameterization that allowed for two specific magnet shapes, namely, arc-shaped and crown-shaped designs. Results showed that for a similar generator performance, the designs with additively manufactured bonded PMs are more cost-competitive in terms of the estimated PM material cost and also have negligible eddy current magnet losses.

additive manufacturing↗
DOE OSTI2015

Voltage Regulation Using a Permanent Magnet Synchronous Generator with a Series Compensator: Preprint

A wind power plant (WPP) is often operated at unity power factor, and the utility host where the WPP connects prefers to regulate the voltage. Although this may not be an issue in a stiff grid, the connection to a weak grid can be a problematic. This paper explores the advantages of having voltage regulation capability via reactive power control. Another issue in wind power generation is that not all turbines are able to control their reactive power due to technical reasons or contractual obligations. A synchronous condenser (SC) using a permanent magnet synchronous generator (PMSG) is proposed to provide necessary reactive power for regulating voltage at a weak grid connection. A PMSG has the advantage of higher efficiency and reliability. Because of its lack of a field winding, a PMSG is typically controlled by a full-power converter, which can be costly. In the proposed system, the reactive power of the SC is controlled by a serially connected compensator operating in a closed-loop configuration. The compensator also damps the PMSG’s tendency to oscillate. The compensator’s VA rating is only a fraction of the rating of the SC and the PMSG. In this initial investigation, the proposed scheme is shown to be effective by computer simulations.

17 WIND ENERGY↗
DOE OSTI2023

Optimization and Comparison of Modern Offshore Wind Turbine Generators Using GeneratorSE 2.0

As the offshore wind industry keeps growing at a rapid pace, developers are bracing themselves for a huge demand in critical rare earth metals which will threaten an already vulnerable supply chain. The wind energy industry is addressing this problem by investing in modern generator technologies that employ magnets with reduced rare earth content and high-field magnets enabled by rare-earth-free superconductors. In this paper we introduce the National Renewable Energy Laboratory's newly advanced GeneratorSE 2.0, which is a design and optimization tool that was developed to investigate the feasibility of such modern generators. Two direct-drive generator topologies with different magnet materials and mounting arrangements are investigated: an outer-rotor, V-shaped interior permanent magnet generator, and an inner-rotor normally conducting armature, paired with a low-temperature superconducting field with race-track coils. These technologies were evaluated for a range of power ratings between 15 and 25 MW, which represent the next generation of offshore wind turbines for both fixed-bottom and floating applications. The analyses indicate a new trend favoring the low-temperature superconducting technology for the direct-drive system.

direct-drive generators↗
DOE OSTI2024

Plasma generator with permanent magnet divertor

A divertor for system supporting plasma for fusion employs permanent magnets providing far weaker magnetic field strength than conventionally used in cryogenic magnetic systems through an ability to place the permanent magnets in close proximity to the plasma containment volume.

Forest, Cary Brett↗
NASA NTRS1983

Cycloconverter on the all-electric airplane

This paper discusses the application of a cycloconverter to a permanent magnet generator. Recent developments, advanced concepts, and advanced technology systems will be covered. Recent developments include permanent magnets, permanent magnet motors and generators, and power semiconductors.

Webb, R. C.↗
DOE OSTI2024

Manufacturing and Additive Design of Electric Machines by 3D Printing (MADE3D) (Final Technical Report)

As the U.S clean energy transition hinges on the growth of offshore wind, this is expected to be a major driver for innovations in manufacturing, material and design advancements to enable robust and cost-competitive wind turbines. The race to build larger and taller turbines rated 10 megawatts (MW) and beyond, has intensified pressure on OEMs in terms of logistics of handling and transporting large wind components, securing critical raw material as well as scaling up necessary domestic production infrastructure to meet the demand. There is increased interest in building lightweight, more efficient, and high-power dense drivetrains that will ease the burden on installation, minimize the raw material demand, increasing domestic sourceability. Despite good efficiency and reliability, existing drivetrain technologies such as direct-drive permanent magnet generators are heavy (> 300 tons), expensive, and often rely on large quantities of rare-earth permanent magnets (PMs), steel and copper.

17 WIND ENERGY↗
DOE OSTI2014

U.S. Wind Energy Manufacturing and Supply Chain: A Competitiveness Analysis

The goal of the project was to develop a greater understanding of the key factors determining wind energy component manufacturing costs and pricing on a global basis in order to enhance the competitiveness of U.S. manufacturers, and to reduce installed systems cost. Multiple stakeholders including DOE, turbine OEMs, and large component manufactures will all benefit by better understanding the factors determining domestic competitiveness in the emerging offshore and next generation land-based wind industries. Major objectives of this project were to: 1. Carry out global cost and process comparisons for 5MW jacket foundations, blades, towers, and permanent magnet generators; 2. Assess U.S. manufacturers’ competitiveness and potential for cost reduction; 3. Facilitate informed decision-making on investments in U.S. manufacturing; 4. Develop an industry scorecard representing the readiness of the U.S. manufacturers’ to produce components for the next generations of wind turbines, nominally 3MW land-based and 5MW offshore; 5. Disseminate results through the GLWN Wind Supply Chain GIS Map, a free website that is the most comprehensive public database of U.S. wind energy suppliers; 6. Identify areas and develop recommendations to DOE on potential R&D areas to target for increasing domestic manufacturing competitiveness, per DOE’s Clean Energy Manufacturing Initiative (CEMI). Lists of Deliverables 1. Cost Breakdown Competitive Analyses of four product categories: tower, jacket foundation, blade, and permanent magnet (PM) generator. The cost breakdown for each component includes a complete Bill of Materials with net weights; general process steps for labor; and burden adjusted by each manufacturer for their process categories of SGA (sales general and administrative), engineering, logistics cost to a common U.S. port, and profit. 2. Value Stream Map Competitiveness Analysis: A tool that illustrates both information and material flow from the point of getting a customer order at the manufacturing plant; to the orders being forwarded by the manufacturing plant to the material suppliers; to the material being received at the manufacturing plant and processed through the system; to the final product being shipped to the Customer. 3. Competitiveness Scorecard: GLWN developed a Wind Industry Supply Chain Scorecard that reflects U.S. component manufacturers’ readiness to supply the next generation wind turbines, 3MW and 5MW, for land-based and offshore applications. 4. Wind Supply Chain Database & Map: Expand the current GLWN GIS Wind Supply Chain Map to include offshore elements. This is an on-line, free access, wind supply chain map that provides a platform for identifying active and emerging suppliers for the land-based and offshore wind industry, including turbine component manufacturers and wind farm construction service suppliers.

17 WIND ENERGY↗
DOE OSTI2020

LandRAY Final Report

The overarching Project objective is to demonstrate the feasibility of using an innovative Power Take-Off (PTO) Module, to be used in the Columbia Power Technologies, Inc. (C·Power) utility-scale wave energy converter (WEC). The PTO Module uniquely combines a large-diameter, direct-drive, rotary permanent magnet generator; a patent-pending rail-bearing system; and a corrosion-resistant fiber-reinforced-plastic structure. The rail bearing system allows for: • A flexible non-rigid and low-cost generator frame as compared to conventional machines. • A reduction of air gap and consequently lower cost electromagnetic design • Ability to reduce costs by increasing diameter to much larger dimensions, while maintaining the small air gap. • A direct drive electro-mechanical solution that is the fastest and most precise approach for responding to the dynamic variability of forces from wave energy. The land-based test of the PTO Module (DDP1) will provide an important risk reduction phase, to demonstrate the reliability and feasibility of a large-diameter, small air-gap generator that is capable of delivering high efficiency, fault-tolerance and relatively simple "at-sea" maintenance capabilities – qualities that are essential for cost-effective wave energy devices. This is the first known test of such a system.

16 TIDAL AND WAVE POWER↗
DOE OSTI2016

Dynamic Braking System of a Tidal Generator

Renewable energy generation has experienced significant cost reductions during the past decades, and it has become more accepted by the global population. In the beginning, wind generation dominated the development and deployment of renewable energy; however, during recent decades, photovoltaic (PV) generation has grown at a very significant pace due to the tremendous decrease in the cost of PV modules. The focus on renewable energy generation has now expanded to include new types with promising future applications, such as river and tidal generation. The input water flow to these types of resources is more predictable than wind or solar generation. The data used in this paper is representative of a typical river or tidal generator. The analysis is based on a generator with a power rating of 40 kW. The tidal generator under consideration is driven by two sets of helical turbines connected to each side of the generator located in between the turbines. The generator is operated in variable speed, and it is controlled to maximize the energy harvested as well as the operation of the turbine generator. The electrical system consists of a three-phase permanent magnet generator connected to a three-phase passive rectifier. The output of the rectifier is connected to a DC-DC converter to match the rectifier output to the DC bus voltage of the DC-AC inverter. The three-phase inverter is connected to the grid, and it is controlled to provide a good interface with the grid. One important aspect of river and tidal generation is the braking mechanism. In a tidal generator, the braking mechanism is important to avoid a runaway condition in case the connection to the grid is lost when there is a fault in the lines. A runaway condition may lead to an overspeed condition and cause extreme stresses on the turbine blade structure and eventual disintegration of the mechanical structure. In this paper, the concept of the dynamic braking system is developed and investigated for normal and abnormal operations. The main objective is to optimize the performance under emergency braking while designing the system to be as simple as possible to avoid overdesigning the power electronics or exceeding the target budget.

13 HYDRO ENERGY↗