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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

The Wind Turbine Rotors of the Future: A Research Agenda from the Big Adaptive Rotor Project

This white paper outlines a roadmap to inform future research efforts around the wind turbine rotors of the future. The document is authored by researchers that have been working on the Big Adaptive Rotor (BAR) and related initiatives at the National Renewable Energy Laboratory and Sandia National Laboratories. The Wind Energy Technologies Office of the U.S. Department of Energy has been funding BAR since 2018. The learnings from BAR have been documented in dozens of publications. This new paper identifies unresolved critical challenges in wind turbine rotor technology and structures them in four large topic areas: 1. Predictive and validated numerical tools. 2. Design methods and standards. 3. Improvements in manufacturing. 4. Technological innovations. Although wind turbines have not changed in their core architecture, with the market almost entirely dominated by three-bladed upwind rotors, a vast amount of research has allowed to introduce technological innovations resulting in a reduction in levelized cost of energy that made wind competitive with all traditional sources of electricity. Focusing on the rotor, blades will keep following the trend of mass and stiffness reduction, will adopt segmentation, and will keep growing in length, both land-based and offshore. To support this continuous innovation, this white paper argues that research efforts in rotor technology at the national labs are best directed to the first three topic areas and to low technology-readiness-levels (1-3) innovations, leaving the task of implementing higher-TRL (4-9) technological innovations to industry stakeholders. This research roadmap is also well aligned with the upcoming roadmap defined during the International Energy Agency 109th Topical Expert Meeting on the Grand Challenges of Wind Energy.

17 WIND ENERGY↗
DOE OSTI2023

An Integrated Traction Drive with a High Speed Surface Permanent Magnet External Rotor Motor for Electric Vehicles

This work presents the detailed design of an outer rotor motor and integrated drive for passenger electric vehicles. The motor uses non-heavy rare earth permanent magnets and operates at a top speed of 20,000rpm. In-slot ceramic heat exchangers are utilized for the cooling of the windings. The external rotor configuration of the motor leaves a significant amount of space in the stator bore, which is leveraged for the integration of the power electronics. A high speed external rotor motor creates a number of mechanical, thermal and assembly challenges and this work presents detailed thermal, mechanical and rotordynamics analysis.

ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2025

A rotor-based multileaf collimator for beam shaping

We introduce a new style of multileaf collimator which employs rotors with angularly dependent radius to control the masking aperture: a rotor-based multileaf collimator (RMLC). Using a padlock-inspired mechanism, a single motor can set dozens of rotors, i.e. leaves, independently. This is especially important for an ultra-high vacuum (UHV) compatible MLC, since this reduces the number of actuators and vacuum feedthroughs required by more than an order of magnitude. This new RMLC will complement previous work employing a UHV compatible MLC with an emittance exchange beamline to create arbitrarily shaped beams on demand. A feed-forward control system which abstracts away the complexity of the RMLC operation, and is adaptable to real beamline conditions, is discussed and demonstrated in simulation.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2023

Rotor and wake aerodynamic analysis of the Hybrid-Lambda concept - an offshore low-specific-rating rotor concept

The low-specific-rating rotor concept Hybrid-Lambda introduces a blade design with nonuniform distribution of design variables (design tip speed ratio and axial induction) along the blade span to alleviate loads of the outboard section in strong winds. In this paper, we validate aerodynamic design calculations, which were carried out with the blade element momentum theory by comparing the results to free vortex wake investigations (FVW). Furthermore, we investigate the wake behaviour with FVW and large-eddy simulations. The results show good agreements between the blade element momentum theory and FVW for integrated rotor quantities (power and thrust). Small deviations are present when the gradients of axial induction along the span are large. The wake of the Hybrid-Lambda Rotor shows advantages in the near-wake region (up to 4 diameters [D] downstream), especially in the outer wake annulus and in low turbulence scenarios. For further downstream positions, the wake is comparable to that of the reference turbine.

17 WIND ENERGY↗
DOE OSTI2023

Mixed quantum/classical theory for rotational energy exchange in symmetric-top-rotor + linear-rotor collisions and a case study of the ND 3 + D 2 system

The extension of mixed quantum/classical theory (MQCT) to describe collisional energy transfer is developed for a symmetric-top-rotor + linear-rotor system and is applied to ND 3 + D 2 . State-to-state transition cross sections are computed in a broad energy range for all possible processes: when both ND 3 and D 2 molecules are excited or both are quenched, when one is excited while the other is quenched and vice versa, when the ND 3 state changes its parity while D 2 is excited or quenched, and when ND 3 is excited or quenched while D 2 remains in the same state, ground or excited. In all these processes the results of MQCT are found to approximately satisfy the principle of microscopic reversibility. For a set of sixteen state-to-state transitions available from the literature for a collision energy of 800 cm –1 the values of cross sections predicted by MQCT are within 8% of accurate full-quantum results. A useful time-dependent insight is obtained by monitoring the evolution of state populations along MQCT trajectories. It is shown that, if before the collision, D 2 is in its ground state, the excitation of ND 3 rotational states proceeds through a two-step mechanism in which the kinetic energy of molecule–molecule collision is first used to excite D 2 and only then is transferred to the excited rotational states of ND 3 . Finally, it is found that both potential coupling and Coriolis coupling play important roles in ND 3 + D 2 collisions.

inelastic cross-sections↗
DOE OSTI2026

Thermal Management Solution for an Integrated Outer-Rotor Motor Drive: Opportunities and Challenges

This work highlights an integrated thermal management solution for the outer-rotor motor (ORM) drive. The integrated ORM drive utilizes water-ethylene glycol coolant for power electronics and stator cooling. Air cooling is used for rotor laminations, magnets and outer-rotor structures, and the rotor shaft. To fully understand the performance of the integrated ORM drive and thermal management coupling effects, a full drive conjugate heat transfer model has been developed to investigate coupled cooling performance of various components of the ORM drive. Various motor rotational speeds, power output scenarios, and cooling options for the integrated ORM drive have been investigated. The model estimates the operating window for the ORM drive while keeping component operating temperatures below prescribed limits. The model also highlights the importance of windage losses at higher rotational speeds for this ORM design, which involves higher rotor surface area per unit width of the rotor. Different designs are also investigated, particularly focusing on rotor cooling with air either naturally induced by rotor spin or forced airflow with the help of a blower, to circumvent challenges imposed by higher windage losses. The work highlights motor rotational speed limitations and the need for potential liquid cooling options for desired rotor performance at higher rotational speeds. Liquid cooling for the rotor may even become more critical for nonuniform rotor-stator gaps, leading to even higher and uneven windage losses across the full circumference of the motor, consequentially, more heating for the rotor.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2023

Large Eddy Simulation of Rotationally Induced Ingress and Egress around an Axial Seal between Rotor and Stator Disks

In gas turbines, the hot gas exiting the combustor can have temperatures as high as 2000 °C, and some of this hot gas enter into the space between the stator and rotor disks (wheelspace). Since the entering hot gas could damage the disks, its ingestion must be minimized. This is carried out by rim seals and by introducing a cooler flow from the compressor (sealing flow) into the wheelspace. Ingress and egress into rim seals are driven by the stator vanes, the rotor and its rotation, and the rotor blades. This study focuses on the ingress and egress driven by the rotor and its rotation. This is carried out by performing wall-resolved large eddy simulation (LES) around an axial seal in a rotor–stator configuration without vanes and blades. Results obtained show the mechanisms by which the rotor and its rotation induce ingress, egress, and flow trajectories. Kelvin–Helmholtz instability was found to create a wavy shear layer and displacement thickness that produces alternating regions of high and low pressures around the rotor side of the seal. Vortex shedding on the backward-facing side of the seal and its impingement on the rotor side of the seal also produces alternating regions of high and low pressures. The locations of the alternating regions of high and low pressures were found to be statistically stationary and to cause ingress to start on the rotor side of the seal. Vortex shedding and recirculating flow in the seal clearance also cause ingress by entrainment. With the effects of the rotor and its rotation on ingress and egress isolated, this study enables the effects of stator vanes and rotor blades to be assessed.

42 ENGINEERING↗
DOE OSTI2023

Aerodynamic Rotor Design for a 25 MW Offshore Downwind Turbine

Continuously increasing offshore wind turbine scales require rotor designs that maximize power and performance. Downwind rotors offer advantages in lower mass due to reduced potential for tower strike, and is especially true at large scales, e.g., for a 25 MW turbine. In this study, three 25 MW downwind rotors, each with different prescribed lift coefficient distributions were designed (chord, geometry, and twist) and compared to maximize power production at unprecedented scales and Reynolds numbers, including a new approach to optimize rotor tilt and coning based on aeroelastic effects. To achieve this objective the design process was focused on achieving high power coefficients, while maximizing swept area and minimizing blade mass. Maximizing swept area was achieved by prescribing pre-cone and shaft tilt angles to ensure the aeroelastic orientation when the blades point upwards was nearly vertical at nearly rated conditions. Maximizing the power coefficient was achieved by prescribing axial induction factor and lift coefficient distributions which were then used as inputs for an inverse rotor design tool. The resulting rotors were then simulated to compare performance and subsequently optimized for minimum rotor mass. To achieve these goals, a high Reynolds number design space was developed using computational predictions as well as new empirical correlations for flatback airfoil drag and maximum lift. Within this design space, three rotors of small, medium and large chords were considered for clean airfoil conditions (effects of premature transition were also considered but did not significantly modify the design space). The results indicated that the medium chord design provided the best performance, producing the highest power in Region 2 from simulations while resulting in the lowest rotor mass, both of which support minimum LCOE. The methodology developed herein can be used for the design of other extreme-scale (upwind and downwind) turbines.

downwind rotors↗
DOE OSTI2023

Diamond rotors

The resolution of magic angle spinning (MAS) nuclear magnetic resonance (NMR) spectra remains bounded by the spinning frequency, which is limited by the material strength of MAS rotors. Since diamond is capable of withstanding 1.5–2.5x greater MAS frequencies, compared to state-of-the art zirconia, we fabricated rotors from single crystal diamond. When combined with bearings optimized for spinning with helium gas, diamond rotors could achieve the highest MAS frequencies to date. Furthermore, the excellent microwave transmission properties and thermal conductivity of diamond could improve sensitivity enhancements in dynamic nuclear polarization (DNP) experiments. The fabrication protocol we report involves novel laser micromachining and produced rotors that presently spin at ω r = 111.000 ± 0.004 kHz, with stable spinning up to 124 kHz, using N 2 gas as the driving fluid. Here, we present the first proton-detected 13 C/ 15 N MAS spectra recorded using diamond rotors, a critical step towards studying currently inaccessible ex-vivo protein samples with MAS NMR. Previously, the high aspect ratio of MAS rotors (~10:1) precluded fabrication of MAS rotors from diamond.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2026

Power performance and loads characterization of laboratory-scale cross-flow rotors fabricated using additive manufacturing

Tidal energy conversion is a relatively new application for additive manufacturing (AM), where the focus has been on fabricating axial-flow turbine blades. AM techniques add material precisely where it is needed, creating more complex shapes with less waste. Cross-flow rotor geometry presents an opportunity for AM to improve rotor performance by fabricating features that cannot be created economically via conventional manufacturing. The challenges associated with using AM in cross-flow design include water resistance and degradation over time while retaining a level of quality equivalent to conventionally machined parts. In this work, AM materials were tested by environmentally conditioning samples in a seawater tank for 5 months, followed by performance and phase-resolved load testing of laboratory-scale rotors in a hydraulic flume. We found that while metals like titanium and Inconel have excellent performance in marine environments, achieving the desired geometry and performance is difficult. Thermoplastics degraded in seawater but were easier to form into desired geometries and could exceed the performance of an aluminum control rotor. Warping and surface finish were significant detractors from AM rotor performance. These results suggest that the primary benefits of using AM for cross-flow rotors is to quickly fabricate and test unconventional rotor geometries.

16 TIDAL AND WAVE POWER↗
DOE OSTI2024

Investigation of a Multi-Rotor Triboelectric Nanogenerator Using a Modular Flexible Circuit Board Stack

Triboelectric nanogenerators (TENGs) are a nascent class of energy harvester that are being explored for scavenging energy from small ocean waves. To date, they have been integrated in wave energy converters (WECs) designed to capture random motion caused by the perturbations of the ocean surface. Blue economy applications such as ocean observation can benefit greatly from more substantial wave-derived power, as such, the power output of existing TENG WECs must be increased several-fold to become viable. This study describes the conceptualization of a rotary TENG, and the subsequent efforts to increase its power output by stacking multiple stator and rotor pairs. In the latter part of this study, we introduce a novel means of incorporating a friction element into the design of the TENG by employing flexible printed circuit board (PCB) rotors. At rest, these flexible rotors will contact the stator, building static charges due to friction, at speed, these flexible rotors will be decoupled from the stator, reducing friction and allowing faster rotation. Initial results indicate that the power output of the flexible PCB rotor does not produce more power than a rigid, acrylic disk rotor, however the current output of the prototype is boosted, and the prototype is far more compact, allowing for a higher energy density than the rigid rotor prototype.

bench testing↗
DOE OSTI2024

Development of Solid Synchronous Reluctance Rotors With Multi-Material Additive Manufacturing

Synchronous reluctance (SynR) machines are promising rare-earth material-free alternatives to permanent magnet machines. However, structural challenges limit their operating speed and power density. This paper proposes and investigates multi-material additive manufacturing (MMAM) as a key-enabler to realize power-dense and high-speed SynR machines. It does so by proposing designs that guide magnetic flux through solid rotors realized by selective placement of magnetic and non-magnetic materials. To explore this concept, first, material samples are additively manufactured and experimentally characterized to assess the structural and magnetic properties that can be expected for the proposed rotors. Second, the design space of each rotor type is explored using these measured properties within finite element analysis. The results reveal that MMAM can enable fabrication of SynR motors with power density levels that are at the leading edge of all conventional electric machine topologies. It is shown that tip speeds in excess of 300 m/s can be achieved, resulting in 3-4x improvement in power density over conventional SynR motors. A solid SynR rotor is printed in an experimental MMAM laser powder bed fusion system. The rotor is paired with an existing stator to create a functional SynR motor with a saliency ratio of 2.59 and torque rating of 4.15 Nm. This is the first publication of a SynR rotor prototype constructed via MMAM.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Mechanical Analysis of Carbon Fiber Retaining Sleeve for A High-speed Outer Rotor SPM Electric Motor Design

Outer rotor motors can be designed with a larger airgap diameter than inner rotor motors for the same overall diameter and therefore provide higher torque which makes them ideal for high torque space constrained applications. This advantage fits well with the increasing demand of high-speed electric machines in many applications due to their inherent high-power density. However, increasing the motor speed results in significant centrifugal loads for the outer rotor motor design. Layers of carbon fiber sleeve winding on the rotor outer surface is necessary to guarantee its structural integrity without introducing too much weight on the motor itself. In this paper, we studied the mechanical stress of a carbon fiber retaining sleeve in a surface permanent magnet outer rotor motor that spins up to 20,000 RPM. Analytical results from finite element method (FEM) confirmed that the maximum stress experienced by the carbon fiber sleeve was under the material’s yield strength. The proposed sleeve will allow this outer rotor motor to operate at high speeds.

Lin, Lianshan↗
DOE OSTI2024

Rotordynamic Analysis and Comparative Study of High-Speed Outer Rotor Permanent Magnet Motor Designs

High–power density electric motor designs are a requirement in aerospace and automotive applications. Outer rotor permanent magnet motors can offer high power density but have mechanical challenges such as structural stability and rotodynamic issues. In this work, a rotodynamic study was performed for two outer rotor permanent magnet motor designs. The first design was a cantilever design in which the rotor was suspended at one end, supported by four bearings; in the second design, the rotor was simply supported by two bearings in each end. Two different finite element method–based approaches, solid rotor and beam rotor methods, were used to extract the critical speed.

Barua, Himel↗
DOE OSTI2026

Multipoint Aerostructural Optimization of Wind Turbine Rotors Using a Coupled Blade‐Resolved Aerostructural Solver

Physics‐based design optimization workflows thread the needle between computational cost limitations and simulation complexity, often compromising between modeling detail and the range of operating design conditions. Multipoint aerostructural optimization of wind turbine rotors has so far been confined to low‐fidelity analyses or to high‐fidelity studies with simplified structural models, leaving the most complex design trade‐offs unexplored. We close this gap by performing the first tightly coupled gradient‐based multipoint aerostructural rotor optimization using 3D aerodynamic and structural solvers with discrete coupled adjoints. The optimizer simultaneously varies blade planform, airfoil shapes, and structural thickness through more than 270 design variables, minimizing a weighted combination of rotor mass and power across multiple wind speeds. Applied to a modified DTU 10‐MW benchmark under conservative structural and aerodynamic constraints, our multipoint optimization reduces rotor mass by up to 36% and increases power by 12%–15% across the main operating conditions; biasing the objective toward power yields power gains up to 18% and a 17% mass reduction. For a nominal wind distribution, 3‐point rotor designs accounting for low RPM and high thrust conditions capture dominant trade‐offs and outperform single‐point designs. Adding two off‐design points changes individual‐condition power by less than 3% but leaves the weighted average within 0.5%, and the mass‐power bias has a stronger effect on the final design than the operating‐point weighting itself. Our framework extends naturally to richer load cases and site‐specific wind distributions, providing a basis for high‐fidelity multipoint design earlier in industrial workflows.

17 WIND ENERGY↗
DOE OSTI2025

Characterization of HRRR-simulated rotor layer wind speeds and clouds along the coast of California

Stratocumulus clouds, with their low cloud base and top, affect the atmospheric boundary layer wind and turbulence profile, thereby modulating wind energy resources. GOES satellite data reveal an abundance of stratocumulus clouds in the late spring and summer months off the coast of northern and central California, where there are active plans to deploy floating offshore wind farms at two lease areas (near Morro Bay and Humboldt). Since the fall of 2020, two buoys equipped with multiple instruments, including Doppler lidar, have been deployed for about 1 year in these wind farm lease areas to assess the rotor layer wind conditions in these locations. The objective of this study is to evaluate how well the High-Resolution Rapid Refresh (HRRR) model represents stratocumulus cloud characteristics and turbine-relevant rotor layer winds (surface to 300 m) by comparing HRRR simulations with buoy and satellite observations. We first find that the HRRR model reproduces the seasonal cycle of cloud top height reasonably well in these regions. However, during the warm season – especially at Morro Bay – the HRRR-simulated stratocumulus clouds tend to have lower tops by about 150 m and exhibit weaker diurnal cycles than satellite observations. Our analysis also shows that rotor layer wind speeds and vertical shear are stronger at Humboldt than at Morro Bay, and both are generally stronger under clear-sky conditions. Finally, the HRRR model bias in rotor layer wind speed is small under cloudy conditions but larger and dependent on observed wind speed under clear skies. Specifically, HRRR underestimates wind speeds at Morro Bay and overestimates them at Humboldt under clear-sky conditions.

17 WIND ENERGY↗
DOE OSTI2023

Combined Dimensional and Topology Optimization of Synchronous Machine Rotors Using a Material Density Interpolation Method

This article presents a magneto-structural combined dimensional and topology optimization technique for interior permanent magnet synchronous machine (IPMSM) and wound field synchronous machine (WFSM) rotors. Dimensional changes to the permanent magnet (PM) and rotor winding location or size are accomplished by interpolating or projecting a smoothed Heaviside rectangular function representing the presence of PM material onto the IPMSM rotor design domain mesh, whereas the presence of copper material for WFSM rotor is interpolated in the same manner. A density based Solid Isotropic Material with Penalization (SIMP) topology optimization approach is then used to vary the presence of electrical steel in mesh elements to form flux barriers around the PM. The proposed method enforces a defined shape for the PM without requiring the mesh in the design domain to be deformed. Four examples are presented to demonstrate the technique: Two flat bar IPMSM, one V-shaped IPMSM, and a WFSM. Here, a comparative study is performed on one of the flat bar IPMSMs using Metamodel of Optimal Prognosis (MOP) based method.

33 ADVANCED PROPULSION SYSTEMS↗