Engineering topics

Palazzolo, Alan

Publications and source records attributed to Palazzolo, Alan.

17 records

NASA NTRS2008

High Temperature, Permanent Magnet Biased, Fault Tolerant, Homopolar Magnetic Bearing Development

This paper summarizes the development of a magnetic bearing designed to operate at 1,000 F. A novel feature of this high temperature magnetic bearing is its homopolar construction which incorporates state of the art high temperature, 1,000 F, permanent magnets. A second feature is its fault tolerance capability which provides the desired control forces with over one-half of the coils failed. The construction and design methodology of the bearing is outlined and test results are shown. The agreement between a 3D finite element, magnetic field based prediction for force is shown to be in good agreement with predictions at room and high temperature. A 5 axis test rig will be complete soon to provide a means to test the magnetic bearings at high temperature and speed.

Palazzolo, Alan↗

NASA NTRS2006

Liquid Annular Seal CFD Analysis for Rotordynamic Force Prediction

A commercially available code is utilized to analyze a plain and grooved liquid annular seal. These type seals are commonly used in modern turbopumps and have a pronounced effect on the rotordynamic behavior of these systems. Accurate prediction of both leakage and dynamic reaction forces is vital to ensure good performance and sound mechanical operation. The code SCISEAL developed by CFDRC is a generic 3-D, finite volume based CFD code solving the 3-D Reynolds averaged Navier Stokes equations. The code allows body-fitted, multi-blocked structured grids, turbulence modeling, rotating coordinate frames, as well as integration of dynamic pressure and shear forces on the rotating journal. The code may be used with the commercially available pre-and post-processing codes from CFDRC as well.

Moore, Jeff↗

NASA NTRS2005

Update on High-Temperature Coils for Electromagnets

A report revisits the subject matter of "High-Temperature Coils for Electromagnets" (LEW-17164), NASA Tech Briefs, Vol. 26, No. 8, (August 2002) page 38. To recapitulate: Wires have been developed for use in electromagnets that operate at high temperatures. The starting material for a wire of this type can be either a nickel-clad, ceramic-insulated copper wire or a bare silver wire. The wire is covered by electrical-insulation material that is intended to withstand operating temperatures in the range from 800 to 1,300 F (.430 to .700 C): The starting wire is either primarily wrapped with S-glass as an insulating material or else covered with another insulating material wrapped in S-glass prior to the winding process. A ceramic binding agent is applied as a slurry during the winding process to provide further insulating capability. The turns are pre-bent during winding to prevent damage to the insulation. The coil is then heated to convert the binder into ceramic. The instant report mostly reiterates the prior information and presents some additional information on the application of the ceramic binding agent and the incorporation of high-temperature wire into the windings.

Kascak, Albert F.↗

NASA NTRS2005

High-Temperature, High-Load-Capacity Radial Magnetic Bearing

A radial heteropolar magnetic bearing capable of operating at a temperature as high as 1,000 F (=540 C) has been developed. This is a prototype of bearings for use in gas turbine engines operating at temperatures and speeds much higher than can be withstood by lubricated rolling-element bearings. It is possible to increase the maximum allowable operating temperatures and speeds of rolling-element bearings by use of cooling-air systems, sophisticated lubrication systems, and rotor-vibration- damping systems that are subsystems of the lubrication systems, but such systems and subsystems are troublesome. In contrast, a properly designed radial magnetic bearing can suspend a rotor without contact, and, hence, without need for lubrication or for cooling. Moreover, a magnetic bearing eliminates the need for a separate damping system, inasmuch as a damping function is typically an integral part of the design of the control system of a magnetic bearing. The present high-temperature radial heteropolar magnetic bearing has a unique combination of four features that contribute to its suitability for the intended application: 1. The wires in its electromagnet coils are covered with an insulating material that does not undergo dielectric breakdown at high temperature and is pliable enough to enable the winding of the wires to small radii. 2. The processes used in winding and potting of the coils yields a packing factor close to 0.7 . a relatively high value that helps in maximizing the magnetic fields generated by the coils for a given supplied current. These processes also make the coils structurally robust. 3. The electromagnets are of a modular C-core design that enables replacement of components and semiautomated winding of coils. 4. The stator is mounted in such a manner as to provide stable support under radial and axial thermal expansion and under a load as large as 1,000 lb (.4.4 kN).

Provenza, Andrew↗

NASA NTRS2004

High Speed, High Temperature, Fault Tolerant Operation of a Combination Magnetic-Hydrostatic Bearing Rotor Support System for Turbomachinery

Closed loop operation of a single, high temperature magnetic radial bearing to 30,000 RPM (2.25 million DN) and 540 C (1000 F) is discussed. Also, high temperature, fault tolerant operation for the three axis system is examined. A novel, hydrostatic backup bearing system was employed to attain high speed, high temperature, lubrication free support of the entire rotor system. The hydrostatic bearings were made of a high lubricity material and acted as journal-type backup bearings. New, high temperature displacement sensors were successfully employed to monitor shaft position throughout the entire temperature range and are described in this paper. Control of the system was accomplished through a stand alone, high speed computer controller and it was used to run both the fault-tolerant PID and active vibration control algorithms.

Jansen, Mark↗

NASA NTRS2003

Fault Tolerant Homopolar Magnetic Bearings

Magnetic suspensions (MS) satisfy the long life and low loss conditions demanded by satellite and ISS based flywheels used for Energy Storage and Attitude Control (ACESE) service. This paper summarizes the development of a novel MS that improves reliability via fault tolerant operation. Specifically, flux coupling between poles of a homopolar magnetic bearing is shown to deliver desired forces even after termination of coil currents to a subset of failed poles . Linear, coordinate decoupled force-voltage relations are also maintained before and after failure by bias linearization. Current distribution matrices (CDM) which adjust the currents and fluxes following a pole set failure are determined for many faulted pole combinations. The CDM s and the system responses are obtained utilizing 1D magnetic circuit models with fringe and leakage factors derived from detailed, 3D, finite element field models. Reliability results are presented vs. detection/correction delay time and individual power amplifier reliability for 4, 6, and 7 pole configurations. Reliability is shown for two success criteria, i.e. (a) no catcher bearing contact following pole failures and (b) re-levitation off of the catcher bearings following pole failures. An advantage of the method presented over other redundant operation approaches is a significantly reduced requirement for backup hardware such as additional actuators or power amplifiers.

Li, Ming-Hsiu↗

NASA NTRS2003

Magnetic Bearing Amplifier Output Power Filters for Flywheel Systems

Five power filters and two types of power amplifiers were tested for use with active magnetic bearings for flywheel applications. Filter topologies included low pass filters and low pass filters combined with trap filters at the PWM switching frequency. Two state and three state PWM amplifiers were compared. Each system was evaluated based on current magnitude at the switching frequency, voltage magnitude at 500 kHz, and power consumption. The base line system was a two state amplifier without a power filter. The recommended system is a three state power amplifier with a 50 kHz low pass filter and a 27 kHz trap filter. This system uses 5.57 W. It reduces the switching current by an order of magnitude and the 500 kHz voltage by two orders of magnitude. The relative power consumption varied depending on the test condition between 60 to 130 percent of the baseline.

Lebron-Velilla, Ramon C.↗

NASA NTRS2003

Experimental High Temperature Characterization of a Magnetic Bearing for Turbomachinery

Open loop, experimental force and power measurements of a radial, redundant-axis, magnetic bearing at temperatures to 1000 F (538 C) and rotor speeds to 15,000 RPM along with theoretical temperature and force models are presented in this paper. The experimentally measured force produced by a single C-core using 22A was 600 lb. (2.67 kN) at room temperature and 380 lb. (1.69 kN) at 1000 F (538 C). These values were compared with force predictions based on a 1D magnetic circuit analysis and a thermal analysis of gap growth as a function of temperature. Tests under rotating conditions showed that rotor speed has a negligible effect on the bearing s load capacity. One C-core required approximately 340 W of power to generate 190 lb. (8.45 kN) of magnetic force at 1000 F (538 C); however the magnetic air gap was much larger than at room temperature. The data presented is after the bearing had already operated six thermal cycles and eleven total (not consecutive) hours at 1000 F (538 C).

Montague, Gerald↗

NASA NTRS2003

High-Temperature Switched-Reluctance Electric Motor

An eight-pole radial magnetic bearing has been modified into a switched-reluctance electric motor capable of operating at a speed as high as 8,000 rpm at a temperature as high as 1,000 F (=540 C). The motor (see figure) is an experimental prototype of starter-motor/generator units that have been proposed to be incorporated into advanced gas turbine engines and that could operate without need for lubrication or active cooling. The unique features of this motor are its electromagnet coils and, to some extent, its control software. Heretofore, there has been no commercial-off-the-shelf wire capable of satisfying all of the requirements for fabrication of electromagnet coils capable of operation at temperatures up to 1,000 F (=540 C). The issues addressed in the development of these electromagnet coils included thermal expansion, oxidation, pliability to small bend radii, micro-fretting, dielectric breakdown, tensile strength, potting compound, thermal conduction, and packing factor. For a test, the motor was supported, along with a rotor of 18 lb (.8-kg) mass, 3-in. (.7.6-cm) diameter, 21-in. (.53-cm) length, on bearings packed with high-temperature grease. The motor was located at the mid span of the rotor and wrapped with heaters. The motor stator was instrumented with thermocouples. At the time of reporting the information for this article, the motor had undergone 14 thermal cycles between room temperature and 1,000 F (.540 C) and had accumulated operating time >27.5 hours at 1,000 F (=540 C). The motor-controller hardware includes a personal computer equipped with analog-to-digital input and digital-to-analog output cards. The controller software is a C-language code that implements a switched-reluctance motor-control principle: that is, it causes the coils to be energized in a sequence timed to generate a rotating magnetic flux that creates a torque on a scalloped rotor. The controller can operate in an open- or closed-loop mode. In addition, the software has been modified to enable the simultaneous operation of the prototype motor or another, similar apparatus as both a motor and a magnetic bearing. Combined bearing/motor operation has been demonstrated at room temperature but had not yet been demonstrated at high temperature at the time of reporting the information for this article.

Montague, Gerald↗

NASA NTRS2002

Room Temperature Characterization of a Magnetic Bearing for Turbomachinery

Open loop, experimental force and power measurements of a three-axis, radial, heteropolar magnetic bearing at room temperature for rotor speeds up to 20,000 RPM are presented in this paper. The bearing, NASA Glenn Research Center's and Texas A&M's third generation high temperature magnetic bearing, was designed to operate in a 1000 F (540 C) environment and was primarily optimized for maximum load capacity. The experimentally measured force produced by one C-core of this bearing was 630 lb. (2.8 kN) at 16 A, while a load of 650 lbs (2.89 kN) was predicted at 16 A using 1D circuit analysis. The maximum predicted radial load for one of the three axes is 1,440 lbs (6.41 kN) at room temperature. The maximum measured load of an axis was 1050 lbs. (4.73 kN). Results of test under rotating conditions showed that rotor speed has a negligible effect on the bearing's load capacity. A single C-core required approximately 70 W of power to generate 300 lb (1.34 kN) of magnetic force. The room temperature data presented was measured after three thermal cycles up to 1000 F (540 C), totaling six hours at elevated temperatures.

Montague, Gerald↗

NASA NTRS2002

Flywheel Magnetic Suspension Developments

The paper provides an overview of many areas of the flywheel magnetic suspension (MS) R&D being performed at the Texas A&M Vibration Control and Electromechanics Lab (TAMU-VCEL). This includes system response prediction, actuator optimization and redundancy, controller realizations and stages, sensor enhancements and backup bearing reliability.

Palazzolo, Alan↗

NASA NTRS2002

Fail Safe, High Temperature Magnetic Bearings

This paper contributes to the magnetic bearing literature in two distinct areas: high temperature and redundant actuation. Design considerations and test results are given for the first published combined 538 C (1000 F) high speed rotating test performance of a magnetic bearing. Secondly, a significant extension of the flux isolation based, redundant actuator control algorithm is proposed to eliminate the prior deficiency of changing position stiffness after failure. The benefit of the novel extension was not experimentally demonstrated due to a high active stiffness requirement. In addition, test results are given for actuator failure tests at 399 C (750 F), 12,500 rpm. Finally, simulation results are presented confirming the experimental data and validating the redundant control algorithm.

Minihan, Thomas↗

NASA NTRS2000

Linear and Nonlinear Analysis of Magnetic Bearing Bandwidth Due to Eddy Current Limitations

Finite element analysis was used to study the bandwidth of alloy hyperco50a and silicon iron laminated rotors and stators in magnetic bearings. A three dimensional model was made of a heteropolar bearing in which all the flux circulated in the plane of the rotor and stator laminate. A three dimensional model of a plate similar to the region of a pole near the gap was also studied with a very fine mesh. Nonlinear time transient solutions for the net flux carried by the plate were compared to steady state time harmonic solutions. Both linear and quasi-nonlinear steady state time harmonic solutions were calculated and compared. The finite element solutions for power loss and flux bandwidth were compared to those determined from classical analytical solutions to Maxwell's equations.

Kenny, Andrew↗

NASA NTRS1997

Developments in Impeller/Seal Secondary Flow Path Modeling for Dynamic Force Coefficients and Leakage

This paper highlights bulk flow and CFD-based models prepared to calculate force and leakage properties for seals and shrouded impeller leakage paths. The bulk flow approach uses a Hir's based friction model and the CFD approach solves the Navier Stoke's (NS) equation with a finite whirl orbit or via analytical perturbation. The results show good agreement in most instances with available benchmarks.

Palazzolo, Alan↗

NASA NTRS1994

Active Vibration Dampers For Rotating Machinery

Active dampers developed to suppress vibrations in rotating machinery. Essentially feedback control systems and reciprocating piezoelectric actuators. Similar active damper containing different actuators described in LEW-14488. Concept also applicable to suppression of vibrations in stationary structures subject to winds and earthquakes. Active damper offers adjustable suppression of vibrations. Small and lightweight and responds faster to transients.

Kascack, Albert F.↗

NASA NTRS1994

Feed-forward control of gear mesh vibration using piezoelectric actuators

This paper presents a novel means for suppressing gear mesh-related vibrations. The key components in this approach are piezoelectric actuators and a high-frequency, analog feed-forward controller. Test results are presented and show up to a 70-percent reduction in gear mesh acceleration and vibration control up to 4500 Hz. The principle of the approach is explained by an analysis of a harmonically excited, general linear vibratory system.

Montague, Gerald T.↗

NASA NTRS1994

Enhanced simulation software for rocket turbopump, turbulent, annular liquid seals

One of the main objectives of this work is to develop a new dynamic analysis for liquid annular seals with arbitrary profile and to analyze a general distorted interstage seal of the space shuttle main engine high pressure oxygen turbopump (SSME-ATD-HPOTP). The dynamic analysis developed is based on a method originally proposed by Nelson and Nguyen. A simpler scheme based on cubic splines is found to be computationally more efficient and has better convergence properties at higher eccentricities. The first order solution of the original analysis is modified by including a more exact solution that takes into account the variation of perturbed variables along the circumference. A new set of equations for dynamic analysis are derived based on this more general model. A unified solution procedure that is valid for both Moody's and Hirs' friction models is presented. Dynamic analysis is developed for three different models: constant properties, variable properties, and thermal effects with variable properties. Arbitrarily varying seal profiles in both axial and circumferential directions are considered. An example case of an elliptical seal with varying degrees of axial curvature is analyzed in detail. A case study based on predicted clearances of an interstage seal of the SSME-ATD-HPOTP is presented. Dynamic coefficients based on external specified load are introduced to analyze seals that support a preload. The other objective of this work is to study the effect of large rotor displacements of SSME-ATD-HPOTP on the dynamics of the annular seal and the resulting transient motion. One task is to identify the magnitude of motion of the rotor about the centered position and establish limits of effectiveness of using current linear models. This task is accomplished by solving the bulk flow model seal governing equations directly for transient seal forces for any given type of motion, including motion with large eccentricities. Based on the above study, an equivalence is established between linearized coefficients based transient motion and the same motion as predicted by the original governing equations. An innovative method is developed to model nonlinearities in an annular seal based on dynamic coefficients computed at various static eccentricities. This method is thoroughly tested for various types of transient motion using bulk flow model results as a benchmark.

Padavala, Satya↗