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At least 271 records · Page 15

Handling Qualities of Multirotor RPM-Controlled Electric-Vertical Take-Off and Landing (eVTOL) Aircraft for Urban Air Mobility (UAM)

A paradigm shift in rotorcraft design is being led by the prospect of propulsive forces being distributed across multiple rotors, such that each rotor can be directly driven by a dedicated electric motor. Crucially, some designers attempt to utilize these direct-drive mechanisms as the sole form of primary flight control. The feasibility of this design choice remains to be proven at the scales required for passenger transport. The paper presents a preliminary handling qualities analysis, for a six-passenger (1,200 lb payload) electric Hexacopter conceptual design, which shows that Level 1 handling qualities for limited agility operations are possible, provided that electric powertrains can deliver transient peak torques twice as high as the rated continuous torque of the conceptual design. Preliminary predictions are then substantiated by the results from a piloted handling qualities evaluation conducted in the NASA-Ames Vertical Motion Simulator (VMS). Three eVTOL configurations (a quadrotor, a hexacopter and a lift+cruise) with flight control laws implementing different levels of stability augmentation (Attitude Command-Attitude Hold and Translational Rate Command response types) were evaluated in four low speed and hover tasks requiring various levels of agility and precision.

UAM↗

Electro-Mechanical Actuator. DC Resonant Link Controller

This report summarizes the work performed on the 68 HP electro-mechanical actuator (EMA) system developed on NASA contract for the Electrical Actuation (ELA) Technology Bridging Program. The system was designed to demonstrate the capability of large, high power linear ELAs for applications such as Thrust Vector Control (TVC) on rocket engines. It consists of a motor controller, drive electronics and a linear actuator capable of up to 32,00 lbs loading at 7.4 inches/second. The drive electronics are based on the Resonant DC link concept and operate at a nominal frequency of 55 kHz. The induction motor is a specially designed high speed, low inertia motor capable of a 68 peak HP. The actuator was originally designed by MOOG Aerospace under an internal R & D program to meet Space Shuttle Main Engine (SSME) TVC requirements. The design was modified to meet this programs linear rate specification of 7.4 inches/second. The motor and driver were tested on a dynamometer at the Martin Marietta Space Systems facility. System frequency response, step response and force-velocity tests were conducted at the MOOG Aerospace facility. A complete description of the system and all test results can be found in the body of the report.

Schreiner, Kenneth E.↗

40 HP Electro-Mechanical Actuator

This report summarizes the work performed on the 40 BP electro-mechanical actuator (EMA) system developed on NASA contract NAS3-25799 for the NASA National Launch System and Electrical Actuation (ELA) Technology Bridging Programs. The system was designed to demonstrate the capability of large, high power linear ELA's for applications such as Thrust Vector Control (TVC) on rocket engines. It consists of a motor controller, high frequency power source, drive electronics and a linear actuator. The power source is a 25kVA 20 kHz Mapham inverter. The drive electronics are based on the pulse population modulation concept and operate at a nominal frequency of 40 kHz. The induction motor is a specially designed high speed, low inertia motor capable of a 68 peak HP. The actuator was originally designed by MOOG Aerospace under an internal R & D program to meet Space Shuttle Main Engine (SSME) TVC requirements. The design was modified to meet this programs linear rate specification of 7.4 inches/second. The motor and driver were tested on a dynamometer at the Martin Marietta Space Systems facility. System frequency response and step response tests were conducted at the Marshall Space Flight Center facility. A complete description of the system and all test results can be found in the body of the report.

Fulmer, Chris↗

Reliability Models and Demonstration of a Fault-Tolerant Motor Concept for Vertical Takeoff and Landing Vehicles

This report documents the completion of the Revolutionary Vertical Lift Technology Project Annual Performance Indicator 24-3.2.4.1: “Apply and document reliability prediction for high reliability motor concept.” Two modeling tools were completed for calculation of reliability of fault-tolerant (FT) motors, and key FT operations of a modular FT motor were demonstrated experimentally. The two models are complementary tools for the stakeholder and user community. Both models employ Markov chain theory. The first model is a time-homogeneous Markov chain model, and the second is a time-inhomogeneous Markov-Weibull model. This report’s main sections are as follows: 1.0 Introduction, 2.0 Theory, 3.0 Motor Reliability Models, 4.0 Validation of FT Operation by Hardware Demonstration, and 5.0 Concluding Remarks. Novel contributions to the field include development of a modular FT motor concept for electrified vertical takeoff and landing (eVTOL) application, solution methods to solve the reliability calculations, development of figures of merit, and the introduction of “linked chains” to formulate a building-block approach for time-inhomogeneous Markov-Weibull modeling of motor reliability. Example case studies have been completed, and results are provided and discussed herein. A four-module FT motor concept was developed to a preliminary-design level of detail. This eVTOL FT motor concept was designed for galvanic, magnetic, and thermal isolation of stator winding faults. The reliability of the concept motor was calculated using a time-inhomogeneous Markov chain model. Employing average failure rate as a metric, 570 times greater reliability was achieved as compared to a baseline motor without fault tolerance. A demonstrator motor was built and tested. The testing demonstrated the key features of FT operation and validated the essential premises of the FT motor concepts presented herein. The experiments included successful demonstration of the feasibility of the following four key FT features: (1) terminal open-circuit operation, (2) thermal isolation after fault, (3) terminal short-circuit operation, and (4) internal short-circuit operation. These works indicate that FT modular motor drives offer promise for addressing the daunting reliability gap that electric aircraft propulsor drives are facing relative to the best conventional motor drive technology that is available today.

Electric Motor↗

Note on some observed effects of rocket motor operation on the base pressures of bodies in free light

Some measurements of the effects of rocket-motor operation on base pressure were obtained incidental to other research on some bodies in free flight. These data are presented and qualitatively analyzed. The analysis indicates that jet effects on drag are of sufficient importance to deserve consideration in the design of jet motor nozzles, especially for aircraft and missiles where the thrust and drag are of the same order of magnitude. The base-pressure changes induced by the jet should be considered in the structural design of the outer body skin on the aft portion of fuselages containing jets. (author)

Purser, Paul E↗

Implementation of a Non-Metallic Barrier in an Electric Motor

Electric motors that run in pure oxygen must be sealed, or "canned," for safety reasons to prevent the oxygen from entering into the electrical portion of the motor. The current canning process involves designing a metallic barrier around the rotor to provide the separation. This metallic barrier reduces the motor efficiency as speed is increased. In higher-speed electric motors, efficiency is greatly improved if a very thin, nonmetallic barrier can be utilized. The barrier thickness needs to be approximately 0.025-in. (.0.6-mm) thick and can be made of a brittle material such as glass. The motors, however, designed for space applications are typically subject to high-vibration environments. A fragile, non-metallic barrier can be utilized in a motor assembly if held in place by a set of standard rubber O-ring seals. The O-rings provide the necessary sealing to keep oxygen away from the electrical portion of the motor and also isolate the fragile barrier from the harsh motor vibration environment. The compliance of the rubber O-rings gently constrains the fragile barrier and isolates it from the harsh external motor environment. The use of a non-metallic barrier greatly improves motor performance, especially at higher speeds, while isolating the electronics from the working fluid with an inert liner.

M?Sadoques, George↗

Rotary Motors Actuated by Traveling Ultrasonic Flexural Waves

Efficient miniature actuators that are compact and consume low power are needed to drive space and planetary mechanisms in future NASA missions. Ultrasonic rotary motors have the potential to meet this NASA need and they are developed as actuators for miniature telerobotic applications. These motors have emerged in commercial products but they need to be adapted for operation at the harsh space environments that include cryogenic temperatures and vacuum and also require effective analytical tools for the design of efficient motors. A finite element analytical model was developed to examine the excitation of flexural plate wave traveling in a piezoelectrically actuated rotary motor. The model uses 3D finite element and equivalent circuit models that are applied to predict the excitation frequency and modal response of the stator. This model incorporates the details of the stator including the teeth, piezoelectric ceramic, geometry, bonding layer, etc. The theoretical predictions were corroborated experimentally for the stator. In parallel, efforts have been made to determine the thermal and vacuum performance of these motors. Experiments have shown that the motor can sustain at least 230 temperature cycles from 0 C to -90 C at 7 Torr pressure significant performance change. Also, in an earlier study the motor lasted over 334 hours at -150 C and vacuum. To explore telerobotic applications for USMs a robotic arm was constructed with such motors.

Bar-Cohen, Yoseph↗

Split-Stirling-cycle displacer linear-electric drive

The retrofit of a 1/4-W split-Stirling cooler with a linear driven on the displacer was achieved and its performance characterized. The objective of this work was to demonstrate that a small linear motor could be designed to meet the existing envelope specifications of the cooler and that an electric linear drive on the displacer could improve the cooler's reliability and performance. The paper describes the characteristics of this motor and presents cooler test results.

Ackermann, R. A.↗

Introduction of laser initiation for the 48-inch Advanced Solid Rocket Motor (ASRM) test motors at Marshall Space Flight Center (MSFC)

The Advanced Solid Rocket Motor is a new design for the Space Shuttle Solid Rocket Booster. The new design will provide more thrust and more payload capability, as well as incorporating many design improvements in all facets of the design and manufacturing process. A 48-inch (diameter) test motor program is part of the ASRM development program. This program has multiple purposes for testing of propellent, insulation, nozzle characteristics, etc. An overview of the evolution of the 48-inch ASRM test motor ignition system which culminated with the implementation of a laser ignition system is presented. The laser system requirements, development, and operation configuration are reviewed in detail.

Zimmerman, Chris J.↗

Design Study of Double-Sided Axial-Flux Magnetically Geared Motors for Electric Aircraft Applications

Electric aircraft require advances in electric motor drivetrain efficiency, specific power, and reliability. In terms of mass and efficiency, mechanically geared electric motor drivetrains will significantly outperform direct drive electric motor drive trains in most applications. Mechanical gears however have numerous wear and failure modes that can result in increased maintenance and reliability penalties for an aircraft. Magnetic gears are being explored by NASA as a potential alternative to mechanical gears for electric aircraft applications. Magnetic gears have none of the surface contact related wear and failure modes of mechanical gears. Therefore, they potentially pose a high reliability alternative to mechanical gears. Magnetic gears can also share magnetic components with an electric motor in a magnetically geared drivetrain to achieve significant weight savings. In this paper, one possible topology of magnetically geared motor, the double-sided axial flux magnetically geared motor, is studied to quantify its achievable performance. Design study results suggest that the topology can achieve greater than 20 Nm/kg and 97% efficiency at a 100 kW output power.

Magnetic gears↗

Motor Configuration Selection for A New Technical Challenge to Develop A 5 MW Cryogenic Motor and Drive

Due to aviation’s appreciable and growing share of humanity’s impact on our environment and estimates that CO2emissions only account for 34% of aviation’s total effective radiative forcing [1], there is a need to reach beyond climate goals that focus only on CO2emissions, such as the US Aviation Climate Action Plan’s [3] goal to reach net-zero carbon emissions by 2050.There is motivation to develop technology that pushes toward future large transport aircraft with net zero climate impact that are highly electrified (i.e., have higher power electrical propulsion system components). This paper describes a new, 6-year technical challenge to address this need by developing a 5 MW superconducting motor and cryogenic drive. Section 1 will detail the motivation for this work. Section 2 will describe the technical challenge and the selected specifications for the motor. Section 3 will present the results of a motor configuration trade study and the down selection of one configuration to develop a detailed design for. The technical challenge focuses on the design of a5 MW superconducting motor and cryogenic drive and demonstration of it at a 2+ MW scale to achieve TRL 3. Both fully superconducting (superconducting stator and rotor) and fully cryogenic (superconducting rotor and cryogenic stator) machine configurations will be explored. An emphasis will be placed on addressing the key tall poles for high power superconducting machines. Further details will be included in the full paper. The requirements and goals of the motor will be detailed. The rated speed (2,000 to 3,000 rpm) is defined to be appropriate for directly driving multi-MW fans or propellers. A range of rated speed is permitted because the motor is not designed for a specific aircraft and to provide design flexibility if AC losses in the stator winding are found to be a significant constraint (i.e., a lower speed can be selected to reduce electrical frequency). Relatively conservative requirements for efficiency (99%) and specific power (20 kW/kg) are defined, because TRL advancement and pushing toward flight readiness is emphasized over performance optimization. However, more aggressive efficiency and specific power goals are specified (99.9% and 40 kW/kg). The 3rd section will present the results of a motor configuration trade study. The study started with a qualitative assessment of sixteen motor configurations based on geometric, mechanical, thermal, and electromagnetic criteria. This assessment has been completed with three evaluators scoring all nine criteria. A configuration down select was made by prioritizing the sixteen configurations into four tiers based on each configuration’s total score and consideration of manufacturability, complexity, and support hardware (e.g., rotary vacuum seals, bearings). Configurations in priority A and B will be further evaluated through quantitative assessments, whereas those in priority C will only be further evaluated if time permits and priority D will not be further evaluated. Eight of the sixteen configurations were down selected for quantitative assessment, which will include analytical calculations and low-to moderate-fidelity finite element analysis to produce a preliminary Pareto front of efficiency versus specific power for each configuration. This assessment emphasizes the calculation of AC losses in the stator winding and an exploration of thermal management approaches to remove that heat and maintain cryogenic temperature. The final paper will include a description of each motor configuration that was considered. The quantitative assessments are underway, and an assessment of one configuration is complete for multiple stator conductor options. The remaining assessments are scheduled to be completed by late March so that the final down select to one configuration can be included in this paper.

Net Zero↗

Design Study of Double-Sided Axial-Flux Magnetically Geared Motors for Electric Aircraft Applications

Electric aircraft require advances in electric motor drivetrain efficiency, specific power, and reliability. In terms of mass and efficiency, mechanically geared electric motor drivetrains will significantly outperform direct drive electric motor drive trains in most applications. Mechanical gears however have numerous wear and failure modes that can result in increased maintenance and reliability penalties for an aircraft. Magnetic gears are being explored by NASA as a potential alternative to mechanical gears for electric aircraft applications. Magnetic gears have none of the surface contact related wear and failure modes of mechanical gears. Therefore, they potentially pose a high reliability alternative to mechanical gears. Magnetic gears can also share magnetic components with an electric motor in a magnetically geared drivetrain to achieve significant weight savings. In this paper, one possible topology of magnetically geared motor, the double-sided axial flux magnetically geared motor, is studied to quantify its achievable performance. Design study results suggest that the topology can achieve greater than 20 Nm/kg and 97% efficiency at a 100 kW output power.

Thomas F Tallerico↗