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NASA NTRS2004

Motor/Generator and Inverter Characterization for Flywheel System Applications

The Advanced Electrical Systems Development Branch at NASA Glenn Research Center (GRC) has been involved in the research and development of high speed flywheels systems for satellite energy storage and attitude applications. These flywheels will serve as replacement for chemical nickel hydrogen, nickel cadmium batteries and gyroscopic wheels. The advantages of using flywheel systems for energy storage on satellites are high energy density, high power density, long life, deep depth of discharge, and broad operating temperature ranges. A flywheel system for space applications consist of a number of flywheel modules, the motor/generator and magnetic bearing, and an electronics package. The motor/generator electronics package includes a pulse-width modulated inverter that drives the flywheel permanent magnet motor/generator located at one end of the shaft. This summer, I worked under the direct supervision of my mentor, Walter Santiago, and the goal for this summer was to characterize motor generator and inverter attributes in order to increase their viability as a more efficient energy storage source for space applications. To achieve this goal, magnetic field measurements around the motor/generator permanent magnet and the impedance of the motor/generator three phase windings were characterized, and a recreation of the inverter pulse width modulated control system was constructed. The Flywheel modules for space use are designed to maximize energy density and minimize loss, and attaining these values will aid in locating and reducing losses within the flywheel system as a whole, making flywheel technology more attractive for use as energy storage in future space applications.

Tamarcus, Jeffries L.↗

NASA NTRS1996

Dynamics of Permanent-Magnet Biased Active Magnetic Bearings

Active magnetic radial bearings are constructed with a combination of permanent magnets to provide bias forces and electromagnets to generate control forces for the reduction of cost and the operating energy consumption. Ring-shaped permanent magnets with axial magnetization are attached to a shaft and share their magnet stators with the electromagnets. The magnet cores are made of solid iron for simplicity. A simplified magnetic circuit of the combined magnet system is analyzed with linear circuit theory by approximating the characteristics of permanent magnets with a linear relation. A linearized dynamical model of the control force is presented with the first-order approximation of the effects of eddy currents. Frequency responses of the rotor motion to disturbance inputs and the motion for impulsive forces are tested in the non-rotating state. The frequency responses are compared with numerical results. The decay of rotor speed due to magnetic braking is examined. The experimental results and the presented linearized model are similar to those of the all-electromagnetic design.

Fukata, Satoru↗

NASA NTRS2003

Radial Clearance Found To Play a Key Role in the Performance of Compliant Foil Air Bearings

Compliant foil air bearings are at the forefront of the Oil-Free turbomachinery revolution, which supports gas turbine engines with hydrodynamic bearings that use air instead of oil as the working fluid. These types of bearings have been around for almost 50 years and have found a home in several commercial applications, such as in air cycle machines, turbocompressors, and microturbines, but are now being aggressively pursued for use in small and midrange aircraft gas turbine engines. Benefits include higher operating speeds and temperatures, lower maintenance costs, and greater reliability. The Oil-Free Turbomachinery team at the NASA Glenn Research Center is working to foster the transition of Oil-Free technology into gas turbine engines by performing in-house experiments on foil air bearings in order to gain a greater insight into their complex operating principles. A research program recently undertaken at Glenn focused on the concept of radial clearance and its influence on bearing performance. The tests were conducted on foil bearings with different radial clearances. As defined for a foil bearing, radial clearance is a measure of the small amount of shaft radial motion that is present from play that exists in the elastic support structure, such as between the top and bump foils and the bump foils and bearing shell (see the drawing). With an insufficient amount of radial clearance, the bearing imparts a high preload on the shaft, which when excessive, can reduce the loadcarrying capability of the bearing. On the other hand, systems using foil bearings with excessive radial clearance may experience rotordynamic instabilities because of low bearing preload. Therefore, without a more thorough understanding of radial clearance, it is difficult to accurately predict the performance of a given bearing design. The test program demonstrated that there is a direct correlation between radial clearance and the performance of foil air bearings. As shown in the graph, an optimum radial clearance exists that will maximize the amount of load that the bearing is capable of supporting. With respect to this optimum, two different performance regimes were observed that are a function of the amount of radial clearance. Tests showed that bearings with radial clearances below the optimum in regime I were susceptible to sudden seizure, a failure mode indicative of thermal runaway caused by high preload. The high preload is in response to an insufficient amount of radial clearance available to accommodate the thermal growth of the bearing and shaft. However, radial clearances greater than the optimum in regime II resulted in low bearing preloads that did not cause any heat-related problems, and the failure mode was due to fluid-film breakdown. In fact, bearings operating with radial clearances twice as much as the optimum suffered a decrease in the maximum load capacity of only about 20 percent. Therefore, special attention has to be given to the range of operating conditions expected in the bearing/shaft system since changes in temperature, centrifugal, and hydrodynamic effects can all affect radial clearance. This enhanced understanding of foil air bearing behavior will greatly aid our efforts to transition Oil-Free technology to future aircraft engines.

Radil, Kevin C.↗

NASA NTRS1991

Aeroelastic loads and stability investigation of a full-scale hingeless rotor

An analytical investigation was conducted to study the influence of various parameters on predicting the aeroelastic loads and stability of a full-scale hingeless rotor in hover and forward flight. The CAMRAD/JA (Comprehensive Analytical Model of Rotorcraft Aerodynamics and Dynamics, Johnson Aeronautics) analysis code is used to obtain the analytical predictions. Data are presented for rotor blade bending and torsional moments as well as inplane damping data obtained for rotor operation in hover at a constant rotor rotational speed of 425 rpm and thrust coefficients between 0.0 and 0.12. Experimental data are presented from a test in the wind tunnel. Validation of the rotor system structural model with experimental rotor blade loads data shows excellent correlation with analytical results. Using this analysis, the influence of different aerodynamic inflow models, the number of generalized blade and body degrees of freedom, and the control-system stiffness at predicted stability levels are shown. Forward flight predictions of the BO-105 rotor system for 1-G thrust conditions at advance ratios of 0.0 to 0.35 are presented. The influence of different aerodynamic inflow models, dynamic inflow models and shaft angle variations on predicted stability levels are shown as a function of advance ratio.

Peterson, Randall L.↗

NASA NTRS1992

Aeroelastic response and blade loads of a composite rotor in forward flight

The aeroelastic response, blade and hub loads, and shaft-fixed aeroelastic stability is investigated for a helicopter with elastically tailored composite rotor blades. A new finite element based structural analysis including nonclassical effects such as transverse shear, torsion related warping and inplane elasticity is integrated with the University of Maryland Advanced Rotorcraft Code. The structural dynamics analysis is correlated against both experimental data and detailed finite element results. Correlation of rotating natural frequencies of coupled composite box-beams is generally within 5-10 percent. The analysis is applied to a soft-inplane hingeless rotor helicopter in free flight propulsive trim. For example, lag mode damping can be increased 300 percent over a range of thrust conditions and forward speeds. The influence of unsteady aerodynamics on the blade response and vibratory hub loads is also investigated. The magnitude and phase of the flap response is substantially altered by the unsteady aerodynamic effects. Vibratory hub loads increase up to 30 percent due to unsteady aerodynamic effects.

Smith, Edward C.↗

NASA NTRS1999

Water Flow Performance of a Superscale Model of the Fastrac Liquid Oxygen Pump

As part of the National Aeronautics and Space Administration's ongoing effort to lower the cost of access to space, the Marshall Space Flight Center has developed a rocket engine with 60,000 pounds of thrust for use on the Reusable Launch Vehicle technology demonstrator slated for launch in 2000. This gas generator cycle engine, known as the Fastrac engine, uses liquid oxygen and RP-1 for propellants and includes single stage liquid oxygen and RP-1 pumps and a single stage supersonic turbine on a common shaft. The turbopump design effort included the first use and application of new suction capability prediction codes and three-dimensional blade generation codes in an attempt to reduce the turbomachinery design and certification costs typically associated with rocket engine development. To verify the pump's predicted cavitation performance, a water flow test of a superscale model of the Fastrac liquid oxygen pump was conducted to experimentally evaluate the liquid oxygen pump's performance at and around the design point. The water flow test article replicated the flow path of the Fastrac liquid oxygen pump in a 1.582x scale model, including scaled seal clearances for correct leakage flow at a model operating speed of 5000 revolutions per minute. Flow entered the 3-blade axial-flow inducer, transitioned to a shrouded, 6-blade radial impeller, and discharged into a vaneless radial diffuser and collection volute. The test article included approximately 50 total and static pressure measurement locations as well as flush-mounted, high frequency pressure transducers for complete mapping of the pressure environment. The primary objectives of the water flow test were to measure the steady-state and dynamic pressure environment of the liquid oxygen pump versus flow coefficient, suction specific speed, and back face leakage flow rate. Results showed excellent correlation between the predicted and experimentally measured pump head rise at low suction specific speeds. Likewise, only small circumferential variations in steady-state impeller exit and radial diffuser pressure distributions were observed from 80% to 120% of the design flow coefficient, matching the computational predictions and confirming that the integrated design approach has minimized any exit volute-induced distortions. The test article exhibited suction performance trends typically observed in inducer designs with virtually constant head rise with decreasing inlet pressure until complete pump head breakdown. Unfortunately, the net positive suction head at 3% head fall-off occurred far below that predicted at all tested flow coefficients, resulting in a negative net positive suction head margin at the design point in water. Additional testing to map the unsteady pressure environment was conducted and interesting rotating phenomena at the inducer inlet were observed. These rotating phenomena's cell numbers, direction, and speed were correlated with pump operating parameters. The impact of the unsteady phenomena and their corresponding energy losses on the unexpectedly poor pump performance is also discussed.

Skelley, Stephen↗

NASA NTRS2001

Water Flow Performance of a Superscale Model of the Fastrac Liquid Oxygen Pump

As part of the National Aeronautics and Space Administration's ongoing effort to lower the cost of access to space, the Marshall Space Flight Center has developed a rocket engine with 60,000 pounds of thrust for use on the Reusable Launch Vehicle technology demonstrator slated for launch in 2000. This gas generator cycle engine, known as the Fastrac engine, uses liquid oxygen and RP-1 for propellants and includes single stage liquid oxygen and RP-1 pumps and a single stage supersonic turbine on a common shaft. The turbopump design effort included the first use and application of new suction capability prediction codes and three-dimensional blade generation codes in an attempt to reduce the turbomachinery design and certification costs typically associated with rocket engine development. To verify the pump's predicted cavitation performance, a water flow test of a superscale model of the Fastrac liquid oxygen pump was conducted to experimentally evaluate the liquid oxygen pump's performance at and around the design point. The water flow test article replicated the flow path of the Fastrac liquid oxygen pump in a 1.582x scale model, including scaled seal clearances for correct leakage flow at a model operating speed of 5000 revolutions per minute. Flow entered the 3-blade axial-flow inducer, transitioned to a shrouded, 6- blade radial impeller, and discharged into a vaneless radial diffuser and collection volute. The test article included approximately 50 total and static pressure measurement locations as well as flush-mounted, high frequency pressure transducers for complete mapping of the pressure environment. The primary objectives of the water flow test were to measure the steady-state and dynamic pressure environment of the liquid oxygen pump versus flow coefficient, suction specific speed, and back face leakage flow rate. Initial results showed acceptable correlation between the predicted and experimentally measured pump head rise at low suction specific speeds. Likewise, only small circumferential variations in steady-state were observed from 80% to 120% of the design flow coefficient, matching the computational predictions and confirming that the integrated design approach has minimized any exit volute-induced distortions. The test article exhibited suction performance trends typically observed in inducer designs with virtually constant head rise with decreasing inlet pressure until complete pump head breakdown. Unfortunately, the net positive suction head at 3% head fall-off occurred far below that predicted at all tested flow coefficients, resulting in a negative net positive suction head margin at the design point in water. Additional testing to map the unsteady pressure environment was conducted and cavitation-induced flow disturbances at the inducer inlet were observed. Two distinct disturbances were identified, one rotating and one stationary relative to the fixed frame of reference, while the transition from one regime to the next produced significant effects on the steady state pump performance. The impact of the unsteady phenomena and the corresponding energy losses on the unexpectedly poor pump performance is also discussed.

Skelley, Stephen↗

NASA NTRS2012

Vibration Propagation of Gear Dynamics in a Gear-Bearing-Housing System Using Mathematical Modeling and Finite Element Analysis

Vibration and noise caused by gear dynamics at the meshing teeth propagate through power transmission components to the surrounding environment. This study is devoted to developing computational tools to investigate the vibro-acoustic propagation of gear dynamics through a gearbox using different bearings. Detailed finite element/contact mechanics and boundary element models of the gear/bearing/housing system are established to compute the system vibration and noise propagation. Both vibration and acoustic models are validated by experiments including the vibration modal testing and sound field measurements. The effectiveness of each bearing type to disrupt vibration propagation is speed-dependent. Housing plays an important role in noise radiation .It, however, has limited effects on gear dynamics. Bearings are critical components in drivetrains. Accurate modeling of rolling element bearings is essential to assess vibration and noise of drivetrain systems. This study also seeks to fully describe the vibro-acoustic propagation of gear dynamics through a power-transmission system using rolling element and fluid film wave bearings. Fluid film wave bearings, which have higher damping than rolling element bearings, could offer an energy dissipation mechanism that reduces the gearbox noise. The effectiveness of each bearing type to disrupt vibration propagation in explored using multi-body computational models. These models include gears, shafts, rolling element and fluid film wave bearings, and the housing. Radiated noise is mapped from the gearbox surface to surrounding environment. The effectiveness of rolling element and fluid film wave bearings in breaking the vibro-acoustic propagation path from the gear to the housing is investigated.

Parker, Robert G.↗

NASA NTRS1991

Analysis of foil bearings for high speed operation in cryogenic applications

The general objective of this project is to develop analysis tools which are required for the design of foil bearings to be used in cryogenic applications. During the second year of this project, a general analysis approach and code for journal bearings operating under steady state conditions will be completed. This will be followed by the initiation of an investigation into transient behavior of foil bearings to determine their performance in rotor systems. Foil bearings have been proposed as an alternative to rolling element bearings for use in cryogenic turbopumps in liquid propellant rocket engines. This type of bearing offers several advantages over rolling element bearings since they would use the cryogenic pump fluid for a lubricant and have structural flexibility. These bearings have the potential of high reliability and long life. The bearing surface is constructed of a 'foil' which resists deflection by a combination of bending, membrane, and elastic foundation effects. The relative motion between the rotating shaft and the foil causes pressure in the fluid film to develop. This pressure deflects the the foil surface away from the shaft. Once a full fluid film is established between the foil and the rotor shaft, contact no longer takes place and there is no subsequent wear of the surfaces. The flexible foil structure of the bearing allows it to compensate for minor tolerance and manufacturing defects. This same flexibility also has a significant effect on the dynamic performance of the rotor-bearing system.

Carpino, Marc↗

NASA NTRS1985

Rotor instability due to loose rotating part

Loosening of a rotating part from its fixed position on the shaft or a part of the stator which comes loose and begins to turn with the rotor very frequently represents machinery malfunction. The loose part becomes involved in rotative motion mostly due to dry or fluid friction, and thus its motion is very erratic. The loose part can also move axially along the shaft. Detachment of the rotating part causes changes in the rotor balance state. Most often this results in higher unbalance. During steady-state operation the effect of a loose rotating part can manifest itself through heat vibration. It can be diagnosed by observing periodic changes of amplitude and phase of the synchronous response. During start-up (or shutdown) a loose rotating part carrying some amount of unbalance may manifest its dynamic action in the form of subsynchronous vibrations, very similar to those of other instabilities. The objective of this demonstration is to observe the effect of a loose rotating part (fixed, however, in the axial direction) under both steady-state (rotor constant speed) and transient (rotor start-up or shutdown) operation. The dynamic response depends very much on the amount of damping in the system: lubrication of the loose part/shaft surfaces and addition/elimination of aerodynamic drag blades, mounted on the loose disk, significantly change the rotor response.

Muszynska, A.↗

NASA NTRS2019

High Efficiency Megawatt Machine Rotating Cryocooler Conceptual Design

Some of the challenges associated with developing electric aircraft propulsion systems include developing powertrain components that are both efficient and light-weight. In particular, electric motors must simultaneously achieve high efficiency by minimizing electrical and mechanical losses while also achieving high specific power by increasing the torque and/or speed. Normally increasing torque or speed will increase electrical and mechanical losses. The High Efficiency Megawatt Machine (HEMM) minimizes electrical losses by incorporating a superconductor to enable increased current on the rotor. And the rotor spins in a vacuum to minimize thermal and mechanical losses. Some organizations have been developing superconducting rotors for similar reasons using either cryogenic fluid transfer systems, fully immersed cryogenic cooling, and in a few cases utilized built-in cryogenic cooling on the rotor using a Brayton or Stirling system but the implementation was too large or inefficient for effective motor integration. Instead, a new approach for cryogenically cooling the superconducting rotor coil with an embedded rotating cryocooler is presented that fits completely within the rotating shaft.

Dyson, Rodger W.↗

NASA NTRS2019

High Efficiency Megawatt Machine Rotating Cryocooler Conceptual Design

Dyson, Rodger W.↗

NASA NTRS1995

Microgravity combustion of dust clouds: Quenching distance measurements

The current level of physical understanding of dust combustion phenomena is still in a rudimentary state compared with the understanding of gas combustion processes. The reason for such a lack of fundamental understanding is partially based on the complexity of multiphase combustion and the enormous diversity of chemical-physical properties of heterogeneous combustible mixtures but is largely due to difficulties in the experimental investigation of dust combustion. The influence of gravity on a dust suspension is the main reason. First of all, when particulates (either solid particles or liquid droplets) with a characteristic size of the order of tens of microns are suspended, they rapidly settle in the gravitational field. To maintain a particulate suspension for a time duration adequate to carry out combustion experiments invariably requires continuous convection of particulates at or in excess of the gravitational settling velocity. Of necessity, this makes the experiments turbulent in character and makes it impossible to study laminar dust flames. For particle sizes of the order of microns a stable laminar dust flow can be maintained only for relatively small dust concentrations (e.g., for low fuel equivalence ratios) at normal gravity conditions. High dust loading leads to gravitational instability of the dust cloud and to the formation of recirculation cells in a dust suspension in a confined volume, or to the rapid sedimentation of the dense dust cloud as a whole in an unconfined volume. In addition, many important solid fuels such as low volatile coal, carbon, and boron have low laminar flame speeds (of the order of several centimeters per second). Gravitational convection that occurs in combustion products due to the buoyancy forces disrupts low speed dust flames and, therefore, makes observation of such flames at normal gravity impossible. The only way to carry out 'clean' fundamental experiments in dust combustion over a wide range of dust cloud parameters is in a gravity-free environment. Access to the microgravity environment provided by the use of large-scale drop towers, parabolic flights of aircraft and rockets, and shuttle and space station orbits has permitted now to proceed with a systematic program of dust combustion microgravity research. For example, the NASA-Lewis drop tower and a Lear jet parabolic flight aircraft were used by Ross et al. and by Berlad and Tangirala for experiments with Iycopodium/air mixtures. The Japan Microgravity Center drop shaft (JAMIC) where a microgravity condition of 10(exp -4) g for 10 s is available, was recently used by Kobayashi, Niioka et al. for measuring flame propagation velocities in polymethyl methacrylate dust/air suspensions. Microgravity dust combustion experiments were started at McGill University in the early 90's under the sponsorship of the Canadian Space Agency. Several generations of dust combustion platforms permitting dust combustion microgravity experiments to be carried out on board a parabolic flight aircraft (KC-135, NASA) have been designed and tested. The experimental data and experience gained from this research allowed us to design and build in a current phase of this program the microgravity apparatus for the visual observation of freely propagating constant pressure laminar dust flames. Quenching distances in aluminum dust suspensions have been measured in a wide range of dust cloud parameters in ground-based experiments and in recent microgravity experiments (KC-135 parabolic flights, Houston, February 1995).

Goroshin, S.↗

NASA NTRS1981

Development of high-speed balancing technology

An investigation into laser material removal showed that laser burns act in a manner typical of mechanical stress raisers causing a reduction in fatigue strength; the fatigue strength is lowered relative to the smooth specimen fatigue strength. Laser-burn zones were studied for four materials: Alloy Steel 4340, Stainless Steel 17-4 PH, Inconel 718, and Aluminum Alloy 6061-T6. Calculations were made of stress concentration factors K, for laser-burn grooves of each material type. A comparison was then made to experimentally determine the fatigue strength reduction factor. These calculations and comparisons indicated that, except for the 17-4 PH material, good agreement (a ratio of close to 1.0) existed between Kt and Kf. The performance of the 17-4 PH material has been attributed to early crack initiation due to the lower fatigue resistance of the soft, unaged laser-affected zone. Also covered in this report is the development, implementation, and testing of an influence coefficient approach to balancing a long, slender shaft under applied-torque conditions. Excellent correlation existed between the analytically predicted results and those data obtained from testing.

Demuth, R.↗

NASA NTRSDate not supplied

A Comparison of Model Predictive Control Architectures for Application to Electrified Aircraft Propulsion Systems

As electrified aircraft propulsion (EAP) systems continue to mature, more sophisticated hardware and software are being developed to balance operations among electric machines and gas-turbine engines. In hybrid-electric propulsion systems, the increased complexity resulting from integrating turbine-engine shafts with electric machines necessitates control methodologies to account for various physical domains. Ideal controllers for hybrid-electric engines manage systems, subsystems, and their interactions in a coordinated fashion, able to account for safety and performance goals while being computationally efficient. In a previous work, linear model predictive control (MPC) schemes were implemented in centralized and distributed frameworks on a nonlinear turbofan engine model as a proof of concept. However, these schemes were not evaluated for computational complexity, prompting further study. The research presented here develops hierarchical MPC schemes to reduce the computational burden of the previous MPC schemes. A two-tier framework is implemented, where a slower sampling MPC controls electric machines and determines fan-speed tracking goals for a faster sampling controller, which is either a MPC or a proportional-integral (PI) controller. The proposed designs are compared to the centralized MPC investigated previously, and performance is measured via fan speed tracking error, energy storage state-of-charge, and computation time. Results reveal that the hierarchical MPC scheme employing a lower-level PI controller improves computation time while maintaining comparable tracking and state-of-charge regulation to the centralized scheme.

model predictive control↗

NASA NTRSDate not supplied

A Comparison of Model Predictive Control Architectures for Application to Electrified Aircraft Propulsion Systems

model predictive control↗

DOE OSTI2024

High-bandwidth Dynamic Load Emulation of Mechanical Systems using Electric Drives

Machine drives are versatile systems that can be programmed to emulate a variety of mechanical loads. In this paper, we walk through the modeling and control framework of a shaft-coupled dual-motor drive system that is programmed to emulate a fictitious mechanical system. We quantitatively evaluate the control performance of such a system and derive a theoretical limit that explains its inaccuracy at high operating frequencies. To overcome this problem, we propose an alternate control structure that achieves the same control objective at high frequencies as well. After suitable adjustments are made to the controller, we validate its performance using simulation results.

machine drives ,load emulation, speed-torque chara↗

NASA NTRS1993

Compliant seal development

The compliant metallic seal combines the noncontact feature of the labyrinth seal, the low leakage of a mechanical seal, and the compliant nature of the brush seal. It consists of several thin metallic elements or leaves mounted within a ring which is press fit into the housing, and in form, sort of resembles a lip seal sections wiping the shaft. A second set of overlapping cover leaves are placed on top of the shaft riding leaves which reduces leakage and provides stiffness. The leaves can be straight or angle cut. The shaft riding fingers are designed with mismatched curvature to provide lift off similar to the Rayleigh lift pads in mechanical seals with leading edge clearances nearly twice those of the trailing edge as as shown by Fleming to be optimal for gas flows in convergent seal passages. Leading edge clearances range from 300 to 500 microinches. Balance pockets beneath the leaves provide fluid film feed to the 'Rayleigh lift' surface and the proper balance ratio (mechanical seal) when combined with the static pressure and film pressure. The leaves flex in the radial direction and accommodate thermomechanical behavior as well as axial motion and angular misalignment. In the static mode, there is a net closing force on the leaves. The seals were tested to 70 psi at speeds to 16,000 rpm or surface speeds to 330 fps and temperatures from ambient to 440 F. A slow cycle through the rig critical at 10,000 rpm induced a radial vibration response of 0.004 to 0.005 inch were accommodated by the seal. Preliminary performance data are encouraging demonstrating hydrodynamic liftoff and noncontacting operation at pressure and speeds typical of gas turbine engines. The leakage performance data are significantly better than commercial labyrinth and brush seals which should be expected as this design incorporates the features of the low leakage face or mechanical seal along with the flexibility of the brush configuration.

Hendricks, Robert C.↗