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DOE OSTI2022

Wound Field and Hybrid Synchronous Machines for EV Traction with Brushless Capacitive Rotor Field Excitation (Final Report)

This project focused on the development of wound field synchronous machines (WFSMs) and hybrid excitation synchronous machines (HESMs) with brushless capacitive power transfer for the field excitation. The target application for the machines developed is the main traction motor in electric vehicles. The magnetization in these types of machines is provided by a field winding on the rotor which is excited with DC current. The magnetization level in the machine can be varied by changing the magnitude of the field current. The variable magnetization or field is one of the key features of WFSMs. WFSMs are commonly used as generators however they have several attractive features for automotive traction applications. 1) No use of permanent magnet: Rare earth permanent magnets are primarily mined and processed in China. They have been subject to large price and supply variations and their export may be restricted during times of geopolitical tension. 2) Easy field weakening: Wound field synchronous machines have complete control of their field excitation. With proper design, this type of machine can electromagnetically have an infinite constant power speed range. 3) High power factor: With proper choice of the field excitation, WFSMs may be operated with high or even unity power factor. This potentially allows for the inverter connected to the stator winding to be downsized. In comparison induction machines and interior permanent magnet synchronous machines must supply reactive power to the stator increasing the kVA rating and cost of the inverter. 4) Reduced iron losses at high speed: By reducing the field excitation, the iron loss in the stator can be reduced. This is in comparison to interior permanent magnet synchronous machines which must use stator current to buck or reduce the flux produced by the permanent magnets. Generally, WFSMs have their highest efficiency at high speed. 5) Torque output at high temperatures: The magnetization provided by the field winding only depends on the field current and not on the field winding temperature. This is in contrast to permanent magnet machines where the permanent magnet flux decreases as the magnet temperature increases. Historically a number of approaches have been developed to provide DC current to the rotating field winding in WFSM’s including brushes and slip rings, low frequency brushless exciters, and high frequency rotary transformers and rectifiers. In this project, a different approach was used: brushless capacitive power transfer. Brushless capacitive power transfer uses two sets of rotating capacitors or electrodes in which an AC electric field is established by a high frequency inverter. A displacement current can flow through the airgap in the rotating capacitors which is rectified on the rotor using a diode bridge. The potential advantage of capacitive power transfer is that there is no need for heavy iron to guide magnetic flux. The electric flux lines terminate on the charges on the rotary capacitor surfaces. This should also limit the electric field outside the rotary capacitor airgaps. The main challenge with capacitive power transfer is that the capacitance and surface area of the rotating capacitors is small. Because capacitive power transfer systems are essentially a dual of a magnetic system, an Ampere per Hertz relationship is characteristic versus a Volts per Hertz relationship. A very high frequency power inverter must be used to provide sufficient excitation to the field winding. The concept of using capacitive power transfer to excite a high performance WFSM was initially developed in a previous U.S.A. Dept. of Energy project, DE-EE0006829. This project focused on increasing the power density of the WFSMs and reducing the cost and manufacturing complexity of the capacitive power transfer system. This project has demonstrated that WFSMs with brushless capacitive field power transfer can provide a high-power density and low-cost automotive powertrain technology.

33 ADVANCED PROPULSION SYSTEMS↗

NASA NTRS1988

Structural dynamics analysis using an unsymmetric block Lanczos algorithm

A method for reducing the order of a dynamical model of a large structure with arbitrary damping is developed analytically and demonstrated. A Lanczos algorithm is described which can reduce square unsymmetric system matrices to block-tridiagonal form, and a procedure for defining the reduced-order model from the right and left Lanczos vectors is outlined. Results for sample problems involving the 8-DOF FEM model of a beam-rotor assembly subjected to random and stepped external forces are presented in extensive graphs and briefly characterized.

Craig, Roy R., Jr.↗

NASA NTRS1996

The Avoidance of Saturation Limits in Magnetic Bearing Systems During Transient Excitation

When a transient event, such as mass loss, occurs in a rotor/magnetic bearing system, optimal vibration control forces may exceed bearing capabilities. This will be inevitable when the mass loss is sufficiently large and a conditionally unstable dynamic system could result if the bearing characteristic become non-linear. This paper provides a controller design procedure to suppress, where possible, bearing force demands below saturation levels while maintaining vibration control. It utilizes H(sub infinity) optimization with appropriate input and output weightings. Simulation of transient behavior following mass loss from a flexible rotor is used to demonstrate the avoidance of conditional instability. A compromise between transient control force and vibration levels was achieved.

Rutland, Neil K.↗

DOE OSTI2024

Validation of new and existing methods for time-domain simulations of turbulence and loads

We seek to obtain a second-by-second match between the simulated and measured structural loads of a utility-scale wind turbine. To obtain the one-to-one load simulations, we start with the furthest upstream component of the modeling chain: the turbulent inflow. We consider new and existing methods to generate constrained-turbulence flow fields. The new method is based on large-eddy simulations (LES) and machine learning (ML). The existing methods include Kaimal-based TurbSim and the superstatistical wind field model. The inflow measurements used to constrain these simulations are obtained with a nacelle-mounted scanning lidar. We compare the flow fields for the different inflow simulation approaches and validate their associated load predictions against measurements collected in the Rotor Aero-dynamics, Aeroelastics, and Wake (RAAW) field campaign. We find that the rotor-position control developed for this study is key in enabling the time match between measurements and simulations. When this control approach is used, the load simulation performance tracks with the inflow simulation fidelity, with LES+ML yielding errors ≤ 4% for the damage-equivalent loads of flapwise bending moment, and tower fore-aft bending moments.

17 WIND ENERGY↗

NASA NTRS1973

Approximate analysis of containment/deflection ring responses to engine rotor fragment impact.

The transient responses of containment and/or deflection rings to impact from an engine rotor-blade fragment are analyzed. Energy and momentum considerations are employed in an approximate analysis to predict the collision-induced velocities which are imparted to the fragment and to the affected ring segment. This collision analysis is combined with the spatial finite-element representation of the ring and a temporal finite-difference solution procedure to predict the resulting large transient elastic-plastic deformations of containment/deflection rings. Some comparisons with experimental data are given.

Wu, R. W.-H.↗

NASA NTRS1978

Design and operating experience on the US Department of Energy experimental Mod-0 100-kW wind turbine

The experimental wind turbine was designed and fabricated to assess technology requirements and engineering problems of large wind turbines. The machine has demonstrated successful operation in all of its design modes and served as a prototype developmental test bed for the Mod-0A operational wind turbines which are currently used on utility networks. The mechanical and control system are described as they evolved in operational tests and some of the experience with various systems in the downwind rotor configurations are elaborated.

Glasgow, J. C.↗

NASA NTRS1996

Analysis of Gas Turbine Rotor Blade Tip and Shroud Heat Transfer

Predictions of the rate of heat transfer to the tip and shroud of a gas turbine rotor blade are presented. The simulations are performed with a multiblock computer code which solves the Reynolds Averaged Navier-Stokes equations. The effect of inlet boundary layer thickness as well as rotation rate on the tip and shroud heat transfer is examined. The predictions of the blade tip and shroud heat transfer are in reasonable agreement with the experimental measurements. Areas of large heat transfer rates are identified and physical reasoning for the phenomena presented.

Ameri, A. A.↗

NASA NTRS1974

Effect of frictional heating on brake materials

An exploratory study of the properties of aircraft brake materials was made to determine ways of improving friction and wear behavior while minimizing surface temperatures. It is found that frictional variation at high temperature involves material softening and metal transfer, formation of oxides, and surface melting. The choice of proper materials to combat these effects is discussed. Minimum surface temperatures are found to result from use of materials with large density-specific heat and density-specific heat-conductivity factors, use of a higher load-lower friction system, and maximization of the contact area. Some useful trade-off criteria for the size of brake disks against weight considerations are suggested. Additional information on material behavior and peak braking temperatures was gathered from an inspection of used brake pads and rotor disks.

Ho, T.-L.↗

NASA NTRS1984

A computational method for helicopter vortex wakes

A method for calculating the wake geometry and blade loads for a hovering helicopter rotor is presented. The approach incorporates a simplified free wake model of the rotor in a finite difference calculation of the flow field. A variation of the 'cloud-in-cell' technique, modified to eliminate self-induced velocity errors for curved vortex filaments, is used. Simple lifting line theory is used to calculate the blade loads. Calculations showing the effect of vortex core size and the number of vortex filaments representing the wake are presented. For large numbers of vortices, it is seen that the wake geometry fails to converge. However, only a few vortices are needed to adequately represent the wake. Comparisons with experimental results are also presented.

Roberts, T. W.↗

NASA NTRS1987

The effects of inlet turbulence and rotor/stator interactions on the aerodynamics and heat transfer of a large-scale rotating turbine model. Part 4: Aerodynamic data tabulation

A combined experimental and analytical program was conducted to examine the effects of inlet turbulence and airfoil heat transfer. The experimental portion of the study was conducted in a large-scale (approx. 5X engine), ambient temperature, rotating turbine model configured in both single-stage and stage-and-a-half arrangements. Heat transfer measurements were obtained using low-conductivity airfoils with miniature thermocouples welded to a thin, electrically heated surface skin. Heat transfer data were acquired for various combinations of low or high inlet turbulence intensity, flow coefficient, first stator-rotor axial spacing, Reynolds number and relative circumferential position of the first and second stators. Aerodynamic measurements obtained include distributions of the mean and fluctuating velocities at the turbine inlet and, for each airfoil row, midspan airfoil surface pressures and circumferential distributions of the downstream steady state pressures and fluctuating velocities. Results include airfoil heat transfer predictions produced using existing 2-D boundary layer computation schemes and an examination of solutions of the unsteady boundary layer equations.

Dring, R. P.↗

NASA NTRS1989

Asymptotic methods for internal transonic flows

For many internal transonic flows of practical interest, some of the relevant nondimensional parameters typically are small enough that a perturbation scheme can be expected to give a useful level of numerical accuracy. A variety of steady and unsteady transonic channel and cascade flows is studied with the help of systematic perturbation methods which take advantage of this fact. Asymptotic representations are constructed for small changes in channel cross-section area, small flow deflection angles, small differences between the flow velocity and the sound speed, small amplitudes of imposed oscillations, and small reduced frequencies. Inside a channel the flow is nearly one-dimensional except in thin regions immediately downstream of a shock wave, at the channel entrance and exit, and near the channel throat. A study of two-dimensional cascade flow is extended to include a description of three-dimensional compressor-rotor flow which leads to analytical results except in thin edge regions which require numerical solution. For unsteady flow the qualitative nature of the shock-wave motion in a channel depends strongly on the orders of magnitude of the frequency and amplitude of impressed wall oscillations or fluctuations in back pressure. One example of supersonic flow is considered, for a channel with length large compared to its width, including the effect of separation bubbles and the possibility of self-sustained oscillations. The effect of viscosity on a weak shock wave in a channel is discussed.

Adamson, T. C., Jr.↗

NASA NTRS1998

Remotely controllable actuating device

An actuating device can change a position of an active member that remains in substantially the same position in the absence of a force of a predetermined magnitude on the active member. The actuating device comprises a shape-memory alloy actuating member for exerting a force when actuated by changing the temperature thereof, which shape-memory alloy actuating member has a portion for connection to the active member for exerting thereon a force having a magnitude at least as large as the predetermined magnitude for moving the active member to a desired position. Actuation circuitry is provided for actuating the shape-memory alloy actuating member by changing the temperature thereof only for the time necessary to move the active member to the desired position. The invention is particularly useful for changing the position of a camber-adjusting tab on a helicopter rotor blade by using two shape-memory alloy members that can act against each other to adjust dynamic properties of the rotor blade as it is rotating.

McKillip, Jr., Robert M.↗

NASA NTRS2013

Application of Climate Impact Metrics to Rotorcraft Design

Multiple metrics are applied to the design of large civil rotorcraft, integrating minimum cost and minimum environmental impact. The design mission is passenger transport with similar range and capacity to a regional jet. Separate aircraft designs are generated for minimum empty weight, fuel burn, and environmental impact. A metric specifically developed for the design of aircraft is employed to evaluate emissions. The designs are generated using the NDARC rotorcraft sizing code, and rotor analysis is performed with the CAMRAD II aeromechanics code. Design and mission parameters such as wing loading, disk loading, and cruise altitude are varied to minimize both cost and environmental impact metrics. This paper presents the results of these parametric sweeps as well as the final aircraft designs.

Russell, Carl↗

NASA NTRS2013

Application of Climate Impact Metrics to Civil Tiltrotor Design

Multiple metrics are applied to the design of a large civil tiltrotor, integrating minimum cost and minimum environmental impact. The design mission is passenger transport with similar range and capacity to a regional jet. Separate aircraft designs are generated for minimum empty weight, fuel burn, and environmental impact. A metric specifically developed for the design of aircraft is employed to evaluate emissions. The designs are generated using the NDARC rotorcraft sizing code, and rotor analysis is performed with the CAMRAD II aeromechanics code. Design and mission parameters such as wing loading, disk loading, and cruise altitude are varied to minimize both cost and environmental impact metrics. This paper presents the results of these parametric sweeps as well as the final aircraft designs.

Russell, Carl R.↗

DOE OSTI2023

New insights on wind turbine wakes from large‐eddy simulation: Wake contraction, dual nature, and temperature effects

Abstract Large‐eddy simulation (LES) has been adopted to study wind turbine wakes because it can capture fine‐scale details of turbulent wind flows and interactions with wind turbines. Here, we use the LES version of the Weather Research and Forecasting (WRF) model with an actuator disk model to gain insights on several wake effects that have been traditionally difficult to measure. The first finding is that the wake has a “dual nature,” meaning that the wind speed deficit behaves differently from the added turbulent kinetic energy (TKE) and the two are not co‐located in space. For example, the wind speed deficit peaks at hub height and reaches the ground within 8D (D is the rotor diameter), but added TKE peaks near the rotor tip and generally remains aloft. Second, temperature changes near the ground are driven by the added TKE in the rotor area and by atmospheric stability. The combination of these two factors determines the sign and intensity of the vertical heat flux divergence below the rotor, with convergence and warming associated with stable conditions and weak divergence and modest cooling with unstable conditions. Third, wakes do not expand indefinitely, as suggested by similarity theory applied to the wind speed deficit, but eventually stop expanding and actually contract, at different rates depending on atmospheric stability. The implication of these findings is that, in order to study wakes, it is not sufficient to focus on wind speed deficit alone, because TKE is also important and yet behaves differently from the wind speed deficit.

17 WIND ENERGY↗

DOE OSTI2024

Bulk viscosity of the rigid rotor one-component plasma

Bulk viscosity of a plasma consisting of strongly coupled diatomic ions is computed using molecular dynamics simulations. The simulations are based on the rigid rotor one-component plasma, which is introduced as a model system that adds two degrees of molecular rotation to the traditional one-component plasma. It is characterized by two parameters: the Coulomb coupling parameter, Γ, and the bond length parameter, Ω. Results show that the long-range nature of the Coulomb potential can lead to long rotational relaxation times, which in turn yield large values for bulk viscosity. Here, the bulk-to-shear viscosity ratio is found to span from small to large values depending on the values of Γ and Ω. Although bulk viscosity is often neglected in plasma modeling, these results motivate that it can be large in molecular plasmas with rotational degrees of freedom.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

NASA NTRS1994

Experimental Study of Vane Heat Transfer and Aerodynamics at Elevated Levels of Turbulence

A four vane subsonic cascade was used to investigate how free stream turbulence influences pressure surface heat transfer. A simulated combustor turbulence generator was built to generate high level (13 percent) large scale (Lu approximately 44 percent inlet span) turbulence. The mock combustor was also moved upstream to generate a moderate level (8.3 percent) of turbulence for comparison to smaller scale grid generated turbulence (7.8 percent). The high level combustor turbulence caused an average pressure surface heat transfer augmentation of 56 percent above the low turbulence baseline. The smaller scale grid turbulence produced the next greatest effect on heat transfer and demonstrated the importance of scale on heat transfer augmentation. In general, the heat transfer scaling parameter U(sub infinity) TU(sub infinity) LU(sub infinity)(exp -1/3) was found to hold for the turbulence. Heat transfer augmentation was also found to scale approximately on Re(sub ex)(exp 1/3) at constant turbulence conditions. Some evidence of turbulence intensification in terms of elevated dissipation rates was found along the pressure surface outside the boundary layer. However, based on the level of dissipation and the resulting heat transfer augmentation, the amplification of turbulence has only a moderate effect on pressure surface heat transfer. The flow field turbulence does drive turbulent production within the boundary layer which in turn causes the high levels of heat transfer augmentation. Unlike heat transfer, the flow field straining was found to have a significant effect on turbulence isotropy. On examination of the one dimensional spectra for u' and v', the effect to isotropy was largely limited to lower wavenumber spectra. The higher wavenumber spectra showed little or no change. The high level large scale turbulence was found to have a strong influence on wake development. The free stream turbulence significantly enhanced mixing resulting in broader and shallower wakes than the baseline case. High levels of flow field turbulence were found to correlate with a significant increase in total pressure loss in the core of the flow. Documenting the wake growth and characteristics provides boundary conditions for the downstream rotor.

Ames, Forrest E.↗

NASA NTRS1995

Steady-state dynamic behavior of an auxiliary bearing supported rotor system

This paper investigates the steady-state responses of a rotor system supported by auxiliary bearings in which there is a clearance between the rotor and the inner race of the bearing. A simulation model based upon the rotor of a production jet engine is developed and its steady-state behavior is explored over a wide range of operating conditions for various parametric configurations. Specifically, the influence of rotor imbalance, support stiffness, and damping is studied. It is found that imbalance may change the rotor responses dramatically in terms of frequency contents at certain operating speeds. Subharmonic responses of 2nd order through 10th order are all observed except the 9th order. Chaotic phenomenon is also observed. Jump phenomena (or double-valued responses) of both hard-spring type and soft-spring type are shown to occur at low operating speeds for systems with low auxiliary bearing damping or large clearance even with relatively small imbalance. The effect of friction between the shaft and the inner race of the bearing is also discussed.

Xie, Huajun↗