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At least 91 records · Page 5

Resonant mode controllers for launch vehicle applications

Electro-mechanical actuator (EMA) systems are currently being investigated for the National Launch System (NLS) as a replacement for hydraulic actuators due to the large amount of manpower and support hardware required to maintain the hydraulic systems. EMA systems in weight sensitive applications, such as launch vehicles, have been limited to around 5 hp due to system size, controller efficiency, thermal management, and battery size. Presented here are design and test data for an EMA system that competes favorably in weight and is superior in maintainability to the hydraulic system. An EMA system uses dc power provided by a high energy density bipolar lithium thionyl chloride battery, with power conversion performed by low loss resonant topologies, and a high efficiency induction motor controlled with a high performance field oriented controller to drive a linear actuator.

Schreiner, Ken E.↗

Locomotor head-trunk coordination strategies following space flight

During locomotion, angular head movements act in a compensatory fashion to oppose the vertical trunk translation that occurs during each step in the gait cycle. This coordinated strategy between head and trunk motion serves to aid gaze stabilization and perhaps simplifies the sensory coordinate transformation between the head and trunk, allowing efficient descending motor control during locomotion. Following space flight, astronauts often experience oscillopsia during locomotion in addition to postural and gait instabilities, suggesting a possible breakdown in head-trunk coordination. The goal of the present investigation was to determine if exposure to the microgravity environment of space flight induces alteration in head-trunk coordination during locomotion. Astronaut subjects were asked to walk (6.4 km/h, 20 s trials) on a motorized treadmill while visually fixating on a centrally located earthfixed target positioned either 2 m (FAR) or 30 cm (NEAR) from the eyes. In addition, some trials were also performed during periodic visual occlusion. Head and trunk kinematics during locomotion were determined with the aid of a video-based motion analyzing system. We report data collected preflight (10 days prior to launch) and postflight (2 to 4 hours after landing). The coherence between pitch head and vertical trunk movements during gaze fixation of both FAR and NEAR targets was significantly reduced following space flight indicating decreased coordination between the head and trunk during postflight locomotion. Astronauts flying on their first mission showed greater alterations in the frequency spectra of pitch head movements as compared to their more experienced counterparts. These modifications in the efficacy of head movement control may account for the reported disruption in gaze performance during locomotion and may contribute to postflight postural and gait dysfunction.

NASA Discipline Neuroscience↗

Electric Propulsion Platforms at DFRC

NASA Dryden Flight Research Center is a world-class flight research facility located at Edwards AFB, CA. With access to a 44 sq. mile dry lakebed and 350 testable days per year, it is the ideal location for flight research. DFRC has been undertaking aircraft research for approximately six decades including the famous X-aircraft (X-1 through X-48) and many science and exploration platforms. As part of this impressive heritage, DFRC has garnered more hours of full-sized electric aircraft testing than any other facility in the US, and possibly the world. Throughout the 80 s and 90 s Dryden was the home of the Pathfinder, Pathfinder Plus, and Helios prototype solar-electric aircraft. As part of the ERAST program, these electric aircraft achieved a world record 97,000 feet altitude for propeller-driven aircraft. As a result of these programs, Dryden s staff has collected thousands of man-hours of electric aircraft research and testing. In order to better answer the needs of the US in providing aircraft technologies with lower fuel consumption, lower toxic emissions (NOx, CO, VOCs, etc.), lower greenhouse gas (GHG) emissions, and lower noise emissions, NASA has engaged in cross-discipline research under the Aeronautics Research Mission Directorate (ARMD). As a part of this overall effort, Mark Moore of LaRC has initiated a cross-NASA-center electric propulsion working group (EPWG) to focus on electric propulsion technologies as applied to aircraft. Electric propulsion technologies are ideally suited to overcome all of the obstacles mentioned above, and are at a sufficiently advanced state of development component-wise to warrant serious R&D and testing (TRL 3+). The EPWG includes participation from NASA Langley Research Center (LaRC), Glenn Research Center (GRC), Ames Research Center (ARC), and Dryden Flight Research Center (DFRC). Each of the center participants provides their own unique expertise to support the overall goal of advancing the state-of-the-art in aircraft electric propulsion technologies. DFRC will leverage its vast experience in flight test to assist in the integration and flight test phases of any electric propulsion program. DFRC s core competencies, that have particular relevance to the goals of the EPWG, include flight research planning and execution and providing aircraft test beds for researching and testing electric propulsion concepts and equipment. There are three flight regimes that the EPWG is focusing on: subsonic small GA and UAV, subsonic transport class, and supersonic. DFRC proposes two classes of test bed aircraft, to answer the early- and mid-phase testing requirements of all flight regimes the EPWG is concerned with. First, a highly efficient PIK motor glider will be used to test concepts and equipment associated with the subsonic GA and UAV aircraft regime (N+1). Second, a small fleet of subscale remotely-piloted aircraft test beds, similar to the X48B Blended Wing Body aircraft tested at Dryden, will be developed to answer the unique testing requirements of the subsonic GA and UAV, subsonic transport and possibly the supersonic class of aircraft (N+2, N+3). These aircraft can be tested in either serial stages or concurrent stages, depending on the actual test requirements and program schedules. Both classes of test bed aircraft are described below.

Baraaclough, Jonathan↗

Static Testing of A Conductively-Cooled, High Temperature Superconducting Rotor for A 1.4 MW Electric Machine in a Thermal Vacuum Chamber

NASA’s high efficiency megawatt motor (HEMM) is a partially superconducting, 1.4 MW electric machine designed for electrified aircraft propulsion. HEMM’s high performance is enabled by a field winding composed of 2nd generation high temperature superconducting (HTS) coils that are designed to operate at temperatures below 62 K. The superconducting rotor is conductively cooled to cryogenic temperatures using a rotating cryocooler embedded inside the machine’s shaft. This paper presents a static test of the full-scale superconducting rotor in a thermal vacuum chamber. The experimental setup is described in detail. Thermal and electromagnetic 3D finite element analyses of the experimental setup are shown along with a comparison of the model results to model results for HEMM. The thermal response during cool down from room temperature is discussed. Electrical measurements are presented for operation at different dc current excitations up to the rated current of the rotor (57.2 A) and temperature limit of the HEMM design (62 K). The results suggest that minor damage to one superconducting coil occurred at 50 A and 61.2 K, causing increased resistance in the system, but that the system could still be stably operated at 57.2 A and 62 K when conductively cooled by a cryocooler.

electrified aircraft propulsion↗

Design Implications of Rotordynamics and Mass Balancing on a 1.4 MW Partially Superconducting Machine

To ensure that rotating machines operate without excessive bearing loads, vibration, and dynamic stresses, their design must consider rotordynamic response and provisions for mass balancing of rotors, even when their rotational speeds are modest. This paper presents a rotordynamics design study for a 1.4 MW, partially superconducting electric machine proposed for electrified aircraft propulsion – NASA’s High Efficiency Megawatt Motor (HEMM). The study includes the selection of mass balancing grade and mount and bearing stiffnesses to yield satisfactory critical speeds, deflection, and unbalance force, and predictions of the expected mass unbalance caused by the superconducting rotor coils. The impact of the machine’s number of rotor poles on expected mass unbalance is also quantified. Design decisions and lessons learned are discussed.

hybrid electric aircraft↗

Design Implications of Rotordynamics and Mass Balancing on a 1.4 MW Partially Superconducting Machine

To ensure that rotating machines operate without excessive bearing loads, vibration, and dynamic stresses, their design must consider rotordynamic response and provisions for mass balancing of rotors, even when their rotational speeds are modest. This paper presents a rotordynamics design study for a 1.4 MW, partially superconducting electric machine proposed for electrified aircraft propulsion – NASA’s High Efficiency Megawatt Motor (HEMM). The study includes the selection of mass balancing grade and mount and bearing stiffnesses to yield satisfactory critical speeds, deflection, and unbalance force, and predictions of the expected mass unbalance caused by the superconducting rotor coils. The impact of the machine’s number of rotor poles on expected mass unbalance is also quantified. Design decisions and lessons learned are discussed.

hybrid electric aircraft↗

Stationary Testing of a Pulse Tube Cryocooler Designed to Rotate at 6800 RPM with the Superconducting Rotor of an Electric Machine

Electrified aircraft are being developed to increase the efficiency and reduce the cost of operating subsonic transport aircraft. Achieving a substantial impact necessitates focusing on single- and twin-aisle aircraft which use propulsion systems with >20 MW ratings. For these aircraft, multi-MW superconducting electric machines are being developed due to their high specific power and high efficiency. Most of these electric machines employ superconductors on their rotor, thereby requiring cryogenic cooling of the rotating system. An attractive solution is to conductively cool the rotor using a cryocooler that rotates with the rotor. NASA has been developing a 50 K pulse tube cryocooler for its High Efficiency Megawatt Motor (HEMM) that can operate while rotating at 6,800 rpm. The design of this cryocooler and testing of its linear motor have been discussed in prior work. This presentation presents the first measurements of the complete HEMM cryocooler. The design and results of a stationary (non-rotating) test of the cryocooler are described.

electrified aircraft propulsion↗

Stationary Testing of a Pulse Tube Cryocooler Designed to Rotate at 6800 RPM with the Superconducting Rotor of an Electric Machine

Electrified aircraft are being developed to increase the efficiency and reduce the cost of operating subsonic transport aircraft. Achieving a substantial impact necessitates focusing on single- and twin-aisle aircraft which use propulsion systems with >20 MW ratings. For these aircraft, multi-MW superconducting electric machines are being developed due to their high specific power and high efficiency. Most of these electric machines employ superconductors on their rotor, thereby requiring cryogenic cooling of the rotating system. An attractive solution is to conductively cool the rotor using a cryocooler that rotates with the rotor. NASA has been developing a 50 K pulse tube cryocooler for its High Efficiency Megawatt Motor (HEMM) that can operate while rotating at up to 6,800 rpm. The first non-rotating tests of the fully assembled HEMM cryocooler have been completed, and initial testing has yielded a no-load temperature of 112 K. A small helium leak into the vacuum system has been identified as the major bottleneck to performance, and based on measurements with the motor turned off there is an observed vacuum-side heat leak of approximately 30 W at 115 K. Immediate next steps for testing are to locate and mitigate the apparent helium leaks into the vacuum chamber. Thus far, compressor performance and the apparent heat lift after correcting for the heat leak are on par with expectations.

Electrified Aircraft Propulsion↗

Voltage Controller Saves Energy, Prolongs Life of Motors

In 1985, Power Efficiency Corporation of Las Vegas licensed NASA voltage controller technology from Marshall Space Flight Center. In the following years, Power Efficiency made patented improvements to the technology and marketed the resulting products throughout the world as the Performance Controller and the Power Efficiency energy-saving soft start. Soft start gradually introduces power to an electric motor, thus eliminating the harsh, violent mechanical stresses of having the device go from a dormant state to one of full activity; prevents it from running too hot; and increases the motor's lifetime. The product can pay for itself through the reduction in electricity consumed (according to Power Efficiency, within 3 years), depending on the duty cycle of the motor and the prevailing power rates. In many instances, the purchaser is eligible for special utility rebates for the environmental protection it provides. Common applications of Power Efficiency's soft start include mixers, grinders, granulators, conveyors, crushers, stamping presses, injection molders, elevators with MG sets, and escalators. The device has been retrofitted onto equipment at major department store chains, hotels, airports, universities, and for various manufacturers

Source record↗

Thermal Analysis of Potted Litz Wire for High-Power-Density Aerospace Electric Machines

Increasing the power density and efficiency of electric machines (motors and generators) is integral to bringing Electrified Aircraft (EA) to commercial realization. To that end an effort to create a High Efficiency Megawatt Motor (HEMM) with a goal of exceeding 98% efficiency and 1.46 MW of power has been undertaken at the NASA Glenn Research Center. Of the motor components the resistive losses in the stator windings are by far the largest contributor (34%) to total motor loss. The challenge is the linear relationship between resistivity and temperature, making machine operation sensitive to temperature increases. In order to accurately predict the thermal behavior of the stator the thermal conductivity of the Litz wire-potting-electrical insulation system must be known. Unfortunately, this multi material system has a wide range of thermal conductivities (0.1 W/m-K – 400 W/m-K) and a high anisotropy (axial vs transverse) making the prediction of the transverse thermal conductivity an in turn the hot spot temperatures in the windings is difficult. In order to do this a device that simulates the thermal environment found in the HEMM stator was designed. This device is not unlike the motorettes (little motors) that are described in IEEE standards for testing electrical insulation lifetimes or other electric motor testing. However, because the HEMM motor design includes significant rotor electrical and thermal considerations the term motorette was not deemed appropriate. Instead statorette (or little stator) was adopted as the term for this test device. This paper discussed the design, thermal heat conjugate analysis (thermal model), manufacturing and testing of HEMM's statorette. Analysis of the results is done by thermal resistance network model and micro thermal model and is compared to analytical predictions of thermal conductivity of the insulated and potted Litz wire system.

Motor↗

Big Savings from Smart Motors

Chesebrough-Pond's operates 32 plants across the nation and in those plants are more than 10,000 electric motors. In an effort to cut down on waste of electrical power used by these motors, Chesebrough organized a Corporate Advanced Technology Group to devise ways of improving productivity and cut manufacturing costs. Chesebrough used NASA's Marshall Space Flight Center's Power Factor Controller technology as a departure point for development of their own computerized motor controller that enables motors to operate at maximum efficiency regardless of the motor's applications or operating condition.

Source record↗

Four quadrant control of induction motors

Induction motors are the nation's workhorse, being the motor of choice in most applications due to their simple rugged construction. It has been estimated that 14 to 27 percent of the country's total electricity use could be saved with adjustable speed drives. Until now, induction motors have not been suited well for variable speed or servo-drives, due to the inherent complexity, size, and inefficiency of their variable speed controls. Work at NASA Lewis Research Center on field oriented control of induction motors using pulse population modulation method holds the promise for the desired drive electronics. The system allows for a variable voltage to frequency ratio which enables the user to operate the motor at maximum efficiency, while having independent control of both the speed and torque of an induction motor in all four quadrants of the speed torque map. Multiple horsepower machine drives were demonstrated, and work is on-going to develop a 20 hp average, 40 hp peak class of machine. The pulse population technique, results to date, and projections for implementation of this existing new motor control technology are discussed.

Hansen, Irving G.↗

Fast-response power saver for induction motors

With control circuit, induction motors run more efficiently at light loads and respond to sudden load changes. It also anticipates power needs so that motor can respond instantly (to a load applied by a clutch, for example).

Nola, F. J.↗

Magnetostrictive direct drive motor

Highly magnetostrictive materials such as Tb.3Dy.7Fe2, commercially known as TERFENOL-D, have been used to date in a variety of devices such as high power actuators and linear motors. The larger magnetostriction available in twinned single crystal TERFENOL-D, approx. 2000 ppm at moderate magnetic field strengths, makes possible a new generation of magnetomechanical devices. NASA researchers are studying the potential of this material as the basis for a direct microstepping rotary motor with torque densities on the order of industrial hydraulics and five times greater than that of the most efficient, high power electric motors. Such a motor would be a micro-radian stepper, capable of precision movements and self-braking in the power-off state. Innovative mechanical engineering techniques are juxtaposed on proper magnetic circuit design to reduce losses in structural flexures, inertias, thermal expansions, eddy currents, and magneto-mechanical coupling, thus optimizing motor performance and efficiency. Mathematical models are presented, including magnetic, structural, and both linear and nonlinear dynamic calculations and simulations. In addition, test results on prototypes are presented.

Naik, Dipak↗

Straight and chopped dc performance data for a Prestolite MTC-4001 motor and a general electric EV-1 controller

Performance data on the Prestolite MTC-4001 series wound dc motor and General Electric EV-1 Chopper Controller is supplied for the electric vehicle manufacturer. Data are provided for both straight and chopped dc input to the motor, at 2 motor temperature levels. Testing was done at 6 voltage increments to the motor, and 2 voltage increments to the controller. Data results are presented in both tabular and graphical forms. Tabular information includes motor voltage and current input data, motor speed and torque output data, power data and temperature data. Graphical information includes torque-speed, motor power output-speed, torque-current, and efficiency-speed plots under the various operating conditions. The data resulting from this testing show the speed-torque plots to have the most variance with operating temperature. The maximum motor efficiency is between 76% and 82%, regardless of temperature or mode of operation.

Edie, P. C.↗

Unified Robot-Control System

Robot-joint motors integrated with control computer or computers. Robot controller uses only 1 microprocessor to control as many as 16 joint-actuating motors. Control system uses high-speed bus to communicate with joint-interface circuits, addressing scheme to write commands to several motors simultaneously, and efficient assembly-language servo code. Features enable control of 16 joints at 1-kHz servo rate. Suitable for control of motors in numerically-controlled manufacturing systems. Use of single joint-control processor results in few components, lower cost, and simpler architecture.

Szakaly, Zoltan F.↗

Big Results From a Smaller Gearbox

Many people will be sad to see the Hubble Space Telescope go, as it was the first instrument of its kind to provide us with such a wealth of imagery and information about the galaxy. The telescope has served us well since its launch in spring of 1990, but it is nearly time for its retirement. The science, however, will continue, as NASA plans the launch of a new, more modern orbiting telescope, the James Webb Space Telescope. Named after the man who ran NASA from 1961 to 1968, years fraught with the anxiety and uncertainty of the Space Race, the scope is scheduled for launch in fall of 2011. It is designed to study the earliest galaxies and some of the first stars formed after the Big Bang. NASA scientists at the Goddard Space Flight Center are busy developing the technologies to build this new machine. Many of the new technologies are available for commercial licensing and development. For example, the NASA Planetary Gear System technology developed to give precise nanometer positioning capabilities for the James Webb Space Telescope is now being employed by Turnkey Design Services, LLC (TDS), of Blue Island, Illinois, to improve electric motors. This revolutionary piece of technology allows more efficient operation of the motors, and is more cost- effective than traditional gearbox designs.

Source record↗

A new wind energy conversion system

It is presupposed that vertical axis wind energy machines will be superior to horizontal axis machines on a power output/cost basis and the design of a new wind energy machine is presented. The design employs conical cones with sharp lips and smooth surfaces to promote maximum drag and minimize skin friction. The cones are mounted on a vertical axis in such a way as to assist torque development. Storing wind energy as compressed air is thought to be optimal and reasons are: (1) the efficiency of compression is fairly high compared to the conversion of mechanical energy to electrical energy in storage batteries; (2) the release of stored energy through an air motor has high efficiency; and (3) design, construction, and maintenance of an all-mechanical system is usually simpler than for a mechanical to electrical conversion system.

Smetana, F. O.↗