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Magnetic coil testing and experiment preparations for magnet facility in simulation of large high field superconducting magnet operation
A methodology (and hardware and software to implement the methodology) has been developed as a means of investigating coupling between certain rotordynamic and hydrodynamic phenomena in turbomachines. Originally, the methodology was intended for application in an investigation of coupled rotordynamic and hydrodynamic effects postulated to have caused high synchronous vibration in the space shuttle s high-pressure oxygen turbopump (HPOTP). The methodology can also be applied in investigating (for the purpose of developing means of suppressing) undesired hydrodynamic rotor/stator interactions in turbomachines in general. The methodology and the types of phenomena that can be investigated by use of the methodology are best summarized by citing the original application as an example. In that application, in consideration of the high synchronous vibration in the space-shuttle main engine (SSME) HPOTP, it was determined to be necessary to perform tests to investigate the influence of inducer eccentricity and/or synchronous whirl motion on inducer hydrodynamic forces under prescribed flow and cavitation conditions. It was believed that manufacturing tolerances of the turbopump resulted in some induced runout of the pump rotor. Such runout, if oriented with an inducer blade, would cause that blade to run with tip clearance smaller than the tip clearances of the other inducer blades. It was hypothesized that the resulting hydraulic asymmetry, coupled with alternating blade cavitation, could give rise to the observed high synchronous vibration. In tests performed to investigate this hypothesis, prescribed rotor whirl motions have been imposed on a 1/3-scale water-rig version of the SSME LPOTP inducer (which is also a 4-biased inducer having similar cavitation dynamics as the HPOTP) in a magnetic-bearing test facility. The particular magnetic-bearing test facility, through active vibration control, affords a capability to impose, on the rotor, whirl orbits having shapes and whirl rates prescribed by the user, and to simultaneously measure the resulting hydrodynamic forces generated by the impeller. Active control also made it possible to modulate the inducer-blade running tip clearance and consequently effect alternating blade cavitation. The measured hydraulic forces have been compared and correlated with shroud dynamic-pressure measurements.
An experimental magnetic leader cable (MLC) system designed to measure aircraft lateral displacement from centerline and heading relative to centerline during rollout, turnoff, and taxi was tested at NASA's Wallops Flight Facility using NASA's Transport System Research Vehicle (TSRV), a modified B-737. The MLC system consisted of ground equipment that produced a magnetic field about a wire along runway centerline and airborne equipment that detected the strength and direction of this field and computed displacement and heading. Results of these tests indicate that estimates of aircraft displacement from centerline produced by the magnetic leader cable system using either of the two algorithms appear to be adequate for use by an automatic control system during rollout, turnoff, and taxi. Estimates of heading, however, are not sufficiently accurate for use, probably because of distortion of the magnetic field by the metal aircraft.
The NASA Glenn Research Center has developed and tested a revolutionary Axial Halbach Magnetic Bearing. The objective of this work is to develop a viable non-contact magnetic thrust bearing utilizing Halbach arrays for all-electric flight, and many other applications. This concept will help to reduce harmful emissions, reduce the Nation s dependence on fossil fuels and mitigate many of the concerns and limitations encountered in conventional axial bearings such as bearing wear, leaks, seals and friction loss. The Axial Halbach Magnetic Bearing is inherently stable and requires no active feedback control system or superconductivity as required in many magnetic bearing designs. The Axial Halbach Magnetic Bearing is useful for very high speed applications including turbines, instrumentation, medical systems, computer memory systems, and space power systems such as flywheels. Magnetic fields suspend and support a rotor assembly within a stator. Advanced technologies developed for particle accelerators, and currently under development for maglev trains and rocket launchers, served as the basis for this application. Experimental hardware was successfully designed and developed to validate the basic principles and analyses. The report concludes that the implementation of Axial Halbach Magnetic Bearings can provide significant improvements in rotational system performance and reliability.
Experiments were performed on a Hybrid Magnetic Bearing designed for cryogenic applications such as turbopumps. This bearing is considerably smaller and lighter than conventional magnetic bearings and is more efficient because it uses a permanent magnet to provide a bias flux. The tests were performed in a test rig that used liquid nitrogen to simulate cryogenic turbopump temperatures. The bearing was tested at room temperature and at liquid nitrogen temperature (-320 F). The maximum speed for the test rig was 14000 rpm. For a magnetic bearing stiffness of 20000 lb/in, the flexible rotor had two critical speeds. A static (nonrotating) bearing stiffness of 85000 lb/in was achieved. Magnetic bearing stiffness, permanent magnet stiffness, actuator gain, and actuator force interaction between two axes were evaluated, and controller/power amplifier characteristics were determined. The tests revealed that it is feasible to use this bearing in the cryogenic environment and to control the rotor dynamics of flexible rotors when passing through bending critical speeds. The tests also revealed that more effort should be placed on enhancing the controller to achieve higher bearing stiffness and on developing displacement sensors that reduce drift caused by temperature and reduce sensor electrical noise.
A supercritical helium testing system for a magnetic refrigerator has been built. Details of the supercritical helium pump, the test system, and the test instrumentation are given. Actual pump tests were not run during this ASEE term because of delivery problems associated with the required pump flow meter. Consequently, efforts were directed on preliminary design of the magnetic refrigeration system for the pump. The first concern with the magnetic refrigerator design was determining how to effectively make use of the pump. A method to incorporate the supercritical helium pump into a magnetic refrigerator was determined by using a computer model. An illustrated example of this procedure is given to provide a tool for sizing the magnetic refrigerator system as a function of the pump size. The function of the computer model and its operation are also outlined and discussed.
The potential utility of magnetic suspension techniques is discussed in the context of current efforts towards realistic aerodynamic simulation in wind tunnels. Design parameters are defined and problems of constructing large size facilities identified. A three stage strategy towards realizing a truly large scale magnetic suspension and balance with full research capability is outlined. Stage one, consisting of building and testing a prototype superconductor coil system to establish the feasibility of the concept has been completed successfully and its principal results are briefly described. This proven feasibility of using superconductors for magnetic suspensions, together with the successful demonstration of the cryogenic wind tunnel concept, appear to have opened the way to clean tunnel, high-Re aerodynamic testing. Results of a comparative analysis of scaling of several coil technologies for a specific magnetic suspension configuration, from the prototype size to a size compatible with the projected high Reynolds number cryogenic wind tunnel facility, are discussed in some detail.
The NASA John H. Glenn Research Center has developed and tested a revolutionary Radial Halbach Magnetic Bearing. The objective of this work is to develop a viable non-contact magnetic bearing utilizing Halbach arrays for all-electric flight, and many other applications. This concept will help reduce harmful emissions, reduce the Nation s dependence on fossil fuels and mitigate many of the concerns and limitations encountered in conventional axial bearings such as bearing wear, leaks, seals and friction loss. The Radial Halbach Magnetic Bearing is inherently stable and requires no active feedback control system or superconductivity as required in many magnetic bearing designs. The Radial Halbach Magnetic Bearing is useful for very high speed applications including turbines, instrumentation, medical applications, manufacturing equipment, and space power systems such as flywheels. Magnetic fields suspend and support a rotor assembly within a stator. Advanced technologies developed for particle accelerators, and currently under development for maglev trains and rocket launchers, served as the basis for this application. Experimental hardware was successfully designed and developed to validate the basic principles and analyses. The report concludes that the implementation of Radial Halbach Magnetic Bearings can provide significant improvements in rotational system performance and reliability.
A self-shielded superconducting magnet was designed for the NASA Goddard Space Flight Center Adiabatic Demagnetization Refrigerator Program. This is the third magnet built from this design. The magnets utilize Cryomagnetics' patented ultra-low current technology. The magnetic system is capable of reaching a central field of two tesla at slightly under two amperes and has a total inductance of 1068 henries. This final report details the requirements of the magnet, the specifications of the resulting magnet, the test procedures and test result data for the third magnet (Serial # C-654-M), and recommended precautions for use of the magnet.
NASA is developing a next-generation CO2 removal system, the Four Bed Carbon Dioxide Scrubber (4BCO2), which will use the International Space Station (ISS) as a testbed. A key component of both the existing and the new system is the blower that provides the airflow through the CO2 sorbent beds. To improve performance and reliability, magnetic bearings will be used in lieu of more conventional bearings (e.g. ball bearings or hydrodynamicbearings) to improve resistance to contaminants and enable extensibility with regards to blower speed, pressure rise and mass flow rate. The new blower features a high-efficiency permanent magnet motor, a five-axis, active magnetic bearing system, and a compact controller containing both a variable speed drive and magnetic bearing controller. The blower uses a centrifugal impeller to pull air from the inlet port and drive it through an annular space around the motor and magnetic bearing components to the exhaust port. Technical challenges of the blower and controller development include survival of the blower system under launch random vibration loads, operation in microgravity, packaging under strict size and weight requirements, and successful operation during 4BCO2 operational changeovers. Each serial build of the blower must pass a severe random vibration test to prove it will survive launch conditions. This paper discusses the vibration test requirements and provides details of a simulation performed to estimate the peak backup bearing displacements and loads. Results from the successful random vibration testing of the prototype build are discussed and compared to the simulation.
A scaled blade-tip-drive test rig was designed at the NASA Glenn Research Center. The rig is a scaled version of a direct-current brushless motor that would be located in the shroud of a thrust fan. This geometry is very attractive since the allowable speed of the armature is approximately the speed of the blade tips (Mach 1 or 1100 ft/s). The magnetic pressure generated in the motor acts over a large area and, thus, produces a large force or torque. This large force multiplied by the large velocity results in a high-power-density motor.
Standards and controls are established for the procurement of wide channel bandwidth one inch video magnetic recording tapes for Very Long Base Interferometer (VLBI) system applications. The Magnetic Tape Certification Facility (MTCF) currently maintains three specifications for the Quality Products List (QPL) and acceptance testing of magnetic tapes. NASA-TM-79724 is used for the QPL and acceptance testing of new analog tapes; NASA-TM-80599 is used for QPL and acceptance testing of new digital tapes; and NASA-TM-100702 is used for the QPL and acceptance testing of new IBM/IBM compatible 3480 magnetic tape cartridges. This specification will be used for the QPL and acceptance testing of new wide channel bandwidth one inch video magnetic recording tapes. The one inch video tapes used by the Jet Propulsion Lab., the Deep Space Network and the Haystack Observatory will be covered by this specification. These NASA stations will use the video tapes for their VLBI system applications. The VLBI system is used for the tracking of quasars and the support of interplanetary exploration.
This report describes the fabrication, design of flow director, fluid flow direction analysis and testing of flow director of a magnetic heat pump. The objectives of the project are: (1) to fabricate a demonstration magnetic heat pump prototype with flow directors installed; and (2) analysis and testing of flow director and to make sure working fluid loops flow through correct directions with minor mixing. The prototype was fabricated and tested at the Development Testing Laboratory of Kennedy Space Center. The magnetic heat pump uses rear earth metal plates rotate in and out of a magnetic field in a clear plastic housing with water flowing through the rotor plates to provide temperature lift. Obtaining the proper water flow direction has been a problem. Flow directors were installed as flow barriers between separating point of two parallel loops. Function of flow directors were proven to be excellent both analytically and experimentally.
A flow geometry and flow rate for mixed flowing gas testing is proposed. Use of an impinging jet of humid polluted air can provide a uniform and reproducible exposure of coupons of metal-based magnetic media. Numerical analysis of the fluid flow and mass transfer in such as system has shown that samples confined within a distance equal to the nozzle radius on the surface of impingement are uniformly accessible to pollutants in the impinging gas phase. The critical factor is the nozzle height above the surface of impingement. In particular, the uniformity of exposure is less than plus/minus 2% for a volumetric flow rate of 1600 cm(exp 3)/minute total flow with the following specifications: For a one inch nozzle, the height of the nozzle opening above the stage should be 0.177 inches; for a 2 inch nozzle - 0.390 inches. Not only is the distribution uniform, but one can calculate the maximum delivery rate of pollutants to the samples for comparison with the observed deterioration.
We report modeling, fabrication, cryogenic tensile testing, and magnetic field measurements of a shield around an adiabatic demagnetization stage (ADR) built for the XRISM/Resolve instrument. During testing of a near-identical stage built for Astro-H, a previous spaceflight mission, it was determined that the magnet at full current generated a field external to the shield that violated the maximum dipole-moment requirement of the spacecraft. In addition, there was an interference with the detector assembly nearby when the magnet was greater than 85% of it's typical maximum current. Starting with the Astro-H shield design, we performed a parametric study that increased the thickness of the shield in critical regions. This calculation proceeded until the magnetic field satisfied the estimated maximum field allowed at the detector array based upon the Astro-H measurements. We also performed a detailed measurement of the field generated by the ADR stage at full current as a function of relative angle between the magnet axis and a series of flux-gate magnetometers. Details and results from the calculation and subsequent measurement will be presented.
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Magnetic gears harness the magnetic force between non-contacting sets of permanent magnets. They achieve a gear ratio through the geometry and constrained motion of the magnets or the transformation of the magnetic fields by carefully shaped soft magnetic material. Their non-contact nature eliminates the need for gear lubrication and the wear mechanisms associated with mechanical contact. Magnetic gears have the potential to reduce the strong, tonal vibration and noise that is inherent to mechanical gears. Magnetic gears are also easily integrated into electric machines because they rely on the same physics and utilize the same materials and many of the same components. For these reasons and the invention of higher performing magnetic gear configurations over the past 20 years, magnetic gears have received growing attention for aerospace applications. This presentation summarizes the motivation for studying magnetic gears and the progress made in developing the technology to meet the demanding requirements of aerospace applications. The focus is on the development completed and ongoing at NASA, but SBIR projects in the field are summarized. The discussion focuses on the application of magnetic gears and magnetically-geared motors in electrified aircraft propulsion systems and actuation systems for space mechanisms. The NASA work includes the design, optimization, and testing of magnetic gears and magnetically-geared motors for electrified vertical takeoff and landing aircraft and the design and ambient environment testing of a magnetically-geared actuator for use in extremely cold and dusty space environments. The presentation concludes with thoughts on the technical barriers to adoption and potentially fruitful topics for future research.
A multidimensional numerical simulation framework aimed at investigating the process of plasma detachment from a magnetic nozzle is introduced. An existing numerical code based on a magnetohydrodynamic formulation of the plasma flow equations that accounts for various dispersive and dissipative processes in plasmas was significantly enhanced to allow for the modeling of axisymmetric domains containing three.dimensiunai momentum and magnetic flux vectors. A separate magnetostatic solver was used to simulate the applied magnetic field topologies found in various nozzle experiments. Numerical results from a magnetic diffusion test problem in which all three components of the magnetic field were present exhibit excellent quantitative agreement with the analytical solution, and the lack of numerical instabilities due to fluctuations in the value of del(raised dot)B indicate that the conservative MHD framework with dissipative effects is well-suited for multi-dimensional analysis of magnetic nozzles. Further studies will focus on modeling literature experiments both for the purpose of code validation and to extract physical insight regarding the mechanisms driving detachment.