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7 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

Regal Beloit Final Technical Report

The original project proposal submitted from NovaTorque Inc (NovaTorque) in 2016 was to improve the existing motor with 95% efficiency by reducing the losses by 21% to achieve 96%. A few months after the proposal was submitted, NovaTorque lost funding and went out of business. The assets of NovaTorque were then acquired by Regal Beloit Corporation (“Regal Beloit” or “Regal”). When the NovaTorque proposal was selected, the project was transferred to Regal Beloit. Once we had production samples from the new Regal production line, they were tested at the Regal Beloit test lab in Wausau, WI. The original NovaTorque motor had an efficiency of 95%, but when the technology was transferred to Regal Beloit, there were multiple manufacturing improvements made, even though the basic electromagnetic design did not change. The test results in Wausau showed that the motors made at the Regal Beloit plant had an efficiency of 96%. Since the goal of the project was to reduce the losses by 21%, a new efficiency target of 96.8% became the project objective. In the first budget period, motors were tested to get the baseline performance. We then used FEA modeling with ANSYS Maxwell to model the existing motor to get correlation between the FEA simulations and the actual test results. Once the model was validated, we evaluated some changes that could be made to the stator to reduce the losses and improve efficiency without changing the rotor or stator housing, keeping the modifications easy to implement. The changes were primarily in the area of making the stator axially shorter and adding Soft Magnetic Composite (SMC) tooth tips. In the second budget period, we proceeded to design and build the new stator that was identified above and identified additional improvements in the process that included a stator machining modification and the use of rectangular wire. When we actually built the motor, the choice of rectangular wire turned out to be a problem. The wire was made by squishing round wire to get the rectangular shape, which caused work hardening, making the wire too stiff to make the desired coils. We shifted to annealed square wire which was better, but we still could not maintain the proper coil envelope. The result was that we had reduced cross section area for stator laminations. We also had to have a radial offset resulting in a radial misalignment between the stator and rotor because of the oversized coils. After the motor was completed, it was shipped to Texas A&M University for testing. With the loss of flux from these issues, the measured motor efficiency was only 96.3%. The primary focus of this motor was to make sure our FEA simulation model predicted the measured losses and overall efficiency, this we moved on to the FEA simulation. The FEA simulations of the motor “as built” with misalignments had good correlation with the test results, so the next step was to use that model to optimize the design of the motor for a final build. This time we considered changes to the stator and rotor and also minor changes to the housing diameter. In the third budget period, we did the detailed design and construction of the final prototypes. The final prototypes had a slight increase in the stator diameter to fit in a standard Regal Beloit housing. We shortened the stator and use more layers of wire in the coils. We also increased the cone angle of the rotor and stator from the original 110 degrees to 130 degrees to get some additional efficiency and optimized the stator cross section. The predicted efficiency from the FEA simulations was 96.9%. When completed, the motors were tested. We were a little short of reaching our target efficiency goal of 96.8%. We were only able to get to 96.7% efficiency. While it may be possible with additional iterations in designs and future builds to gain that additional 0.1%, we believe that we are close to the best we can achieve from a practical viewpoint, and additional iterations would be more work than the potential gains would be worth. No other motor in this class can even reach the 96% that we started with.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
NASA NTRS2013

Levitation Performance of Two Opposed Permanent Magnet Pole-Pair Separated Conical Bearingless Motors

In standard motor applications, rotor suspension with traditional mechanical bearings represents the most economical solution. However, in certain high performance applications, rotor suspension without contacting bearings is either required or highly beneficial. Examples include applications requiring very high speed or extreme environment operation, or with limited access for maintenance. This paper expands upon a novel bearingless motor concept, in which two motors with opposing conical air-gaps are used to achieve full five-axis levitation and rotation of the rotor. Force in this motor is created by deliberately leaving the motor s pole-pairs unconnected, which allows the creation of different d-axis flux in each pole pair. This flux imbalance is used to create lateral force. This approach is different than previous bearingless motor designs, which require separate windings for levitation and rotation. This paper examines the predicted and achieved suspension performance of a fully levitated prototype bearingless system.

Kascak, Peter↗
NASA NTRS2012

Counteracting Rotor Imbalance in a Bearingless Motor System with Feedforward Control

In standard motor applications, traditional mechanical bearings represent the most economical approach to rotor suspension. However, in certain high performance applications, rotor suspension without bearing contact is either required or highly beneficial. Such applications include very high speed, extreme environment, or limited maintenance access applications. This paper extends upon a novel bearingless motor concept, in which full five-axis levitation and rotation of the rotor is achieved using two motors with opposing conical air-gaps. By leaving the motors' pole-pairs unconnected, different d-axis flux in each pole-pair is created, generating a flux imbalance which creates lateral force. Note this is approach is different than that used in previous bearingless motors, which use separate windings for levitation and rotation. This paper will examine the use of feedforward control to counteract synchronous whirl caused by rotor imbalance. Experimental results will be presented showing the performance of a prototype bearingless system, which was sized for a high speed flywheel energy storage application, with and without feedforward control.

Bearingless Motor↗
NASA NTRS2000

Novel Integrated Radial and Axial Magnetic Bearing

Typically, fully active magnetically suspended systems require one axial and two radial magnetic bearings. Combining radial and axial functions into a single device allows for more compact and elegant packaging. Furthermore, in the case of high-speed devices such as energy storage flywheels, it is beneficial to minimize shaft length to keep rotor mode frequencies as high as possible. Attempts have been made to combine radial and axial functionality, but with certain drawbacks. One approach requires magnetic control flux to flow through a bias magnet reducing control effectiveness, thus resulting in increased resistive losses. This approach also requires axial force producing magnetic flux to flow in a direction into the rotor laminate that is undesirable for minimizing eddy-current losses resulting in rotational losses. Another approach applies a conical rotor shape to what otherwise would be a radial heteropolar magnetic bearing configuration. However, positional non-linear effects are introduced with this scheme and the same windings are used for bias, radial, and axial control adding complexity to the controller and electronics. For this approach, the amount of axial capability must be limited. It would be desirable for an integrated radial and axial magnetic bearing to have the following characteristics, separate inputs for radial and axial control for electronics and control simplicity, all magnetic control fluxes should only flow through their respective air gaps and should not flow through any bias magnets for minimal resistive losses, be of a homopolar design to minimize rotational losses, position related non-linear effects should be minimized, and dependent upon the design parameters, be able to achieve any radial/axial force or power ratio as desired. The integrated radial and axial magnetic bearing described in this paper exhibits all these characteristics. Magnetic circuit design, design equations, and analysis results will be presented.

Blumenstock, Kenneth A.↗
NASA NTRS2000

Novel Integration Radial and Axial Magnetic Bearing

Typically, fully active magnetically suspended systems require one axial and two radial magnetic bearings. Combining radial and axial functions into a single device allows for more compact and elegant packaging. Furthermore, in the case of high-speed devices such as energy storage flywheels, it is beneficial to minimize shaft length to keep rotor mode frequencies as high as possible. Attempts have been made to combine radial and axial functionality, but with certain drawbacks. One approach requires magnetic control flux to flow through a bias magnet reducing control effectiveness, thus resulting in increased resistive losses. This approach also requires axial force producing magnetic flux to flow in a direction into the rotor laminate that is undesirable for minimizing eddy-current losses resulting in rotational losses. Another approach applies a conical rotor shape to what otherwise would be a radial heteropolar magnetic bearing configuration. However, positional non-linear effects are introduced with this scheme and the same windings are used for bias, radial, and axial control adding complexity to the controller and electronics. For this approach, the amount of axial capability must be limited. It would be desirable for an integrated radial and axial magnetic bearing to have the following characteristics; separate inputs for radial and axial control for electronics and control simplicity, all magnetic control fluxes should only flow through their respective air gaps and should not flow through any bias magnets for minimal resistive losses, be of a homopolar design to minimize rotational losses, position related non-linear effects should be minimized, and dependent upon the design parameters, be able to achieve any radial/axial force or power ratio as desired. The integrated radial and axial magnetic bearing described in this paper exhibits all these characteristics. Magnetic circuit design, design equations, and magnetic field modeling results will be presented.

Blumenstock, Kenneth↗
NASA NTRS2000

QuikSCAT Mission

The QuikSCAT Mission of the National Aeronautics and Space Administration (NASA) is planned for launch in Spring 1999, reducing the data gap in ocean-wind vector created by the loss of the NASA Scatterometer (NSCAT) on the Japanese Advanced Earth Observing Satellite (ADEOS) spacecraft. The NSCAT instrument ceased functioning when ADEOS failed on June 30, 1997. The follow-on scatterometer for monitoring ocean winds, called SeaWinds, is scheduled for launch on the Japanese ADEOS-II spacecraft in 2000. The Jet Propulsion Laboratory (JPL) has met the challenge to develop and integrate the instrument, ground system, and launch vehicle in less than a year. QuikSCAT will use pencil-beam-antennas in a conical-scan design which is more compact than the fixed fan-beam design of NSCAT. The antenna will radiate ku-band microwaves at 40 and 46 incident angle and measure the backscatter power across a continuous 1800 km swath. QuikSCAT is capable of providing wind-speed and wind-direction at 25 km resolution over 92 percent of the Earth's ice-free oceans every day, under both clear and cloudy conditions. Standard data products will be delivered to science users within 14-days, and fast data products will be available to operational users within two hours of data acquisition. QuikSCAT will be managed by JPL for the NASA's Office of Earth Science Enterprise. It will be launched from Vandenberg Air Force Base, aboard a Titan II vehicle. The satellite core-systems was built by Ball Aerospace Systems Division, Boulder, CO. The operation of QuikSCAT is expected to overlap with ERS-2 and SeaWinds. Spaceborne scatterometers have demonstrated a broad spectrum of scientific applications, including weather systems, wind-driven ocean circulation, land vegetation, polar ice morphology and dynamics, and Ocean-atmosphere-ice interaction.

Liu, W. Timothy↗