HEATheR: High-Efficiency Electrified Aircraft Thermal Research
Presentation overview of Convergent Aeronautics Solutions - High-Efficiency Electrified Aircraft Thermal Research.
Jansen, Ralph↗
Engineering topics
Jansen, Ralph
Publications and source records attributed to Jansen, Ralph.
Creating a Multifunctional Composite Stator Slot Material System to Enable High Power Density Electric Machines for Electrified Aircraft Applications
Increasing the power density and efficiency of electric machines (motors and generators) is integral to bringing Electrified Aircraft (EA) to commercial realization. However, power density and efficiency are not qualities that can be developed independently. At the heart of any electric machine are the conductors (usually copper) that carry current and generate magnetic fields. Increased power density means increased current density and increased joule heating in a smaller volume. To increase efficiency at the wire level means minimizing electrical resistance and hence power lost to joule heating. There are fundamental challenges with concomitantly increasing both power density and efficiency since the copper resistivity is very temperature sensitive at common electric machine operating conditions. Simple calculations of the linear increase in resistivity of copper as a function of temperature, reveals that a one degree Celsius increase in temperature results in a 0.39% decrease in efficiency. Conversely, a 20 degree Celsius decrease in copper temperature produces a 7.8% increase in efficiency. Therefore, improved thermal management concepts for electric machine building blocks such as stator winding are a priority for improving efficiency and power density. This paper proposing changing the view of component materials in the stator slots from individual components with singular functionality to a composite system where the components take on a multifunctional roles. In the composite framework, achievable material development goals are defined that together have maximum system impact on the thermal environment inside of high power density electric machines for aerospace applications.
thermal management↗
Building Blocks for Transport-Class Hybrid and Turboelectric Vehicles
NASA has been investing in research efforts to define potential vehicles that use hybrid and turboelectric propulsion to enable savings in fuel burn and carbon usage. This paper overviews the fundamental building blocks that have been derived from those studies and details what key performance parameters have been defined, what key ground and flight tests need to occur, and highlights progress toward each.
hybrid electric turboelectric aircraft elecric mac↗
Hybrid Electric Propulsion Technologies for Commercial Transports
NASA Aeronautics Research Mission Directorate has set strategic research thrusts to address the major drivers of aviation such as growth in demand for high-speed mobility, addressing global climate and capitalizing in the convergence of technological advances. Transitioning aviation to low carbon propulsion is one of the key strategic research thrust and drives the search for alternative and greener propulsion system for advanced aircraft configurations. This work requires multidisciplinary skills coming from multiple entities. The Hybrid Gas-Electric Subproject in the Advanced Air Transportation Project is energizing the transport class landscape by accepting the technical challenge of identifying and validating a transport class aircraft with net benefit from hybrid propulsion. This highly integrated aircraft of the future will only happen if airframe expertise from NASA Langley, modeling and simulation expertise from NASA Ames, propulsion expertise from NASA Glenn, and the flight research capabilities from NASA Armstrong are brought together to leverage the rich capabilities of U.S. Industry and Academia.
electric motor vehicles↗
Key Performance Parameter Driven Technology Goals for Electric Machines and Power Systems
Transitioning aviation to low carbon propulsion is one of the crucial strategic research thrust and is a driver in the search for alternative propulsion system for advanced aircraft configurations. This work requires multidisciplinary skills coming from multiple entities. The feasibility of scaling up various electric drive system technologies to meet the requirements of a large commercial transport is discussed in terms of key parameters. Functional requirements are identified that impact the power system design. A breakeven analysis is presented to find the minimum allowable electric drive specific power and efficiency that can preserve the range, initial weight, operating empty weight, and payload weight of the base aircraft.
Electric Machines↗
Turboelectric Aircraft Drive Key Performance Parameters and Functional Requirements
The purpose of this presentation is to propose specific power and efficiency as the key performance parameters for a turboelectric aircraft power system and investigate their impact on the overall aircraft. Key functional requirements are identified that impact the power system design. Breguet range equations for a base aircraft and a turboelectric aircraft are found. The benefits and costs that may result from the turboelectric system are enumerated. A break-even analysis is conducted to find the minimum allowable electric drive specific power and efficiency that can preserve the range, initial weight, operating empty weight, and payload weight of the base aircraft.
aircraft engines↗
Partnering with NASA's Glenn Research Center on Flywheels for Energy Storage
No abstract available
Dever, Timothy↗
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↗
Five-Axis, Three-Magnetic-Bearing Dynamic Spin Rig
The Five-Axis, Three-Magnetic-Bearing Dynamic Spin Rig is an apparatus for vibration testing of turbomachine blades in a vacuum at rotational speeds from 0 to 40,000 rpm. This rig includes (1) a vertically oriented shaft on which is mounted an assembly comprising a rotor holding the blades to be tested, (2) two actively controlled heteropolar radial magnetic bearings at opposite ends of the shaft, and (3) an actively controlled magnetic thrust bearing at the upper end of the shaft. This rig is a more capable successor to a prior apparatus, denoted the Dynamic Spin Rig (DSR), that included a vertically oriented shaft with a mechanical thrust bearing at the upper end and a single actively controlled heteropolar radial magnetic bearing at the lower end.
Morrison, Carlos R.↗
High-Temperature, High-Load-Capacity Radial Magnetic Bearing
A radial heteropolar magnetic bearing capable of operating at a temperature as high as 1,000 F (=540 C) has been developed. This is a prototype of bearings for use in gas turbine engines operating at temperatures and speeds much higher than can be withstood by lubricated rolling-element bearings. It is possible to increase the maximum allowable operating temperatures and speeds of rolling-element bearings by use of cooling-air systems, sophisticated lubrication systems, and rotor-vibration- damping systems that are subsystems of the lubrication systems, but such systems and subsystems are troublesome. In contrast, a properly designed radial magnetic bearing can suspend a rotor without contact, and, hence, without need for lubrication or for cooling. Moreover, a magnetic bearing eliminates the need for a separate damping system, inasmuch as a damping function is typically an integral part of the design of the control system of a magnetic bearing. The present high-temperature radial heteropolar magnetic bearing has a unique combination of four features that contribute to its suitability for the intended application: 1. The wires in its electromagnet coils are covered with an insulating material that does not undergo dielectric breakdown at high temperature and is pliable enough to enable the winding of the wires to small radii. 2. The processes used in winding and potting of the coils yields a packing factor close to 0.7 . a relatively high value that helps in maximizing the magnetic fields generated by the coils for a given supplied current. These processes also make the coils structurally robust. 3. The electromagnets are of a modular C-core design that enables replacement of components and semiautomated winding of coils. 4. The stator is mounted in such a manner as to provide stable support under radial and axial thermal expansion and under a load as large as 1,000 lb (.4.4 kN).
Provenza, Andrew↗
Single Axis Flywheel IPACS @1300W, 0.8 N-m
NASA Glenn Research Center is developing flywheels for space systems. A single axis laboratory version of an integrated power and attitude control (IPACs) system has been experimentally demonstrated. This is a significant step on the road to a flight qualified three axes IPACS system. The presentation outlines the flywheel development process at NASA GRC, the experimental hardware and approach, the IPACS control algorithm that was formulated and the results of the test program and then proposes a direction for future work. GRC has made progress on flywheel module design in terms of specific energy density and capability through a design and test program resulting in three flywheel module designs. Two of the flywheels are used in the 1D-IPACS experiment with loads and power sources to simulate a satellite power system. The system response is measured in three power modes: charge, discharge, and charge reduction while simultaneously producing a net output torque which could be used for attitude control. Finally, recommendations are made for steps that should be taken to evolve from this laboratory demonstration to a flight like system.
Jansen, Ralph↗
Control of a High Speed Flywheel System for Energy Storage in Space Applications
A novel control algorithm for the charge and discharge modes of operation of a flywheel energy storage system for space applications is presented. The motor control portion of the algorithm uses sensorless field oriented control with position and speed estimates determined from a signal injection technique at low speeds and a back EMF technique at higher speeds. The charge and discharge portion of the algorithm use command feed-forward and disturbance decoupling, respectively, to achieve fast response with low gains. Simulation and experimental results are presented demonstrating the successful operation of the flywheel control up to the rated speed of 60,000 rpm.
Kenny, Barbara H.↗
Demonstration of Single Axis Combined Attitude Control and Energy Storage Using Two Flywheels
The energy storage and attitude control subsystems of the typical satellite are presently distinct and separate. Energy storage is conventionally provided by batteries, either NiCd or NiH, and active attitude control is accomplished with control moment gyros (CMGs) or reaction wheels. An overall system mass savings can be realized if these two subsystems are combined using multiple flywheels for simultaneous kinetic energy storage and momentum transfer. Several authors have studied the control of the flywheels to accomplish this and have published simulation results showing the feasibility and performance. This paper presents the first experimental results showing combined energy storage and momentum control about a single axis using two flywheels.
Kenny, Barbara H.↗
Fully Suspended, Five-Axis, Three-Magnetic-Bearing Dynamic Spin Rig With Forced Excitation
The Five-Axis, Three-Magnetic-Bearing Dynamic Spin Rig, a significant advancement in the Dynamic Spin Rig (DSR), is used to perform vibration tests of turbomachinery blades and components under rotating and nonrotating conditions in a vacuum. The rig has as its critical components three magnetic bearings: two heteropolar radial active magnetic bearings and a magnetic thrust bearing. The bearing configuration allows full vertical rotor magnetic suspension along with a feed-forward control feature, which will enable the excitation of various natural blade modes in bladed disk test articles. The theoretical, mechanical, electrical, and electronic aspects of the rig are discussed. Also presented are the forced-excitation results of a fully levitated, rotating and nonrotating, unbladed rotor and a fully levitated, rotating and nonrotating, bladed rotor in which a pair of blades was arranged 180 degrees apart from each other. These tests include the bounce mode excitation of the rotor in which the rotor was excited at the blade natural frequency of 144 Hz. The rotor natural mode frequency of 355 Hz was discerned from the plot of acceleration versus frequency. For nonrotating blades, a blade-tip excitation amplitude of approximately 100 g/A was achieved at the first-bending critical (approximately 144 Hz) and at the first-torsional and second-bending blade modes. A blade-tip displacement of 70 mils was achieved at the first-bending critical by exciting the blades at a forced-excitation phase angle of 908 relative to the vertical plane containing the blades while simultaneously rotating the shaft at 3000 rpm.
Morrison, Carlos R.↗
PWM Switching Frequency Effects on Eddy Current Sensors for Magnetically Suspended Flywheel Systems
A flywheel magnetic bearing (MB) pulse width modulated power amplifier (PWM) configuration is selected to minimize noise generated by the PWMs in the flywheel position sensor system. Two types of noise are addressed: beat frequency noise caused by variations in PWM switching frequencies, and demodulation noise caused by demodulation of high order harmonics of the switching voltage into the MB control band. Beat frequency noise is eliminated by synchronizing the PWM switch frequencies, and demodulation noise is minimized by selection of a switching frequency which does not have harmonics at the carrier frequency of the sensor. The recommended MB PWM system has five synchronized PWMs switching at a non-integer harmonic of the sensor carrier.
Jansen, Ralph↗
A Flywheel Energy Storage System Demonstration for Space Applications
A novel control algorithm for the charge and discharge modes of operation of a flywheel energy storage system for space applications is presented. The motor control portion of the algorithm uses sensorless field oriented control with position and speed estimates determined from a signal injection technique at low speeds and a back EMF technique at higher speeds. The charge and discharge portion of the algorithm use command feed-forward and disturbance decoupling, respectively, to achieve fast response with low gains. Simulation and experimental results are presented.
Kenny, Barbara H.↗
Experimental High Temperature Characterization of a Magnetic Bearing for Turbomachinery
Open loop, experimental force and power measurements of a radial, redundant-axis, magnetic bearing at temperatures to 1000 F (538 C) and rotor speeds to 15,000 RPM along with theoretical temperature and force models are presented in this paper. The experimentally measured force produced by a single C-core using 22A was 600 lb. (2.67 kN) at room temperature and 380 lb. (1.69 kN) at 1000 F (538 C). These values were compared with force predictions based on a 1D magnetic circuit analysis and a thermal analysis of gap growth as a function of temperature. Tests under rotating conditions showed that rotor speed has a negligible effect on the bearing s load capacity. One C-core required approximately 340 W of power to generate 190 lb. (8.45 kN) of magnetic force at 1000 F (538 C); however the magnetic air gap was much larger than at room temperature. The data presented is after the bearing had already operated six thermal cycles and eleven total (not consecutive) hours at 1000 F (538 C).
Montague, Gerald↗