Engineering topics
Publications and source records attributed to Mclyman, W. T..
Report describes tests to characterize unwanted electric and magnetic fields, at frequencies up to few megahertz, radiated by two dc-to-dc converters, one 20-kHz square-wave converter; the other, a 33-kHz sine-wave converter. Part of effort to develop "quiet" power converter for use aboard spacecraft. Converter required to interfere minimally with delicate instruments measuring electric and magnetic fields.
Direct-current transducer withstands thermal and mechanical shocks. Operates from single, nominally 15-V power supply and nearly insensitive to both large variations in temperature and variations of as much as plus or minus 5 V in supply voltage. Its output voltage highly linear function of sensed current, with full-scale value of about 3 Vdc and offset of about 0.1 Vdc at 0 sensed current. Ruggedness of transducer due in large part to novel magnetic core, machined from solid block of nickel/iron high-permeability, low-hysteresis alloy.
Technique for winding toroidal inductor results in even spacing of windings around toroidal core. Heat-shrinkable tubing locks it in place. Shrinkable tubing not necessary to get good results. Minimizes proportion of leakage inductances, especially if core has relatively low permeability. Intended for use in power supply operating at frequency between 250 kHz and 2 MHz.
Improved rotary transformer for Inductosyn (or equivalent) shaft-position-indicating circuit has pair of ferrite cores instead of the solid-iron cores. Designed with view toward decreasing excitation power (to maximum allowable 2 W) supplied to shaft-position-indicating circuit to increase its output signal and make tracking system less vulnerable to electromagnetic interference.
A toroidal core is mounted on an alignment disc having uniformly distributed circumferential notches or holes therein. Wire is then wound about the toroidal core in a uniform pattern defined by the notches or holes. Prior to winding, the wire may be placed within shrink tubing. The shrink tubing is then wound about the alignment disc and core and then heat-shrunk to positively retain the wire in the uniform position on the toroidal core.
Regulating circuit maintains nearly-constant alternating current in sodium-vapor lamp. Regulator part of dc-to-ac inverter circuit used to supply power to street lamp from battery charged by solar-cell array.
Direct current sensed via saturable-core reactor. Transducer senses direct current magnetically, providing isolation between input and output. Detecting-and-isolating element saturable reactor, where input current passes through one-turn control coil. Provides output of 0 to 3 Vdc for input current of 0 to 15 Adc and consumes power of 22 mW at 10 Adc input. Input sensed magnetically, output electrically isolated from input.
Computer program eliminates trial and error. Determines size and number of strands of wire for low resistance at high frequency in switching power supplies.
Both pulsed and continuous outputs available. Switching power-supply circuit converts input power from two 9-V batteries in series to output of 5 Vdc regulated within 1.5 percent, either at continuous current of 5 mA or at current of 500 mA in 0.5-s pulses at 1-min intervals. Power supply is buck converter. Principle of operation inductive and capacitive filtering of controlled pulses of battery voltage.
Design procedure developed for dc-to-dc power converters with multiple outputs having inductors wound on common core. With common core, minimum load current consistent with good output regulation is lower, output regulation is improved, and total inductor size and weight is reduced.
The major considerations in the design of high frequency ac inductors are reviewed. Two methods for designing the inductor: the area product method and the core geometry method, are presented. The two major effects of the inductor air gap, fringing flux power loss and increase of inductance, are discussed. Equations for the inductor design and a step-by-step design procedure are given. The use of a lumped air gap or a distributed air gap are discussed and a comparison of the losses resulting from these gaps, together with experimental results are presented.
Many future satellites and spacecraft with spun and despun configurations will require the transfer of power across rotating interfaces in lieu of slip-rings and/or flexures. This is particularly true of spacecraft that have to demonstrate a long life expectancy. The rotary transformer has the desirable characteristics of high reliability and low noise, which qualify it as a potential replacement for slip rings. Development of a rotary power transformer follows the successful completion of a task to develop rotary signal-level transformers for the Galileo Spacecraft Project. The physical configuration of a rotary power transformer has a significant effect on its magnetic and electrical characteristics and therefore impacts the design of the dc/ac inverter driver. Important characteristics addressed during this development effort include: operating frequency, efficiency, transformer gap size, leakage inductance, and leakage flux. A breadboard inverter and rotary transformer were designed, fabricated and tested.
In a push-pull converter, switching transistors are protected from peak power stresses by a separate snubber circuit in parallel with each comprising a capacitor and an inductor in series, and a diode in parallel with the inductor. The diode is connected to conduct current of the same polarity as the base-emitter juction of the transistor so that energy stored in the capacitor while the transistor is switched off, to protect it against peak power stress, discharges through the inductor when the transistor is turned on, and after the capacitor is discharges through the diode. To return this energy to the power supply, or to utilize this energy in some external circuit, the inductor may be replaced by a transformer having its secondary winding connected to the power supply or to the external circuit.
Current spikes in a buck power converter due to commutating diode turn-off time are eliminated by using a tapped inductor in the converter with the tap connected to the switching transistor. The commutating diode is not in the usual place, but is instead connected to conduct current from one end of the tapped inductor remote from the load during the interval in which the transistor is not conducting. In the case of a converter having a center-tapped (primary and secondary) transformer between two switching power transistors operated in a push-pull mode and two rectifying diodes in the secondary circuit, current spikes due to transformer saturation are also eliminated by using a tapped inductor in the converter with the tap connected to the rectifying diodes and a diode connected to conduct current from one end of the tapped inductor remote from the load during the interval in which the transistors are not conducting.
Transformer transmits power and digital data across rotating interface. Array has many parallel data channels, each with potential l megabaud data rate. Ferrite-cored transformers are spaced along rotor; airgap between them reduces crosstalk.
Converting input ac to higher frequency reduce size and weight and makes possible unique kind of regulation. Since conversion frequency is above range of human hearing, supply generated on audible noise. It also exploits highfrequency conversion features to regulate its output voltage in novel way. Circuit is inherently short-circuit proof.
Improved manufacturing techniques make reproducible gaps and minimize cracking. Molded, unfired transformer cores are cut with thin saw and then fired. Hardened semicircular core sections are bonded together, placed in aluminum core box, and fluidized-coated. After winding is run over box, core is potted. Economical method significantly reduces number of rejects.
Circuit, employing tapped inductor to back-bias rectifying diodes and extra diode to cummutate current, minimizes current spikes that cause premature transistor failure in switching-regulator circuits.