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Montague, Gerald

Publications and source records attributed to Montague, Gerald.

11 records
All sourcesNASA NTRSDOE OSTI
NASA NTRS2005

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.↗
NASA NTRS2005

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↗
NASA NTRS2004

High Speed, High Temperature, Fault Tolerant Operation of a Combination Magnetic-Hydrostatic Bearing Rotor Support System for Turbomachinery

Closed loop operation of a single, high temperature magnetic radial bearing to 30,000 RPM (2.25 million DN) and 540 C (1000 F) is discussed. Also, high temperature, fault tolerant operation for the three axis system is examined. A novel, hydrostatic backup bearing system was employed to attain high speed, high temperature, lubrication free support of the entire rotor system. The hydrostatic bearings were made of a high lubricity material and acted as journal-type backup bearings. New, high temperature displacement sensors were successfully employed to monitor shaft position throughout the entire temperature range and are described in this paper. Control of the system was accomplished through a stand alone, high speed computer controller and it was used to run both the fault-tolerant PID and active vibration control algorithms.

Jansen, Mark↗
NASA NTRS2004

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.↗
NASA NTRS2003

Control Study for Five-axis Dynamic Spin Rig Using Magnetic Bearings

The NASA Glenn Research Center (GRC) has developed a magnetic bearing system for the Dynamic Spin Rig (DSR) with a fully suspended shaft that is used to perform vibration tests of turbomachinery blades and components under spinning conditions in a vacuum. Two heteropolar radial magnetic bearings and a thrust magnetic bearing and the associated control system were integrated into the DSR to provide magnetic excitation as well as non-contact mag- netic suspension of a 15.88 kg (35 lb) vertical rotor with blades to induce turbomachinery blade vibration. For rotor levitation, a proportional-integral-derivative (PID) controller with a special feature for multidirectional radial excitation worked well to both support and shake the shaft with blades. However, more advanced controllers were developed and successfully tested to determine the optimal controller in terms of sensor and processing noise reduction, smaller rotor orbits, more blade vibration amplitude, and energy savings for the system. The test results of a variety of controllers that were demonstrated up to 10.000 rpm are shown. Furthermore, rotor excitation operation and conceptual study of active blade vibration control are addressed.

Choi, Benjamin↗
NASA NTRS2003

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↗
NASA NTRS2003

High-Temperature Switched-Reluctance Electric Motor

An eight-pole radial magnetic bearing has been modified into a switched-reluctance electric motor capable of operating at a speed as high as 8,000 rpm at a temperature as high as 1,000 F (=540 C). The motor (see figure) is an experimental prototype of starter-motor/generator units that have been proposed to be incorporated into advanced gas turbine engines and that could operate without need for lubrication or active cooling. The unique features of this motor are its electromagnet coils and, to some extent, its control software. Heretofore, there has been no commercial-off-the-shelf wire capable of satisfying all of the requirements for fabrication of electromagnet coils capable of operation at temperatures up to 1,000 F (=540 C). The issues addressed in the development of these electromagnet coils included thermal expansion, oxidation, pliability to small bend radii, micro-fretting, dielectric breakdown, tensile strength, potting compound, thermal conduction, and packing factor. For a test, the motor was supported, along with a rotor of 18 lb (.8-kg) mass, 3-in. (.7.6-cm) diameter, 21-in. (.53-cm) length, on bearings packed with high-temperature grease. The motor was located at the mid span of the rotor and wrapped with heaters. The motor stator was instrumented with thermocouples. At the time of reporting the information for this article, the motor had undergone 14 thermal cycles between room temperature and 1,000 F (.540 C) and had accumulated operating time >27.5 hours at 1,000 F (=540 C). The motor-controller hardware includes a personal computer equipped with analog-to-digital input and digital-to-analog output cards. The controller software is a C-language code that implements a switched-reluctance motor-control principle: that is, it causes the coils to be energized in a sequence timed to generate a rotating magnetic flux that creates a torque on a scalloped rotor. The controller can operate in an open- or closed-loop mode. In addition, the software has been modified to enable the simultaneous operation of the prototype motor or another, similar apparatus as both a motor and a magnetic bearing. Combined bearing/motor operation has been demonstrated at room temperature but had not yet been demonstrated at high temperature at the time of reporting the information for this article.

Montague, Gerald↗
NASA NTRS2002

Room Temperature Characterization of a Magnetic Bearing for Turbomachinery

Open loop, experimental force and power measurements of a three-axis, radial, heteropolar magnetic bearing at room temperature for rotor speeds up to 20,000 RPM are presented in this paper. The bearing, NASA Glenn Research Center's and Texas A&M's third generation high temperature magnetic bearing, was designed to operate in a 1000 F (540 C) environment and was primarily optimized for maximum load capacity. The experimentally measured force produced by one C-core of this bearing was 630 lb. (2.8 kN) at 16 A, while a load of 650 lbs (2.89 kN) was predicted at 16 A using 1D circuit analysis. The maximum predicted radial load for one of the three axes is 1,440 lbs (6.41 kN) at room temperature. The maximum measured load of an axis was 1050 lbs. (4.73 kN). Results of test under rotating conditions showed that rotor speed has a negligible effect on the bearing's load capacity. A single C-core required approximately 70 W of power to generate 300 lb (1.34 kN) of magnetic force. The room temperature data presented was measured after three thermal cycles up to 1000 F (540 C), totaling six hours at elevated temperatures.

Montague, Gerald↗
NASA NTRS2002

Flywheel Magnetic Suspension Developments

The paper provides an overview of many areas of the flywheel magnetic suspension (MS) R&D being performed at the Texas A&M Vibration Control and Electromechanics Lab (TAMU-VCEL). This includes system response prediction, actuator optimization and redundancy, controller realizations and stages, sensor enhancements and backup bearing reliability.

Palazzolo, Alan↗
NASA NTRS1990

Use of piezoelectric actuators in active vibration control of rotating machinery

Theoretical and test results for the development of piezoelectric-actuator-based active vibration control (AVC) are presented. The evolution of this technology starts with an ideal model of the actuator and progresses to a more sophisticated model where the pushers force the squirrel cage ball bearing supports of a rotating shaft. The piezoelectric pushers consist of a stack of piezoelectric ceramic disks that are arranged on top of one another and connected in parallel electrically. This model consists of a prescribed displacement that is proportional to the input voltage and a spring that represents the stiffness of the stack of piezoelectric disks. System tests were carried out to stabilize the AVC system, verify its effectiveness in controlling vibration, and confirm the theory presented.

Lin, Reng Rong↗