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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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All sourcesNASA NTRSDOE OSTI
NASA NTRS2003

Flywheels Upgraded for Systems Research

With the advent of high-strength composite materials and microelectronics, flywheels are becoming attractive as a means of storing electrical energy. In addition to the high energy density that flywheels provide, other advantages over conventional electrochemical batteries include long life, high reliability, high efficiency, greater operational flexibility, and higher depths of discharge. High pulse energy is another capability that flywheels can provide. These attributes are favorable for satellites as well as terrestrial energy storage applications. In addition to energy storage for satellites, the several flywheels operating concurrently can provide attitude control, thus combine two functions into one system. This translates into significant weight savings. The NASA Glenn Research Center is involved in the development of this technology for space and terrestrial applications. Glenn is well suited for this research because of its world-class expertise in power electronics design, rotor dynamics, composite material research, magnetic bearings, and motor design and control. Several Glenn organizations are working together on this program. The Structural Mechanics and Dynamics Branch is providing magnetic bearing, controls, and mechanical engineering skills. It is working with the Electrical Systems Development Branch, which has expertise in motors and generators, controls, and avionics systems. Facility support is being provided by the Space Electronic Test Engineering Branch, and the program is being managed by the Space Flight Project Branch. NASA is funding an Aerospace Flywheel Technology Development Program to design, fabricate, and test the Attitude Control/Energy Storage Experiment (ACESE). Two flywheels will be integrated onto a single power bus and run simultaneously to demonstrate a combined energy storage and 1-degree-of-freedom momentum control system. An algorithm that independently regulates direct-current bus voltage and net torque output will be experimentally demonstrated.

Jansen, Ralph H.↗
DOE OSTI2024

The Simons Observatory: Cryogenic half wave plate rotation mechanism for the small aperture telescopes

We present the requirements, design, and evaluation of the cryogenic continuously rotating half-wave plate (CHWP) for the Simons Observatory (SO). SO is a cosmic microwave background polarization experiment at Parque Astronómico de Atacama in northern Chile that covers a wide range of angular scales using both small (Ø0.42 m) and large (Ø6 m) aperture telescopes. In particular, the small aperture telescopes (SATs) focus on large angular scales for primordial B-mode polarization. To this end, the SATs employ a CHWP to modulate the polarization of the incident light at 8 Hz, suppressing atmospheric 1/f noise and mitigating systematic uncertainties that would otherwise arise due to the differential response of detectors sensitive to orthogonal polarizations. The CHWP consists of a 505 mm diameter achromatic sapphire HWP and a cryogenic rotation mechanism, both of which are cooled down to ~50 K to reduce detector thermal loading. Under normal operation, the HWP is suspended by a superconducting magnetic bearing and rotates with a constant 2 Hz frequency, controlled by an electromagnetic synchronous motor. We find that the number of superconductors and the number of magnets that make up the superconducting magnetic bearing are important design parameters, especially for the rotation mechanism’s vibration performance. The rotation angle is detected through an angular encoder with a noise level of 0.07 μrad √ $\overline{s}$. During a cooldown process, the rotor is held in place by a grip-and-release mechanism that serves as both an alignment device and a thermal path. In this paper, we provide an overview of the SO SAT CHWP: its requirements, hardware design, and laboratory performance.

47 OTHER INSTRUMENTATION↗
NASA NTRS1991

The Rocketdyne Multifunction Tester. Part 1: Test Method

The Rocketdyne Multifunction Tester is a general purpose test apparatus which utilizes axial and radial magnetic bearings as shaft excitation devices. The tester is modular in design so that different seal and bearing packages can be tested on the same test stand. The tester will be used for rotordynamic coefficient extraction, as well as life and fluid/material compatibility evaluations. Use of a magnetic bearing as a shaft excitation device opens up many possibilities for shaft excitation and rotordynamic coefficient extraction. In addition to describing the basic apparatus, some of the excitation and extraction methods are described. Some of the excitation methods to be discussed include random, aperiodic, harmonic, impulse and chirp.

Murphy, Brian T.↗
NASA NTRS1979

A distributed system adaptive control strategy

One attitude control device being studied for large spacecraft consists of two counter-rotating rings, each designated as an annular momentum control device (AMCD), that are attached to a spacecraft using several magnetic bearings distributed along the circumference of the rings. For large spacecraft large rings are desirable. Unfortunately, for large rings flexibility is appreciable and it becomes necessary to account for the distributed nature of the rings in the design of the magnetic bearing controllers. Also ring behavior is unpredictably sensitive to ring temperature, spin rate, manufacturing imperfections, and other variables. For that reason a distributed adaptive microcomputer-based control system is being sought for ring stabilization and maneuvering. An original adaptive-control methodology for distributed-parameter systems is detailed and application to spinning ring, i.e., AMCD, stabilization is used as an illustration. The proposed methodology, presented as a step-by-step procedure, combines a lumped-parameter expansion description of distributed parameter systems with a fundamental simultaneous identification and control strategy. Simulations are presented providing preliminary evidence of the capabilities of the proposed procedure.

Johnson, C. R., Jr.↗
NASA NTRS1994

In Operation Detection and Correction of Rotor Imbalance in Jet Engines Using Active Vibration Control

Jet Engines may experience severe vibration due to the sudden imbalance caused by blade failure. This research investigates employment of on board magnetic bearings or piezoelectric actuators to cancel these forces in flight. This operation requires identification of the source of the vibrations via an expert system, determination of the required phase angles and amplitudes for the correction forces, and application of the desired control signals to the magnetic bearings or piezo electric actuators. This paper will show the architecture of the software system, details of the control algorithm used for the sudden imbalance correction project described above, and the laboratory test results.

Manchala, Daniel W.↗
NASA NTRS2007

Electromagnetic Radial Forces in a Hybrid Eight-Stator-Pole, Six-Rotor-Pole Bearingless Switched-Reluctance Motor

Analysis and experimental measurement of the electromagnet force loads on the hybrid rotor in a novel bearingless switched-reluctance motor (BSRM) have been performed. A BSRM has the combined characteristics of a switched-reluctance motor and a magnetic bearing. The BSRM has an eight-pole stator and a six-pole hybrid rotor, which is composed of circular and scalloped lamination segments. The hybrid rotor is levitated using only one set of stator poles. A second set of stator poles imparts torque to the scalloped portion of the rotor, which is driven in a traditional switched reluctance manner by a processor. Analysis was done for nonrotating rotor poles that were oriented to achieve maximum and minimum radial force loads on the rotor. The objective is to assess whether simple one-dimensional magnetic circuit analysis is sufficient for preliminary evaluation of this machine, which may exhibit strong three-dimensional electromagnetic field behavior. Two magnetic circuit geometries, approximating the complex topology of the magnetic fields in and around the hybrid rotor, were employed in formulating the electromagnetic radial force equations. Reasonable agreement between the experimental results and the theoretical predictions was obtained with typical magnetic bearing derating factors applied to the predictions.

Morrison, Carlos R.↗
NASA NTRS2002

Energy Storage Flywheels on Spacecraft

With advances in carbon composite material, magnetic bearings, microprocessors, and high-speed power switching devices, work has begun on a space qualifiable Energy Momentum Wheel (EMW). An EMW is a device that can be used on a satellite to store energy, like a chemical battery, and manage angular momentum, like a reaction wheel. These combined functions are achieved by the simultaneous and balanced operation of two or more energy storage flywheels. An energy storage flywheel typically consists of a carbon composite rotor driven by a brushless DC motor/generator. Each rotor has a relatively large angular moment of inertia and is suspended on magnetic bearings to minimize energy loss. The use of flywheel batteries on spacecraft will increase system efficiencies (mass and power), while reducing design-production time and life-cycle cost. This paper will present a discussion of flywheel battery design considerations and a simulation of spacecraft system performance utilizing four flywheel batteries to combine energy storage and momentum management for a typical LEO satellite. A proposed set of control laws and an engineering animation will also be presented. Once flight qualified and demonstrated, space flywheel batteries may alter the architecture of most medium and high-powered spacecraft.

Bartlett, Robert O.↗
NASA NTRS2004

Resolving the Issues with Flywheel Position Sensors

For the past few years, the Advanced Electrical Systems Branch here at NASA Glenn has been pursuing research in the area of flywheels. The purpose of these pursuits has been t o explore the potential for flywheels to replace current battery-powered systems in space. So far it has been learned that flywheels offer large momentum storage capacity, comparatively small volume, high durability, and near- complete discharge capabilities, all of which are advancements over the existing nickel hydrogen and nickel cadmium batteries. Another significant advantage of flywheels is the potential they offer for combining the function of attitude control with energy storage. During the summer of 2004, I worked with Dr. Barbara Kenny in the Advanced Electrical Systems Branch, supporting the work she is doing by analyzing and testing some new components for the new Generation-2 flywheel. To monitor the speed and angular position of the flywheel rotor, a once-around (OAR) signal along with a sensorless algorithm is used. The OAR signal is used for the magnetic bearings that keep the flywheel suspended for frictionless operation. The sensorless algorithm is used for the flywheel motor/generator control. The OAR is generated from position sensors that monitor a circular plate. The plate has a cut down the middle such that one half of the circle is on a slightly lower level than the other. Every half-turn, or 180, the sensors detect the "cut" on the plate, and trigger the OAR, telling the computer that the rotor has made half a revolution. This, however, doesn't provide needed detailed information about the angular position of the rotor, since it only provides a signal alert every half- revolution. This is enough information for the magnetic bearing control but is insufficient for the motor/generator control. A new resolver was designed such that it would give continuous angle information rather than the 180 degree information of the OAR. The new resolver has two separate observable pieces: a flat middle section to monitor vertical motion, and an angled section around the circumference, which, when observed from above, produces a sine-wave displacement through the entire 360" revolution. My first job when I arrived this summer was to calibrate the sensors that would be mounted on the inside of the flywheel casing to monitor the position (angular and vertical) of the shaft. After calibration, I used the sensors to evaluate voltage outputs created by position differences between two pairs of sensors on the angled portion of the resolver for eight different angular positions, moving the resolver vertically and laterally through its entire potential range of motion. The results of these tests will be used to determine the rotor angular (and axial) position from the sensor readings once the new flywheel unit is assembled. The sensorless algorighm mentioned above consists of two operations: the signal injection method and the back electro-motive force (EMF). The signal injection is meant to work at low speeds, while the back EMF algorithm is meant to work at higher speeds. Both work together to determine the correct estimate of rotor position and speed based on the measured motor/generator current. It was determined that we wanted to know exactly how accurate our estimation methods were, and so a resolver (a commercially available mechanical sensor mounted to the motor/generator shaft to measure rotor position and speed) and a "Resolver to Digital" (R2D) circuit board was purchased to make the comparison to the existing estimation. My work related to the R2D board has included the following: creating two connector cables (one to power the circuit and one to get readable output off the board), writing Simulink code to process the board's output, and building a dSpace panel to control and monitor the circuit. The next step in the process will be to perform tests to compare the estimated rotor position and speed from the sensorless algorithm to the actual rotor and speed from the resolver signal.

Fehrmann, Elizabeth A.↗
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 NTRS1999

A Spherical Earth Solution for TOA Lightning Location Retrieval

With the advent of high-speed digital computers, the method of chi square minimization is a highly practical means for analyzing a wide variety of (otherwise intractable) nonlinear inversion problems in applied mathematical physics. Little thought or effort is required to apply the chi square method to obtain quick and reasonable estimates of a solution, and the method offers a means to assess retrieval errors. Because the method is simple and practical it is sometimes hastily applied to problems that can be solved by formal analytic or quasi-analytic means. Presently, Global Atmospherics Inc. (GAI) finds the minimum of a chi square function to analyze time-of-arrival (TOA) and magnetic bearing data derived from the National Lightning Detection Network (NLDN); ellipsoidal Earth geometry is assumed. An analytic solution to this problem has not yet been attained, but the consideration and solving of less general problem statements might eventually lead to a final solution. In the present study, the problem of retrieving lightning ground-strike location on a spherical Earth surface using a network of 4 or more time-of-arrival (TOA) sensors is considered. It is shown that this problem has an analytic solution and therefore does not require the use of nonlinear estimation theory (such as the chi square method mentioned above). The mathematical robustness of the analytic solution is tested using computer-generated lightning sources and simulated TOA measurement errors. A quasi-analytic extension of the spherical Earth solution for an oblate spheroidal Earth geometry is considered in a related study. The incorporation of magnetic bearing information into these analytic solutions would lead to a general and elegant analytic retrieval scheme that would most likely replace the chi square estimation theory currently employed by Global Atmospherics Inc. (GAI).

Koshak, William J,↗
NASA NTRS1996

Magnetically Suspended Linear Pulse Motor for Semiconductor Wafer Transfer in Vacuum Chamber

This paper describes a magnetically suspended linear pulse motor for a semiconductor wafer transfer robot in a vacuum chamber. The motor can drive a wafer transfer arm horizontally without mechanical contact. In the construction of the magnetic suspension system, four pairs of linear magnetic bearings for the lift control are used for the guidance control as well. This approach allows us to make the whole motor compact in size and light in weight. The tested motor consists of a double-sided stator and a transfer arm with a width of 50 mm and a total length of 700 mm. The arm, like a ladder in shape, is designed as the floating element with a tooth width of 4 mm (a tooth pitch of 8 mm). The mover mass is limited to about 1.6 kg by adopting such an arm structure, and the ratio of thrust to mover mass reaches to 3.2 N/kg under a broad air gap (1 mm) between the stator teeth and the mover teeth. The performance testing was carried out with a transfer distance less than 450 mm and a transfer speed less than 560 mm/s. The attitude of the arm was well controlled by the linear magnetic bearings with a combined use, and consequently the repeatability on the positioning of the arm reached to about 2 micron. In addition, the positioning accuracy was improved up to about 30 micron through a compensation of the 128-step wave current which was used for the micro-step drive with a step increment of 62.5 micron.

Moriyama, Shin-Ichi↗
NASA NTRS2007

Control Code for Bearingless Switched-Reluctance Motor

A computer program has been devised for controlling a machine that is an integral combination of magnetic bearings and a switched-reluctance motor. The motor contains an eight-pole stator and a hybrid rotor, which has both (1) a circular lamination stack for levitation and (2) a six-pole lamination stack for rotation. The program computes drive and levitation currents for the stator windings with real-time feedback control. During normal operation, two of the four pairs of opposing stator poles (each pair at right angles to the other pair) levitate the rotor. The remaining two pairs of stator poles exert torque on the six-pole rotor lamination stack to produce rotation. This version is executable in a control-loop time of 40 s on a Pentium (or equivalent) processor that operates at a clock speed of 400 MHz. The program can be expanded, by addition of logic blocks, to enable control of position along additional axes. The code enables adjustment of operational parameters (e.g., motor speed and stiffness, and damping parameters of magnetic bearings) through computer keyboard key presses.

Morrison, Carlos R.↗
DOE OSTI2014

Overview of Air Liquide refrigeration systems between 1.8 K and 200 K

Cryogenic refrigeration systems are necessary for numerous applications. Gas purification and distillation require temperatures between 15 K and 200 K depending on the application, space simulation chambers down to 15 K, superconductivity between 1.8 K and up to 75 K (magnets, cavities or HTS devices like cables, FCL, SMES, etc), Cold Neutron Sources between 15 and 20 K, etc. Air Liquide Advanced Technologies is designing and manufacturing refrigerators since 60 years to satisfy those needs. The step by step developments achieved have led to machines with higher efficiency and reliability. In 1965, reciprocating compressors and Joule Thomson expansion valves were used. In 1969, centripetal expanders began to be used. In 1980, oil lubricated screw compressors took the place of reciprocating compressors and a standard range of Claude cycle refrigerators was developed: the HELIAL series. 1980 was also the time for cryogenic centrifugal compressor development. In 2011, driven by the need for lower operational cost (high efficiency and low maintenance), cycle oil free centrifugal compressors on magnetic bearings were introduced instead of screw compressors. The power extracted by centripetal expanders was recovered. Based on this technology, a range of Turbo-Brayton refrigerators has been designed for temperatures between 40 K and 150 K. On-going development will enable widening the range of Turbo-Brayton refrigerators to cryogenic temperatures down to 15 K.. Cryogenic centrifugal circulators have been developed in order to answer to an increasing demand of 4 K refrigerators able to distribute cold power.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
NASA NTRS1980

Superconducting bearings for application in cryogenic experiments in space

Linear superconducting magnetic bearings suitable for use in a proposed orbital equivalence principle experiment and for general application in space were developed and tested. Current flows in opposite directions in adjacent superconducting wires arranged parallel to the axis of a cylinder. This configuration provides maximum stiffness radially while allowing the test mass to move freely along the cylinder axis. In a space application, the wires are extended to cover the entire perimeter of the cylinder: for the earth-based tests it was desirable to use only the bottom half. Control of the axial position of the test mass is by small control coils which may be positioned inside or outside the main bearing. The design is suitable for application to other geometries where maximum stiffness is desired. A working model scaled to operate in a 1-g environment was perfected approximate solutions for the bearings were developed. A superconducting transformer method of charging the magnets for the bearing, and a position detector based on a SQUID magnetometer and associated superconducting circuit were also investigated.

Everitt, C. W. F.↗
NASA NTRS1998

Magnetic Suspension Technology Development

This Cooperative Agreement, intended to support focused research efforts in the area of magnetic suspension systems, was initiated between NASA Langley Research Center (LaRC) and Old Dominion University (ODU) starting January 1, 1997. The original proposal called for a three-year effort, but funding for the second year proved to be unavailable, leading to termination of the agreement following a 5-month no-cost extension. This report covers work completed during the entire 17-month period of the award. This research built on work that had taken place over recent years involving both NASA LARC and the Principal Investigator (PI). The research was of a rather fundamental nature, although specific applications were kept in mind at all times, such as wind tunnel Magnetic Suspension and Balance Systems (MSBS), space payload pointing and vibration isolation systems, magnetic bearings for unconventional applications, magnetically levitated ground transportation and electromagnetic launch systems. Fundamental work was undertaken in areas such as the development of optimized magnetic configurations, analysis and modelling of eddy current effects, control strategies for magnetically levitated wind tunnel models and system calibration procedures. Despite the termination of this Cooperative Agreement, several aspects of the research work are currently continuing with alternative forms of support.

Britcher, Colin↗
NASA NTRS1984

Design of electromagnetic bearing for vibration control of flexible transmission shaft

Recently magnetic bearings were proposed by several researchers and shown to be viable on a variety of rotor assemblies. The design and construction of such a bearing, which employs features hitherto not used by other workers is examined. These include an original approach to the design of the electromagnets and their amplifiers, and to software in a digital control system, to condition the control signals so as to make the magnets appear to be linear and uncoupled. The resulting system is used to control a rotor-bearing assembly, whose speed range covers two flexural-critical speeds.

Gondhalekar, V.↗
NASA NTRS1979

Magnetic suspension system for a laboratory model annular momentum control device

Feasibility of the annular momentum control device (AMCD) for the control and stabilization of spacecraft is presented. The AMCD is momentum storage equipment consisting of a thin rim, magnetically suspended and rotated by noncontacting electromagnetic actuators. The laboratory model AMCD, the rim, and the magnetic suspension system are described, along with their evaluation tests. Because it utilizes permanent magnet flux biased magnetic bearing elements, the original laboratory model magnetic suspension system produced control limitations, and a new suspension system which used zero flux bias was designed and fabricated. Tests of the improved system show that a medium control loop bandwidth is required to achieve stability at low rim velocities, but at higher rim speed the bandwidth of the control loop interacts with bending modes of the rim and causes instability. Decreasing the bandwidth by changing to a precession control mode is discussed, and the results of such a computer simulation are presented.

Groom, N. J.↗
NASA NTRS1983

A magnetically suspended linearly driven cryogenic refrigerator

This paper described a novel Stirling cycle cryogenic refrigerator which was designed, fabricated and successfully tested at Philips Laboratories. The prominent features of the machine are an electro-magnetic bearing system, a pair of moving magnet linear motors, and clearance seals with a 25 mu m radial gap. The all-metal and ceramic construction eliminates long-term organic contamination of the helium working fluid. The axial positions of the piston and displacer are electronically controlled, permitting independent adjustment of the amplitude of each and their relative phase relationship during operation. A simple passive counterbalance reduces axial vibrations. The design of the refrigerator system components is discussed and a comparison is made between performance estimates and measured results.

Stolfi, F.↗