Development of MgB2-Cabled Conductors for Fully Superconducting Rotating Electric Machines
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Philip C. Michael↗
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Reducing Coal Dust With Water Jets
Jets also cool and clean cutting equipment. Modular pick-and-bucket miner suffers from disadvantage: Creates large quantities of potentially explosive coal dust. Dust clogs drive chain and other parts and must be removed by hand. Picks and bucket lips become overheated by friction and be resharpened or replaced frequently. Addition of oscillating and rotating water jets to pick-and-bucket machine keeps down dust, cools cutting edges, and flushes machine. Rotating jets wash dust away from drive chain. Oscillating jets cool cutting surfaces. Both types of jet wet airborne coal dust; it precipitates.
Gangal, M. D.↗
New Representation of Bearings in LS-DYNA
Non-linear, dynamic, finite element analysis is used in various engineering disciplines to evaluate high-speed, dynamic impact and vibration events. Some of these applications require connecting rotating to stationary components. For example, bird impacts on rotating aircraft engine fan blades are a common analysis performed using this type of analysis tool. Traditionally, rotating machines utilize some type of bearing to allow rotation in one degree of freedom while offering constraints in the other degrees of freedom. Most times, bearings are modeled simply as linear springs with rotation. This is a simplification that is not necessarily accurate under the conditions of high-velocity, high-energy, dynamic events such as impact problems. For this reason, it is desirable to utilize a more realistic non-linear force-deflection characteristic of real bearings to model the interaction between rotating and non-rotating components during dynamic events. The present work describes a rolling element bearing model developed for use in non-linear, dynamic finite element analysis. This rolling element bearing model has been implemented in LS-DYNA as a new element, *ELEMENT_BEARING.
bearings↗
High-Performance Wireless Telemetry
Prior technology for machinery data acquisition used slip rings, FM radio communication, or non-real-time digital communication. Slip rings are often noisy, require much space that may not be available, and require access to the shaft, which may not be possible. FM radio is not accurate or stable, and is limited in the number of channels, often with channel crosstalk, and intermittent as the shaft rotates. Non-real-time digital communication is very popular, but complex, with long development time, and objections from users who need continuous waveforms from many channels. This innovation extends the amount of information conveyed from a rotating machine to a data acquisition system while keeping the development time short and keeping the rotating electronics simple, compact, stable, and rugged. The data are all real time. The product of the number of channels, times the bit resolution, times the update rate, gives a data rate higher than available by older methods. The telemetry system consists of a data-receiving rack that supplies magnetically coupled power to a rotating instrument amplifier ring in the machine being monitored. The ring digitizes the data and magnetically couples the data back to the rack, where it is made available. The transformer is generally a ring positioned around the axis of rotation with one side of the transformer free to rotate and the other side held stationary. The windings are laid in the ring; this gives the data immunity to any rotation that may occur. A medium-frequency sine-wave power source in a rack supplies power through a cable to a rotating ring transformer that passes the power on to a rotating set of electronics. The electronics power a set of up to 40 sensors and provides instrument amplifiers for the sensors. The outputs from the amplifiers are filtered and multiplexed into a serial ADC. The output from the ADC is connected to another rotating ring transformer that conveys the serial data from the rotating section to the stationary section. From there, a cable conveys the serial data to the remote rack, where it is reconditioned to logic level specifications, de-serialized, and converted back to analog. In the rotating electronics are code generators to indicate the beginning of files for data synchronization.
Griebeler, Elmer↗
Dynamics of Orbital Masses in an Unbalanced Rotor
Historically, orbital masses have been used as automatic balancers in rotating machines. However, in these applications, the masses are free to move and rotate with the rotor from zero to operating speeds. For gas turbine applications it is desirable for the orbital masses to be fixed and unmoving, until their release from a sudden unbalance at the operating speed, such as occurs from a blade-out event. The objective of this work is to develop the dynamical equations of motion for orbital masses on a rotating shaft. In subsequent work these equations will be incorporated into a rotor structural dynamics computer code and the feasibility of attenuating rotor unbalance response with orbital masses will be investigated.
Gallardo, Vicente↗
Variable force, eddy-current or magnetic damper
An object of the invention is to provide variable damping for resonant vibrations which may occur at different rotational speeds in the range of rpms in which a rotating machine is operated. A variable force damper in accordance with the invention includes a rotating mass carried on a shaft which is supported by a bearing in a resilient cage. The cage is attached to a support plate whose rim extends into an annular groove in a housing. Variable damping is effected by tabs of electrically conducting nonmagnetic material which extend radially from the cage. The tabs at an index position lie between the pole face of respective C shaped magnets. The magnets are attached by cantilever spring members to the housing.
Cunningham, R. E.↗
Acoustical Detection Of Leakage In A Combustor
Abnormal combustion excites characteristic standing wave. Acoustical leak-detection system gives early warning of failure, enabling operating personnel to stop combustion process and repair spray bar before leak grows large enough to cause damage. Applicable to engines, gas turbines, furnaces, and other machines in which acoustic emissions at known frequencies signify onset of damage. Bearings in rotating machines monitored for emergence of characteristic frequencies shown in previous tests associated with incipient failure. Also possible to monitor for signs of trouble at multiple frequencies by feeding output of transducer simultaneously to multiple band-pass filters and associated circuitry, including separate trigger circuit set to appropriate level for each frequency.
Puster, Richard L.↗
More About the Phase-Synchronized Enhancement Method
A report presents further details regarding the subject matter of "Phase-Synchronized Enhancement Method for Engine Diagnostics" (MFS-26435), NASA Tech Briefs, Vol. 22, No. 1 (January 1998), page 54. To recapitulate: The phase-synchronized enhancement method (PSEM) involves the digital resampling of a quasi-periodic signal in synchronism with the instantaneous phase of one of its spectral components. This resampling transforms the quasi-periodic signal into a periodic one more amenable to analysis. It is particularly useful for diagnosis of a rotating machine through analysis of vibration spectra that include components at the fundamental and harmonics of a slightly fluctuating rotation frequency. The report discusses the machinery-signal-analysis problem, outlines the PSEM algorithms, presents the mathematical basis of the PSEM, and presents examples of application of the PSEM in some computational simulations.
Jong, Jen-Yi↗
Systems and methods for self-synchronized digital sampling
Systems and methods for self-synchronized data sampling are provided. In one embodiment, a system for capturing synchronous data samples is provided. The system includes an analog to digital converter adapted to capture signals from one or more sensors and convert the signals into a stream of digital data samples at a sampling frequency determined by a sampling control signal; and a synchronizer coupled to the analog to digital converter and adapted to receive a rotational frequency signal from a rotating machine, wherein the synchronizer is further adapted to generate the sampling control signal, and wherein the sampling control signal is based on the rotational frequency signal.
Samson, Jr., John R.↗
A Review of Superconducting Electric Machines with On-Board Cryocoolers
This paper reviews the evolution and emerging direction of superconducting electric machines that employ onboard cryocoolers integrated directly into the rotor, eliminating the need for cryogenic fluid coupling and, in some cases, rotary seals. Traditional low-temperature superconducting (LTS) machines relied on external cryogenic systems and liquid helium transfer couplers, which introduced excessive complexity, poor reliability, and significant parasitic energy losses. The advent of high-temperature superconductors (HTS) has enabled compact, closed-cycle cryocoolers that support self-contained, fluid-free refrigeration architectures suitable for rotating applications. This paper examines the key technological challenges associated with on-board cryocooler integration and reviews three representative efforts by KAIST, NASA, and Hinetics, each illustrating distinct strategies and milestones toward practical implementation. KAIST demonstrated early proof-of-concept for rotating machines with on-board cryocoolers, NASA developed a shaft-integrated Stirling-type pulse tube cryocooler for a 1.4 MW hybrid-electric motor, and Hinetics achieved full-scale validation of a self-contained HTS rotor incorporating a commercial Stirling cryocooler and spoke-suspension torque tube. Collectively, these achievements confirm the technical feasibility of on-board cryogenic refrigeration and highlight steady progress toward compact and efficient superconducting rotating systems across various applications. Embedding cryocoolers directly within the rotor enables practical, efficient, and commercially viable superconducting propulsion technologies.
Cryogenics↗
Shaft mode shape demonstration
The dynamic response of a rotating machine is directly influenced by its geometric configuration and all aspects of the rotor construction. These determine two significant parameters, mass distribution and stiffness, which yield a spectrum of natural frequencies and mode shapes. The mode shapes can be presented as snapshots of the characteristic amplitude/phase reponse patterns of the shaft, due to the major forcing function of unbalance, at different rotative speeds. To demonstrate the three shaft mode shapes of the rotor rig using the Shaft Mode Demonstrator and oscilloscopes. The synchronous (1X) amplitude and phase of the rotor vibration in the vertical direction from several points along the shaft is displayed on corresponding points of the demonstrator. Unfiltered vibration from vertical and horizontal probe pairs is displayed on the oscilloscopes in orbit format for a dynamic presentation of the mode shape.
Grissom, R.↗
Fiber-Optic Sensor Would Detect Movements Of Shaft
Fiber-optic sensor senses both rotational speed and axial displacement of shaft in motor, pump, or other rotating machine. Does not require magnetic materials, notches, or grooves in shaft. Required modification of shaft is etching or plating surface to make ring black around half circumference and reflective around other half along short length at one end or some other convenient location. Triangular bundle of sending and receiving optical fibers aimed at black/reflective ring on shaft. Frequency and amplitude of output pulses of fiber-optic probe indicates rotational frequency and axial position of shaft.
Roschak, Edmund J.↗
Stabilizing Gyroscopic Modes in Magnetic-Bearing-Supported Flywheels by Using Cross-Axis Proportional Gains
For magnetic-bearing-supported high-speed rotating machines with significant gyroscopic effects, it is necessary to stabilize forward and backward tilt whirling modes. Instability or low damping of these modes can prevent the attainment of desired shaft speed. We show analytically that both modes can be stabilized by using cross-axis proportional gains and high- and low-pass filters in the magnetic bearing controller. Furthermore, at high shaft speeds, where system phase lags degrade the stability of the forward-whirl mode, a phasor advance of the control signal can partially counteract the phase lag. In some range of high shaft speed, the derivative gain for the tilt modes (essential for stability for slowly rotating shafts) can be removed entirely. We show analytically how the tilt eigenvalues depend on shaft speed and on various controller feedback parameters.
Brown, Gerald V.↗
Insulation end life determination for completed form-wound generators
Tests were conducted to predict remaining electrical insulation life of a polyimide-epoxy insulated 60 kW form-wound homopolar inductor generator following completion of 23,130 hours of turbo-generator endurance tests. The generator stator was sectioned to provide five sections, designated statorettes, and to permit 33 coil dielectric measurements on each section. Thermal aging tests were conducted on each section at select elevated temperatures to establish an Arrhenius life-temperature plot for end-life prediction and product or application use. The statorette fabrication technique is considered novel and provides means to establish insulation life-temperature profiles on completed electromagnetic components of rotating machines.
Penn, W. B.↗
A new controller for battery-powered electric vehicles
This paper describes the development, under a NASA/DOE contract, of a new concept for efficient and reliable control of battery-powered vehicles. It avoids the detrimental effects of pulsed-power controllers like the SCR 'chopper' by using rotating machines to meter continuous currents to the traction motor. The concept is validated in a proof-of-principle demonstration system and a complete vehicle is simulated on an analog computer. Test results show exceptional promise for a full-scale system. Optimum control strategies to minimize controller weight are developed by means of the simulated vehicle. The design for an Engineering Model is then prepared in the form of a practical, compact two-bearing package with forced air cooling. Predicted performance is outstanding, with controller efficiency of over 90% at high speed.
Belsterling, C. A.↗
Permanent-Magnet Motors and Generators for Aircraft
Electric motors and generators that use permarotating machinery, but aspects of control and power conditioning are also considered. The discussion is structured around three basic areas: rotating machine design considerations presents various configuration and material options, generator applications provides insight into utilization areas and shows actual hardware and test results, and motor applications provides the same type of information for drive systems.
Echolds, E. F.↗
Mechanical Design Handbook for Elastomers
Mechanical Design Handbook for Elastomers reviews state of art in elastomer-damper technology with particular emphasis on applications of highspeed rotor dampers. Self-contained reference but includes some theoretical discussion to help reader understand how and why dampers used for rotating machines. Handbook presents step-by-step procedure for design of elastomer dampers and detailed examples of actual elastomer damper applications.
Darlow, M.↗
Variable-Force Eddy-Current Damper
Variable damping achieved without problems of containing viscous fluids. Eddy-current damping obtained by moving copper or aluminum conductors through magnetic fields. Position of magnet carrier determines amount of field engagement and, therefore, amount of damping. Three advantages of concept: Magnitudes of stiffness and damping continously varied from maximum to zero without bringing rotor or shaft to stop; used in rotating machines not having viscous fluids available such as lubricating oils; produces sizable damping forces in machines that pump liquid hydrogen at - 246 degrees C and liquid oxygen at - 183 degrees C and are compact in size.
Cunningham, R. E.↗