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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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NASA NTRS2004

Motor Control of Two Flywheels Enabling Combined Attitude Control and Bus Regulation

This presentation discussed the flywheel technology development work that is ongoing at NASA GRC with a particular emphasis on the flywheel system control. The "field orientation" motor/generator control algorithm was discussed and explained. The position-sensorless angle and speed estimation algorithm was presented. The motor current response to a step change in command at low (10 kRPM) and high (60 kRPM) was discussed. The flywheel DC bus regulation control was explained and experimental results presented. Finally, the combined attitude control and energy storage algorithm that controls two flywheels simultaneously was presented. Experimental results were shown that verified the operational capability of the algorithm. shows high speed flywheel energy storage (60,000 RPM) and the successful implementation of an algorithm to simultaneously control both energy storage and a single axis of attitude with two flywheels. Overall, the presentation demonstrated that GRC has an operational facility that

Kenny, Barbara H.↗
NASA NTRS2002

Flywheel Energy Storage System Designed for the International Space Station

Following successful operation of a developmental flywheel energy storage system in fiscal year 2000, researchers at the NASA Glenn Research Center began developing a flight design of a flywheel system for the International Space Station (ISS). In such an application, a two-flywheel system can replace one of the nickel-hydrogen battery strings in the ISS power system. The development unit, sized at approximately one-eighth the size needed for ISS was run at 60,000 rpm. The design point for the flight unit is a larger composite flywheel, approximately 17 in. long and 13 in. in diameter, running at 53,000 rpm when fully charged. A single flywheel system stores 2.8 kW-hr of useable energy, enough to light a 100-W light bulb for over 24 hr. When housed in an ISS orbital replacement unit, the flywheel would provide energy storage with approximately 3 times the service life of the nickel-hydrogen battery currently in use.

Delventhal, Rex A.↗
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.↗
NASA NTRS2005

Modeling and Development of a Magnetic Bearing Controller for a High Speed Flywheel System

This paper describes a modeling effort used to develop an improved type of magnetic bearing controller, called a modal controller, for use on high speed flywheel systems. The controller design is based on models of the flywheel system, is designed to directly control the natural dynamics of the spinning rotor, and is generic enough to be readily adapted to future flywheel systems. Modeling and development are described for two key controller subsystems: the modal controller subsystem, which allows direct control over the rotor rigid body modes, and the bending mode compensation subsystem, which tracks, and prevents interference from, the rotor bending modes during flywheel operation. Integration of modeling results into the final controller is described and data taken on the NASA Glenn D1 flywheel module during high speed operation are presented and discussed. The improved modal controller described in this paper has been successfully developed and implemented and has been used for regular hands-free operation of the D1 flywheel module up to its maximum operating speed of 60,000 RPM.

Dever, Timothy P.↗
NASA NTRS2005

Integrated Power and Attitude Control System Demonstrated With Flywheels G2 and D1

On September 14, 2004, NASA Glenn Research Center's Flywheel Development Team experimentally demonstrated a full-power, high-speed, two-flywheel system, simultaneously regulating a power bus and providing a commanded output torque. Operation- and power-mode transitions were demonstrated up to 2000 W in charge and 1100 W in discharge, while the output torque was simultaneously regulated between plus or minus 0.8 N-m. The G2 and D1 flywheels--magnetically levitated carbon-fiber wheels with permanent magnet motors--were used for the experiment. The units were mounted on an air bearing table in Glenn's High Energy Flywheel Facility. The operational speed range for these tests was between 20,000 and 60,000 rpm. The bus voltage was regulated at 125 V during charge and discharge, and charge-discharge and discharge-charge transitions were demonstrated by changing the amount of power that the power supply provided between 300 and 0 W. In a satellite system, this would be the equivalent of changing the amount of energy that the solar array provides to the spacecraft. In addition to regulating the bus voltage, we simultaneously controlled the net torque produced by the two flywheel modules. Both modules were mounted on an air table that was restrained by a load cell. The load cell measured the force on the table, and the torque produced by the two flywheels on the table could be calculated from that measurement. This method was used to measure the torque produced by the modules, yielding net torques from -0.8 to 0.8 N-m. This was the first Glenn demonstration of the Integrated Power and Attitude Control System (IPACS) at high power levels and speeds.

Jansen, Ralph H.↗
NASA NTRS2007

Experimental Performance Evaluation of a High Speed Permanent Magnet Synchronous Motor and Drive for a Flywheel Application at Different Frequencies

This paper presents the results of an experimental performance characterization study of a high speed, permanent magnet motor/generator (M/G) and drive applied to a flywheel module. Unlike the conventional electric machine the flywheel M/G is not a separated unit; its stator and rotor are integrated into a flywheel assembly. The M/G rotor is mounted on a flywheel rotor, which is magnetically levitated and sealed within a vacuum chamber during the operation. Thus, it is not possible to test the M/G using direct load measurements with a dynamometer and torque transducer. Accordingly, a new in-situ testing method had to be developed. The paper describes a new flywheel M/G and drive performance evaluation technique, which allows the estimation of the losses, efficiency and power quality of the flywheel high speed permanent magnet M/G, while working in vacuum, over wide frequency and torque ranges. This method does not require any hardware modification nor any special addition to the test rig. This new measurement technique is useful for high-speed applications, when applying an external load is technically difficult.

Nagorny, Aleksandr S.↗
NASA NTRS1979

Study of advanced electric propulsion system concept using a flywheel for electric vehicles

Advanced electric propulsion system concepts with flywheels for electric vehicles are evaluated and it is predicted that advanced systems can provide considerable performance improvement over existing electric propulsion systems with little or no cost penalty. Using components specifically designed for an integrated electric propulsion system avoids the compromises that frequently lead to a loss of efficiency and to inefficient utilization of space and weight. A propulsion system using a flywheel power energy storage device can provide excellent acceleration under adverse conditions of battery degradation due either to very low temperatures or high degrees of discharge. Both electrical and mechanical means of transfer of energy to and from the flywheel appear attractive; however, development work is required to establish the safe limits of speed and energy storage for advanced flywheel designs and to achieve the optimum efficiency of energy transfer. Brushless traction motor designs using either electronic commutation schemes or dc-to-ac inverters appear to provide a practical approach to a mass producible motor, with excellent efficiency and light weight. No comparisons were made with advanced system concepts which do not incorporate a flywheel.

Younger, F. C.↗
NASA NTRS1980

Initial guidelines and estimates for a power system with inertial (flywheel) energy storage

The starting point for the assessment of a spacecraft power system utilizing inertial (flywheel) energy storage. Both general and specific guidelines are defined for the assessment of a modular flywheel system, operationally similar to but with significantly greater capability than the multimission modular spacecraft (MMS) power system. Goals for the flywheel system are defined in terms of efficiently train estimates and mass estimates for the system components. The inertial storage power system uses a 5 kw-hr flywheel storage component at 50 percent depth of discharge (DOD). It is capable of supporting an average load of 3 kw, including a peak load of 7.5 kw for 10 percent of the duty cycle, in low earth orbit operation. The specific power goal for the system is 10 w/kg, consisting of a 56w/kg (end of life) solar array, a 21.7 w-hr/kg (at 50 percent DOD) flywheel, and 43 w/kg power processing (conditioning, control and distribution).

Slifer, L. W., Jr.↗
NASA NTRS1984

The multipurpose composite flywheel

The twin disk composite flywheel shows that the techniques that were developed at Rocketdyne to successfully design, fabricate, and test high-speed rotating machinery (turbopumps) for rocket engines could be used to develop advanced flywheels. This flywheel not only demonstrates that successful mating of metal flywheel characteristics (high torque and ruggedness) and composite flywheel characteristics (lightweight and high energy density) can be achieved, but the unique design lends itself to easy adaptation to other configurations.

Ginsburg, B. R.↗
NASA NTRS1985

Rotor stresses in a magnetically suspended flywheel system

A stress analysis of a composite-based multiring/multiwheel flywheel system for space applications is described. It is shown that the specific energy density (SED) of a given flywheel system geometry can be increased by a factor of two or more by means of an interference assembly. Radial stresses in the interference assembly are redistributed in such a way that the outer flywheel rings will separate at their interfaces when the critical flywheel speed is exceeded. It is pointed out that proper use of this condition can reduce the containment weight requirements of flywheel systems in general.

Kirk, J. A.↗
NASA NTRS1987

Dynamic response of a magnetically suspended flywheel with mass unbalance

The forced translational and rotational motion of a magnetically suspended flywheel due to mass unbalance is investigated. It is found that a magnetically suspended flywheel can tolerate greater mass unbalance than a conventional rotor system because in a magnetic suspension system, vibration and the transmission of dynamic loads are eliminated in the absence of mechanical contact. It is shown that although vibration and dynamic loads are not transmitted between the rotor and stator of a magnetically suspended flywheel, inertial forces and moments due to mass unbalance are generated when the flywheel is spinning. Numerical results demonstrate that the inertial forces and moments cause the flywheel to tilt and to displace radially from its centered position.

Wong, Kenneth↗
NASA NTRS1991

Flywheel energy storage for electromechanical actuation systems

The authors describe a flywheel energy storage system designed specifically to provide load-leveling for a thrust vector control (TVC) system using electromechanical actuators (EMAs). One of the major advantages of an EMA system over a hydraulic system is the significant reduction in total energy consumed during the launch profile. Realization of this energy reduction will, however, require localized energy storage capable of delivering the peak power required by the EMAs. A combined flywheel-motor/generator unit which interfaces directly to the 20-kHz power bus represents an ideal candidate for this load leveling. The overall objective is the definition of a flywheel energy storage system for this application. The authors discuss progress on four technical objectives: (1) definition of the specifications for the flywheel-motor/generator system, including system-level trade-off analysis; (2) design of the flywheel rotor; (3) design of the motor/generator; and (4) determination of the configuration for the power management system.

Hockney, Richard L.↗
NASA NTRS1994

Manufacturing and testing of a magnetically suspended composite flywheel energy storage system

This paper presents the work performed to develop a multiring composite material flywheel and improvements of a magnetically suspended energy storage system. The flywheel is constructed of filament would graphite/epoxy and is interference assembled for better stress distribution to obtain higher speeds. The stationary stack in the center of the disk supports the flywheel with two magnetic bearings and provides power transfer to the flywheel with a motor/generator. The system operates under a 10(exp -4) torr environment and has been demonstrated to 20,000 rpm with a total stored energy of 15.9 Wh. When this flywheel cycles between its design speeds (45,000 to 90,000 rpm), it will deliver 242 Wh and have a usable specific energy density of 42.6 Wh/kg.

Wells, Stephen↗
NASA NTRS1996

Parameter Design and Optimal Control of an Open Core Flywheel Energy Storage System

In low earth orbit (LEO) satellite applications spacecraft power is provided by photovoltaic cells and batteries. To overcome battery shortcomings the University of Maryland, working in cooperation with NASA/GSFC and NASA/LeRC, has developed a magnetically suspended flywheel for energy storage applications. The system is referred to as an Open Core Composite Flywheel (OCCF) energy storage system. Successful application of flywheel energy storage requires integration of several technologies, viz. bearings, rotor design, motor/generator, power conditioning, and system control. In this paper we present a parameter design method which has been developed for analyzing the linear SISO model of the magnetic bearing controller for the OCCF. The objective of this continued research is to principally analyze the magnetic bearing system for nonlinear effects in order to increase the region of stability, as determined by high speed and large air gap control. This is achieved by four tasks: (1) physical modeling, design, prototyping, and testing of an improved magnetically suspended flywheel energy storage system, (2) identification of problems that limit performance and their corresponding solutions, (3) development of a design methodology for magnetic bearings, and (4) design of an optimal controller for future high speed applications. Both nonlinear SISO and MIMO models of the magnetic system were built to study limit cycle oscillations and power amplifier saturation phenomenon observed in experiments. The nonlinear models include the inductance of EM coils, the power amplifier saturation, and the physical limitation of the flywheel movement as discussed earlier. The control program EASY5 is used to study the nonlinear SISO and MIMO models. Our results have shown that the characteristics and frequency responses of the magnetic bearing system obtained from modeling are comparable to those obtained experimentally. Although magnetic saturation is shown in the bearings, there are good correlations between the theoretical model and experimental data. Both simulation and experiment confirm large variations of the magnetic bearing characteristics due to air gap growth. Therefore, the gap growth effect should be considered in the magnetic bearing system design. Additionally, the magnetic bearing control system will be compared to other design methods using not only parameter design but H-infinity optimal control and mu synthesis.

Pang, D.↗
NASA NTRS2003

Dynamics and Control of Attitude, Power, and Momentum for a Spacecraft Using Flywheels and Control Moment Gyroscopes

Several laws are designed for simultaneous control of the orientation of an Earth-pointing spacecraft, the energy stored by counter-rotating flywheels, and the angular momentum of the flywheels and control moment gyroscopes used together as an integrated set of actuators for attitude control. General, nonlinear equations of motion are presented in vector-dyadic form, and used to obtain approximate expressions which are then linearized in preparation for design of control laws that include feedback of flywheel kinetic energy error as a means of compensating for damping exerted by rotor bearings. Two flywheel steering laws are developed such that torque commanded by an attitude control law is achieved while energy is stored or discharged at the required rate. Using the International Space Station as an example, numerical simulations are performed to demonstrate control about a torque equilibrium attitude, and illustrate the benefits of kinetic energy error feedback. Control laws for attitude hold are also developed, and used to show the amount of propellant that can be saved when flywheels assist the CMGs. Nonlinear control laws for large-angle slew maneuvers perform well, but excessive momentum is required to reorient a vehicle like the International Space Station.

Roithmayr, Carlos M.↗
NASA NTRS2004

Filtering and Control of High Speed Motor Current in a Flywheel Energy Storage System

The NASA Glenn Research Center has been developing technology to enable the use of high speed flywheel energy storage units in future spacecraft for the last several years. An integral part of the flywheel unit is the three phase motor/generator that is used to accelerate and decelerate the flywheel. The motor/generator voltage is supplied from a pulse width modulated (PWM) inverter operating from a fixed DC voltage supply. The motor current is regulated through a closed loop current control that commands the necessary voltage from the inverter to achieve the desired current. The current regulation loop is the innermost control loop of the overall flywheel system and, as a result, must be fast and accurate over the entire operating speed range (20,000 to 60,000 rpm) of the flywheel. The voltage applied to the motor is a high frequency PWM version of the DC bus voltage that results in the commanded fundamental value plus higher order harmonics. Most of the harmonic content is at the switching frequency and above. The higher order harmonics cause a rapid change in voltage to be applied to the motor that can result in large voltage stresses across the motor windings. In addition, the high frequency content in the motor causes sensor noise in the magnetic bearings that leads to disturbances for the bearing control. To alleviate these problems, a filter is used to present a more sinusoidal voltage to the motor/generator. However, the filter adds additional dynamics and phase lag to the motor system that can interfere with the performance of the current regulator. This paper will discuss the tuning methodology and results for the motor/generator current regulator and the impact of the filter on the control. Results at speeds up to 50,000 rpm are presented.

Kenny, Barbara H.↗
NASA NTRS2004

Flywheel Single-Axis Integrated Momentum and Power Control System Demonstrated

On July 10, 2003, the NASA Glenn Research Center flywheel team experimentally demonstrated a two-flywheel-module system that simultaneously provided attitude control in a single axis and regulated power. The test was conducted using the D1 flywheel module and the high-speed shaft (HSS) in the High Energy Flywheel Facility (HEFF). Both of these flywheel modules consist of a magnetically levitated rotor with an integral motor/generator, a vacuum housing, and mechanical touchdown bearings. Energy is stored kinetically in the rotor. The motor/generator allows energy to be added to or withdrawn from the rotor, and magnetic bearings and a vacuum enclosure are used to minimize losses.

Soeder, James F.↗
NASA NTRS2001

Flywheel Charge/Discharge Control Developed

A control algorithm developed at the NASA Glenn Research Center will allow a flywheel energy storage system to interface with the electrical bus of a space power system. The controller allows the flywheel to operate in both charge and discharge modes. Charge mode is used to store additional energy generated by the solar arrays on the spacecraft during insolation. During charge mode, the flywheel spins up to store the additional electrical energy as rotational mechanical energy. Discharge mode is used during eclipse when the flywheel provides the power to the spacecraft. During discharge mode, the flywheel spins down to release the stored rotational energy.

Beach, Raymond.F.↗