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Computer-controlled automatic system processes accelerometer data from rotating machines, producing mathematical description and graphical display of shaft motion. Program saves processing time, readily identifies type of motion (circular, looped, or elliptical), provides annotated assessments to assist in failure analysis, alerts user to look for distinctive characteristics of machinery, and creates informative plots.
The space station represents the next major U.S. commitment in space. The efficient delivery of power to multiple user loads is key to that success. In 1969, NASA Lewis Research Center began a series of studies with component and circuit developments that led to the high frequency, bi-directional, four quadrant resonant driven converter. Additional studies and subsequent developments into the early 1980's have shown how the high frequency ac power system could provide overall advantages to many aerospace power systems. Because of its wide versatility, it also has outstanding advantages for the Space Station Program and its wide range of users. High frequency ac power provides higher efficiency, lower cost, and improved safety. The 20 kHz power system has exceptional flexibility, is inherently user friendly, and is compatible with all types of energy sources - photovoltaic, solar dynamic, rotating machines or nuclear. Lewis has recently completed development under contract a 25 kW, 20 kHz ac power distribution system testbed. The testbed demonstrates flexibility, versatility, and transparency to user technology as well as high efficiency, low mass, and reduced volume.
Specific aspects of the application of Modal Analysis to rotating machines are discussed. For lowest mode analysis, the circular force perturbation testing gives the best results. Examples of application are presented.
Two aspects of internal friction affecting stability of rotating machines are discussed. The first role of internal friction consists of decreasing the level of effective damping during rotor subsynchronous and backward precessional vibrations caused by some other instability mechanisms. The second role of internal frication consists of creating rotor instability, i.e., causing self-excited subsynchronous vibrations. Experimental test results document both of these aspects.
The Space Station represents the next major U.S. commitment in space. The efficient delivery of power to multiple user loads is key to that success. In 1969, NASA Lewis Research Center began a series of studies with component and circuit developments that led to the high frequency bi-directional, four quadrant resonant driven converter. Additional studies and subsequent developments into the early 1980's have shown how the high frequency ac power system could provide overall advantages to many aerospace power systems. Because of its wide versatility, it also has outstanding advantages for the Space Station Program and its wide range of users. High frequency ac power provides higher efficiency, lower cost, and improved safety. The 20 kHz power system has exceptional flexibility, is inherently user friendly, and is compatible with all types of energy sources - photovoltaic, solar dynamic, rotating machines or nuclear Lewis distribution system testbed. The testbed demonstrates flexibility, versatility, and transparency to user technology as well as high efficiency, low mass, and reduced volume.
Magnets and Hall-effect transducers used to monitor tip-to-shroud clearances. Mounting permanent magnet in end of fan blade and monitoring tip-to-shroud distance by use of output of Hall-effect transducers affixed to surface of shroud. Transducers provide real-time information. By placing magnets in each fan-blade tip, complete set monitored sequentially as each blade rotates past sensor. Application in many rotating machines, providing surrounding materials nonmagnetic and temperatures not severe.
Compared to existing systems, high frequency ac power provides higher efficiency, lower cost, and improved safety benefits. The 20 kHz power system has exceptional flexibility, is inherently user friendly, and is compatible with all types of energy sources; photovoltaic, solar dynamic, rotating machines and nuclear. A 25 kW, 20 kHz ac power distribution system testbed was recently (1986) developed. The testbed possesses maximum flexibility, versatility, and transparency to user technology while maintaining high efficiency, low mass, and reduced volume. Several aspects of the 20 kHz power management and distribution (PMAD) system that have particular benefits for a nuclear power Space Station are discussed.
The building blocks of a computer algorithm developed for the time-accurate flow analysis of rotating machines are described. The flow model is a finite volume method utilizing a high resolution approximate Riemann solver for interface flux definitions. This block LU implicit numerical scheme possesses apparent unconditional stability. Multi-block composite gridding is used to orderly partition the field into a specified arrangement. Block interfaces, including dynamic interfaces, are treated such as to mimic interior block communication. Special attention is given to the reduction of in-core memory requirements by placing the burden on secondary storage media. Broad applicability is implied, although the results presented are restricted to that of an even blade count configuration. Several other configurations are presently under investigation, the results of which will appear in subsequent publications.
Some problems associated with non-synchronous vibrations are analyzed by describing three cases experienced with fairly large rotating machines in operating conditions. In each case, a brief description is first given of the machine and of the instrumentation used. The experimental results are then presented, with reference to time or frequency domain recordings. The lines followed in diagnosis are then discussed and, lastly, the corrective action undertaken is presented.
Many rotating machines such as compressors, turbines and pumps have long thin shafts with resulting vibration problems, and would benefit from additional damping near the center of the shaft. Magnetic dampers have the potential to be employed in these machines because they can operate in the working fluid environment unlike conventional bearings. An experimental test rig is described which was set up with a long thin shaft and several masses to represent a flexible shaft machine. An active magnetic damper was placed in three locations: near the midspan, near one end disk, and close to the bearing. With typical control parameter settings, the midspan location reduced the first mode vibration 82 percent, the disk location reduced it 75 percent and the bearing location attained a 74 percent reduction. Magnetic damper stiffness and damping values used to obtain these reductions were only a few percent of the bearing stiffness and damping values. A theoretical model of both the rotor and the damper was developed and compared to the measured results. The agreement was good.
Ball-pass cage-modulation detector puts out signal useful in detecting incipient failure of bearing in rotating machine. Part of system of electronic equipment measuring various components of vibrations in such bearings. Bearing sensor - strain gauge or deflectometer on bearing housing - measures deflections of housing as balls pass by. Output of sensor filtered to extract ball-pass cage modulation, indicative of wear in bearing.
Improvements are presented of a computer algorithm developed for the time-accurate flow analysis of rotating machines. The flow model is a finite volume method utilizing a high-resolution approximate Riemann solver for interface flux definitions. The numerical scheme is a block LU implicit iterative-refinement method which possesses apparent unconditional stability. Multiblock composite gridding is used to orderly partition the field into a specified arrangement of blocks exhibiting varying degrees of similarity. Block-block relative motion is achieved using local grid distortion to reduce grid skewness and accommodate arbitrary time step selection. A general high-order numerical scheme is applied to satisfy the geometric conservation law. An even-blade-count counterrotating unducted fan configuration is chosen for a computational study comparing solutions resulting from altering parameters such as time step size and iteration count. The solutions are compared with measured data.
A 3D finite element (FE) approach was developed and implemented for computation of global magnetic fields in a 14.3 kVA modified Lundell alternator. The essence of the new method is the combined use of magnetic vector and scalar potential formulations in 3D FEs. This approach makes it practical, using state of the art supercomputer resources, to globally analyze magnetic fields and operating performances of rotating machines which have truly 3D magnetic flux patterns. The 3D FE-computed fields and machine inductances as well as various machine performance simulations of the 14.3 kVA machine are presented in this paper and its two companion papers.
Dual-actuator active vibration-control (DAAVC) system is developmental system of type described in "Active Vibration Dampers for Rotating Machinery" (LEW-15427). System features sensors and actuators positioned and oriented at bearings to measure and counteract vibrations of shaft along either of two axes perpendicular to axis of rotation. Effective in damping vibrations of helicopter-engine test stand, making it safer to operate engine at speeds near and above first resonance of engine/test-stand system. Opens new opportunities for engine designers to draw more power from engine, and concept applicable to other rotating machines.
Two algorithms capable of computing a transonic 3-D inviscid flow field about rotating machines are considered for parallel implementation. During the study of these algorithms, a significant new method of measuring the performance of parallel algorithms is developed. The theory that supports this new method creates an empirical definition of scalable parallel algorithms that is used to produce quantifiable evidence that a scalable parallel application was developed. The implementation of the parallel application and an automated domain decomposition tool are also discussed.
In support of the power requirements for the Space Station Alpha (SSA), a joint program by the U.S. and Russia for a permanently manned space station to be launched into orbit by 1998, a robust control scheme is needed to assure the stability of the rotating machines that will be integrated into the power subsystem. A framework design and systems studies for modeling and analysis is presented. It employs classical d-q axes machine model with voltage/frequency dependent loads. To guarantee that design requirements and necessary trade studies are done, a functional analysis tool CORE is used for the study. This provides us with different control options for stability assessment. Initial studies and recommendations using advanced simulation tools are also presented. The benefits of the stability/control scheme for evaluating future designs and power management are discussed.
A double-acting electromagnetic thrust bearing is normally used to counter the axial loads in many rotating machines that employ magnetic bearings. It essentially consists of an actuator and drive electronics. Existing thrust bearing design programs are based on several assumptions. These assumptions, however, are often violated in practice. For example, no distinction is made between maximum external loads and maximum bearing forces, which are assumed to be identical. Furthermore, it is assumed that the maximum flux density in the air gap occurs at the nominal gap position of the thrust runner. The purpose of this paper is to present a clear theoretical basis for the design of the electromagnetic thrust bearing which obviates such assumptions.
Several previous annual reports were written and numerous papers published on the topics for this grant. That work is not repeated here in this final report. Only the work completed in the final year of the grant is presented in this final report. This final year effort concentrated on power loss measurements in magnetic bearing rotors. The effect of rotor power losses in magnetic bearings are very important for many applications. In some cases, these losses must be minimized to maximize the length of time the rotating machine can operate on a fixed energy or power supply. Examples include aircraft gas turbine engines, space devices, or energy storage flywheels. In other applications, the heating caused by the magnetic bearing must be removed. Excessive heating can be a significant problem in machines as diverse as large compressors, electric motors, textile spindles, and artificial heart pumps.