Low temperature thermal cycle survivability and reliability study for brushless motor drive electronics (#1360)
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Design and development of liquid hydrogen mixer unit
A dc brushless motor driven mixer unit (a vaneaxial fan) was designed and evaluated for use in cryogenic fluids (liquids and gases). It was found to operate well in all fluids in which it was tested. The test fluids were liquid and gaseous helium, hydrogen in the liquid phase gas phase and mixtures of the two phases, and liquid nitrogen. It operated for over 100 hr at cryogenic temperatures without damage to the bearings and at the conclusion of testing the condition of the bearings was such that an operational life of 5000 hr appeared possible. The unit demonstrated that (with the brushless dc motor principle) useful pumping of cryogenic fluids could be accomplished with very small power inputs to the mixer motor. During test, the motor input power varied from approximately 0.5 W to 2.5 W, depending on fluid density. The high power input produced a mixer efficiency of over 49 percent. In an earlier program (see NASA Report CR-72365), a mixer using an ac induction motor demonstrated an efficiency of 17.7 percent under the same conditions, illustrating the advantage of the dc brushless motor driven unit. The mixer also demonstrated its ability to automatically vary speed as a function of the density of the fluid being pumped. This causes the unit to deliver higher volumetric flow rates as fluid density decreases.
Morgan, R. W.↗
Design of power electronics for TVC EMA systems
The Composite Development Division of the Propulsion Laboratory at Marshall Space Flight Center (MSFC) is currently developing a class of electromechanical actuators (EMA's) for use in space transportation applications such as thrust vector control (TVC) and propellant control valves (PCV). These high power servomechanisms will require rugged, reliable, and compact power electronic modules capable of modulating several hundred amperes of current at up to 270 volts. MSFC has selected the brushless dc motor for implementation in EMA's. This report presents the results of an investigation into the applicability of two new technologies, MOS-controlled thyristors (MCT's) and pulse density modulation (PDM), to the control of brushless dc motors in EMA systems. MCT's are new power semiconductor devices, which combine the high voltage and current capabilities of conventional thyristors and the low gate drive requirements of metal oxide semiconductor field effect transistors (MOSFET's). The commanded signals in a PDM system are synthesized using a series of sinusoidal pulses instead of a series of square pulses as in a pulse width modulation (PWM) system. A resonant dc link inverter is employed to generate the sinusoidal pulses in the PDM system. This inverter permits zero-voltage switching of all semiconductors which reduces switching losses and switching stresses. The objectives of this project are to develop and validate an analytical model of the MCT device when used in high power motor control applications and to design, fabricate, and test a prototype electronic circuit employing both MCT and PDM technology for controlling a brushless dc motor.
Nelms, R. Mark↗
Design of power electronics for TVC and EMA systems
The Component Development Division of the Propulsion Laboratory at Marshall Space Flight Center (MSFC) is currently developing a class of electromechanical actuators (EMA's) for use in space transportation applications such as thrust vector control (TVC) and propellant control valves (PCV). These high power servomechanisms will require rugged, reliable, and compact power electronic modules capable of modulating several hundred amperes of current at up to 270 volts. MSFC has selected the brushless dc motor for implementation in EMA's. A previous project performed by Auburn University examined the use of the resonant dc link (RDCL) inverter, pulse density modulation (PDM), and mos-controlled thyristors (MCT's) for speed control of a brushless dc motor. The speed of the brushless dc motor is proportional to the applied stator voltage. In a PDM system, the control system determines the number of resonant voltage pulses which must be applied to the stator to achieve a desired speed. The addition of a waveshaping circuit to the front end of a standard three-phase inverter yields a RDCL inverter; the resonant voltage pulses are produced through the action of this wave shaping circuit and the inverter. This project has focused on the implementation of a system which permits zero-voltage switching with the bus voltage clamped at the input voltage level. In the same manner as the RDCL inverter, the inverter selected for this implementation is a combination of waveshaping circuit and a standard three-phase inverter. In addition, this inverter allows a pulse-width modulated (PWM)-like control scheme instead of a PDM scheme. The operation of waveshaping circuit will be described through analysis and waveforms. Design relationships will also be presented.
Nelms, R. Mark↗
Practical application of power conditioning to electric propulsion for passenger vehicles
A functional model 15 HP, 120 volt, 4-pole, 7600 r.p.m. samarium-cobalt permanent magnet type brushless dc motor-transistorized power conditioner unit was designed, fabricated and tested for specific use in propulsion of electric passenger vehicles. This new brushless motor system, including its power conditioner package, has a number of important advantages over existing systems such as reduced weight and volume, higher reliability, and potential for improvements in efficiencies. These advantages are discussed in this paper in light of the substantial test data collected during experimentation with the newly developed conditioner motor propulsion system. Details of the power conditioner design philosophy and particulars are given in the paper. Also, described here are the low level electronic design and operation in relation to the remainder of the system.
Demerdash, N. A.↗
GSFC Flywheel Status
The assessment of flywheel energy storage for spacecraft power system is based on the conceptual flywheel design. This conceptual design of an integrated flywheel is based on the Mechanical Capacitor which evolved from development of magnetic bearings and permanent magnet ironless-brushless DC motors. The mechanical capacitor is based on three key technologies: (1) a composite rotor with a low ID to OD ratio for high energy density (weight and volume); (2) magnetic suspension close to the geometric center of the rotating mass to minimize loads normally encountered on the ends of a shaft, a no-wear mechanism in a vacuum environment, and to minimize losses at high rotational speeds; (3) permanent magnet ironless-brushless DC motor/generator for high efficiency of conversion and low losses at high rotational speeds. The complete system would include the necessary electronics for the motor/generator, containment, and counterrotating wheels for attitude control compatibility.
Rodriguez, G. E.↗
Design and application of electromechanical actuators for deep space missions
The annual report Design and Application of Electromechanical Actuators for Deep Space Missions is presented. The reporting period is 16 Aug. 1992 to 15 Aug. 1993. However, the primary focus will be work performed since submission of our semi-annual progress report in Feb. 1993. Substantial progress was made. We currently feel confident in providing guidelines for motor and control strategy selection in electromechanical actuators to be used in thrust vector control (TVC) applications. A small portion was presented in the semi-annual report. At this point, we have implemented highly detailed simulations of various motor/drive systems. The primary motor candidates were the brushless dc machine, permanent magnet synchronous machine, and the induction machine. The primary control implementations were pulse width modulation and hysteresis current control. Each of the two control strategies were applied to each of the three motor choices. With either pulse width modulation or hysteresis current control, the induction machine was always vector controlled. A standard test position command sequence for system performance evaluation is defined. Currently, we are gathering all of the necessary data for formal presentation of the results. Briefly stated for TVC application, we feel that the brushless dc machine operating under PWM current control is the best option. Substantial details on the topic, with supporting simulation results, will be provided later, in the form of a technical paper prepared for submission and also in the next progress report with more detail than allowed for paper publication.
Haskew, Tim A.↗
Design and application of electromechanical actuators for deep space missions
This progress report documents research and development efforts performed from August 16, 1993 through February 15, 1994 on NASA Grant NAG8-240, 'Design and Application of Electromechanical Actuators for Deep Space Missions.' Following the executive summary are four report sections: Motor Selection, Tests Stand Development, Health Monitoring and Fault Management, and Experiment Planning. Three specific motor types have been considered as prime movers for TVC EMA applications: the brushless dc motor, the permanent magnet synchronous motor, and the induction motor. The fundamental finding was that, in general, the primary performance issues were energy efficiency and thermal dissipation (rotor heating). In terms of all other issues, the three motor types were found to compare quite equally. Among the design changes made to the test stand since the last progress report is the addition of more mounting holes in the side beams. These additional holes allow the movable end beam to be attached in a greater number of positions than previously. With this change the movable end beam can move from full forward to full back in three inch increments. Specific mathematical details on the approach that have been employed for health monitoring and fault management (HMFM) have been reported previously. This approach is based on and adaptive Kalman filter strategy. In general, a bank of filters can be implemented for each primary fault type. Presently under consideration for the brushless dc machine are the following faults: armature winding open-circuits, armature winding short-circuits (phase-to-phase and phase-to-ground), bearing degradation, and rotor flux weakening. The mechanically oriented experiments include transient loading experiments, transverse loading experiment, friction experiment, motor performance experiment, and HMFM experiment.
Haskew, Tim A.↗
Hubble Space Telescope EVA Power Ratchet Tool redesign
The Power Ratchet Tool (PRT) is a self contained, power-driven, 3/8 inch drive ratchet wrench which will be used by astronauts during Extravehicular Activities (EVA). This battery-powered tool is controlled by a dedicated electonic controller. The PRT was flown during the Hubble Space Telescope (HST) Deployment Mission STS-31 to deploy the solar arrays if the automatic mechanisms failed. The PRT is currently intended for use during the first HST Servicing Mission STS-61 as a general purpose power tool. The PRT consists of three major components; the wrench, the controller, and the battery module. Fourteen discrete combinations of torque, turns, and speed may be programmed into the controller before the EVA. The crewmember selects the desired parameter profile by a switch mounted on the controller. The tool may also be used in the manual mode as a non-powered ratchet wrench. The power is provided by a silver-zinc battery module, which fits into the controller and is replaceable during an EVA. The original PRT did not meet the design specification of torque output and hours of operation. To increase efficiency and reliability the PRT underwent a redesign effort. The majority of this effort focused on the wrench. The original PRT drive train consisted of a low torque, high speed brushless DC motor, a face gear set, and a planocentric gear assembly. The total gear reduction was 300:1. The new PRT wrench consists of a low speed, high torque brushless DC motor, two planetary gear sets and a bevel gear set. The total gear reduction is now 75:1. A spline clutch has also been added to disengage the drive train in the manual mode. The design changes to the controller will consist of only those modifications necessary to accomodate the redesigned wrench. The battery design will be unaffected.
Richards, Paul W.↗
Design and Performance Improvements of the Prototype Open Core Flywheel Energy Storage System
A prototype magnetically suspended composite flywheel energy storage (FES) system is operating at the University of Maryland. This system, designed for spacecraft applications, incorporates recent advances in the technologies of composite materials, magnetic suspension, and permanent magnet brushless motor/generator. The current system is referred to as an Open Core Composite Flywheel (OCCF) energy storage system. This paper will present design improvements for enhanced and robust performance. Initially, when the OCCF prototype was spun above its first critical frequency of 4,500 RPM, the rotor movement would exceed the space available in the magnetic suspension gap and touchdown on the backup mechanical bearings would occur. On some occasions it was observed that, after touchdown, the rotor was unable to re-suspend as the speed decreased. Additionally, it was observed that the rotor would exhibit unstable oscillations when the control system was initially turned on. Our analysis suggested that the following problems existed: (1) The linear operating range of the magnetic bearings was limited due to electrical and magnetic saturation; (2) The inductance of the magnetic bearings was affecting the transient response of the system; (3) The flywheel was confined to a small movement because mechanical components could not be held to a tight tolerance; and (4) The location of the touchdown bearing magnifies the motion at the pole faces of the magnetic bearings when the linear range is crucial. In order to correct these problems an improved design of the flywheel energy storage system was undertaken. The magnetic bearings were re-designed to achieve a large linear operating range and to withstand load disturbances of at least 1 g. The external position transducers were replaced by a unique design which were resistant to magnetic field noise and allowed cancellation of the radial growth of the flywheel at high speeds. A central rod was utilized to ensure the concentricity of the magnetic bearings, the motor/generator, and the mechanical touchdown bearings. In addition, the mechanical touchdown bearings were placed at two ends of the magnetic bearing stack to restrict the motion at pole faces. A composite flywheel was made using a multi-ring interference assembled design for a high specific energy density. To achieve a higher speed and better efficiency, a permanent magnet DC brushless motor was specially designed and fabricated. A vacuum enclosure was constructed to eliminate windage losses for testing at high speeds. With the new improvements the OCCF system was tested to 20,000 RPM with a total stored energy of 15.9 WH and an angular momentum of 54.8 N-m-s (40.4 lb-ft-s). Motor current limitation, caused by power loss in the magnetic bearings, was identified as causing the limit in upper operating speed.
Pang, D.↗
Linear Actuator Has Long Stroke and High Resolution
The term precision linear actuator, direct drive ( PLADD ) refers to a robust linear actuator designed to be capable of repeatedly performing, over a lifetime of the order of 5 to 10 years, positioning maneuvers that include, variously, submicron increments or slews of the order of a centimeter. The PLADD is capable of both long stroke (120 mm) and high resolution (repeatable increments of 20 nm). Unlike precise linear actuators of prior design, the PLADD contains no gears, levers, or hydraulic converters. The PLADD, now at the prototype stage of development, is intended for original use as a coarse-positioning actuator in a spaceborne interferometer. The PLADD could also be adapted to terrestrial applications in which there are requirements for long stroke and high resolution: potential applications include medical imaging and fabrication of semiconductor devices. The PLADD (see figure) includes a commercially available ball-screw actuator driven directly by a commercially available three-phase brushless DC motor. The ball-screw actuator comprises a spring-preloaded ball nut on a ball screw that is restrained against rotation as described below. The motor is coupled directly (that is, without an intervening gear train) to a drive link that, in turn, is coupled to the ball nut. By eliminating the gear train, the direct-drive design eliminates the complexity, backlash, and potential for misalignment associated with a gear train. To prevent inadvertent movement, there is a brake that includes flexured levers compressed against the drive link by preload springs. This is a power-off brake: There are also piezoelectric stacks that can be activated to oppose the springs and push the levers away from the drive link. Hence, power must be applied to the piezoelectric stacks to release the drive link from braking. To help ensure long operational life, all of the mechanical drive components are immersed in an oil bath within hermetically sealed bellows. The outer end of the bellows holds the outer end of the ball screw, thereby preventing rotation of the ball screw. Positioning is controlled by an electronic control system that includes digital and analog subsystems that interact with the motor and brake and with two sensor/encoder units: a Hall-effect-sensor rotation encoder and a linear glass-scale encoder. This system implements a proportional + integral + derivative control algorithm that results in variation of voltage commands to each of the three pairs of windings of the brushless DC motor. In one of two alternative control modes, the voltages are applied to the windings in a trapezoidal commutation scheme on the basis of timing signals obtained from the Hall-effect sensors; this scheme yields relatively coarse positioning - 24 steps per motor revolution. The second control mode involves a sinusoidal commutation scheme in which the output of the linear glass-scale encoder is transposed to rotational increments to yield much finer position feedback - more than 400,000 steps per revolution.
Cook, Brant T.↗
Electro-Mechanical Systems for Extreme Space Environments
Exploration beyond low earth orbit presents challenges for hardware that must operate in extreme environments. The current state of the art is to isolate and provide heating for sensitive hardware in order to survive. However, this protection results in penalties of weight and power for the spacecraft. This is particularly true for electro-mechanical based technology such as electronics, actuators and sensors. Especially when considering distributed electronics, many electro-mechanical systems need to be located in appendage type locations, making it much harder to protect from the extreme environments. The purpose of this paper to describe the advances made in the area of developing electro-mechanical technology to survive these environments with minimal protection. The Jet Propulsion Lab (JPL), the Glenn Research Center (GRC), the Langley Research Center (LaRC), and Aeroflex, Inc. over the last few years have worked to develop and test electro-mechanical hardware that will meet the stringent environmental demands of the moon, and which can also be leveraged for other challenging space exploration missions. Prototype actuators and electronics have been built and tested. Brushless DC actuators designed by Aeroflex, Inc have been tested with interface temperatures as low as 14 degrees Kelvin. Testing of the Aeroflex design has shown that a brushless DC motor with a single stage planetary gearbox can operate in low temperature environments for at least 120 million cycles (measured at motor) if long life is considered as part of the design. A motor control distributed electronics concept developed by JPL was built and operated at temperatures as low as -160 C, with many components still operational down to -245 C. Testing identified the components not capable of meeting the low temperature goal of -230 C. This distributed controller is universal in design with the ability to control different types of motors and read many different types of sensors. The controller form factor was designed to surround or be at the actuator. Communication with the slave controllers is accomplished by a bus, thus limiting the number of wires that must be routed to the extremity locations. Efforts have also been made to increase the power capability of these electronics for the ability to power and control actuators up to 2.5KW and still meet the environmental challenges. For commutation and control of the actuator, a resolver was integrated and tested with the actuator. Testing of this resolver demonstrated temperature limitations. Subsequent failure analysis isolated the low temperature failure mechanism and a design solution was negotiated with the manufacturer. Several years of work have resulted in specialized electro-mechanical hardware to meet extreme space exploration environments, a test history that verifies and finds limitations of the designs and a growing knowledge base that can be leveraged by future space exploration missions.
Mojarradi, Mohammad M.↗
Simulation of an Electromechanical Spin Motor System of a Control Moment Gyroscope
A two-phase brushless DC motor (BDCM) with pulse-width modulated (PWM) voltage drive is simulated to control the flywheel speed of a control moment gyroscope (CMG). An overview of a double-gimballed control moment gyroscope (DGCMG) assembly is presented along with the CMG torque effects on the spacecraft. The operating principles of a two-phase brushless DC motor are presented and the system's electro-mechanical equations of motion are developed for the root-mean-square (RMS) currents and wheel speed. It is shown that the system is an extremely "stiff" set of first-order equations for which an implicit Euler integrator is required for a stable solution. An adaptive proportional voltage controller is presented which adjusts the PWM voltages depending on several control modes for speed, current, and torque. The simulation results illustrate the interaction between the electrical system and the load dynamics and how these influence the overall performance of the system. As will be shown, the CMG spin motor model can directly provide electrical power use and thermal power output to spacecraft subsystems for effective (average) calculations of CMG power consumption.
Inampudi, Ravi↗
Acoustic Characterization and Prediction of Representative, Small-Scale Rotary-Wing Unmanned Aircraft System Components
In this study, hover performance and acoustic measurements are taken on two different isolated rotors representative of small-scale rotary-wing unmanned aircraft systems (UAS) for a range of rotation rates. Each rotor system consists of two fixed-pitch blades powered by a brushless motor. For nearly the same thrust condition, significant differences in overall sound pressure level (OASPL), up to 8 dB, and directivity were observed between the two rotor systems. Differences are shown to be in part attributed to different rotor tip speeds, along with increased broadband and motor noise levels. In addition to acoustic measurements, aeroacoustic predictions were implemented in order to better understand the noise content of the rotor systems. Numerical aerodynamic predictions were computed using the unsteady Reynoldsaveraged Navier Stokes code OVERFLOW2 on one of the isolated rotors, while analytical predictions were computed using the Propeller Analysis System of the Aircraft NOise Prediction Program (ANOPP-PAS) on the two rotor configurations. Preliminary semi-empirical frequency domain broadband noise predictions were also carried out based on airfoil self-noise theory in a rotational reference frame. The prediction techniques further supported trends identified in the experimental data analysis. The brushless motors were observed to be important noise contributors and warrant further investigation. It is believed that UAS acoustic prediction capabilities must consider both rotor and motor components as part of a combined noise-generating system.
Zawodny, Nikolas S.↗
Spacecraft endless loop recorder quarterly report, 1 jan. - 1 apr. 1965
Spacecraft endless loop magnetic recorder - completion of speed servo with substitute motor, testing of brushless direct current motor, and assembly of prototype transport
DIRECT CURRENT /DC/↗
Power Systems Research at MSFC
Power system developments for rockets and space flights - fuel cells, improved zinc-silver oxide battery, brushless dc motors, switching transformer regulator, and Pegasus electricity
ELECTRIC MOTOR↗
Guidance and control components for space applications.
Space guidance and control system components, noting control moment gyro, actuator, brushless DC motor, electrically supported gyro and laser gyro
Janow, C.↗
Electronically controlled motor drive system has ultra-high reliability and long lifetime
Direct drive electromechanical system is composed of brushless dc torque motor, offset-tooth magnetic sensor that derives position and rate information directly from output shaft, and rotary power transformer that transfers electrical power from external source to proper load. System has high servo loop stiffness and minimum power consumption.
Veillette, L. J.↗