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The system discussed adopts a well established and space proven motor, the 'stepper-motor' and shows that with simple commutation techniques it can be operated as a brushless dc motor at high speeds.
This mechanism was developed to dispense a small diameter wire which serves as a receiving antenna for electric field measurements on an Earth orbiting satellite. The antenna is deployed radially from a spinning satellite. A brushless dc motor drives a storage spool to dispense the wire at a controlled rate. Centrifugal force, acting on a mass attached to the end of the wire, keeps the wire in the radial position. The mechanism design, testing, and performance characteristics are discussed. Finally, operational data of the mechanism while in orbit are presented.
The Planetary Pointing and Tracking System (PPTS) is being developed to provide precision pointing for science platforms on future autonomous planetary spacecraft. The PPTS design approach using a CCD optical sensor for closed-loop control with respect to the target body, a gyro for inertial stabilization, and brushless dc torque motors for smooth and continuous platform articulation is essential for high resolution planetary imaging and automated science execution. An integral part of PPTS is the correlation tracker which has the potential to revolutionize autonomous guidance.
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.
A motor development program to explore the feasibility of electronically commutated dc motors (also known as brushless) for electric cars is described. Two different design concepts and a number of design variations based on these concepts are discussed. One design concept is based on a permanent magnet, medium speed, machine rated at 7000 to 9000 rpm, and powered via a transistor inverter power conditioner. The other concept is based on a permanent magnet, high speed, machine rated at 22,000 to 26,000 rpm, and powered via a thyristor inverter power conditioner. Test results are presented for a medium speed motor and a high speed motor each of which have been fabricated using samarium cobalt permanent magnet material.
The requirements, capabilities, and unique design features of the instrument pointing system drive units (DU) are presented. The DU's are identical for all three gimbal axes (elevation, cross elevation, and azimuth) and provide alternating rotation of shaft versus the housing of + or - 180 deg. The design features include: two ball bearing cartridges using cemented carbide balls coated with TiC a layer; redundant brushless torque motors and resolvers; a load by-pass mechanism driven by a dc torque motor to off-load the bearings during ascent/descent, ground transportation, and to provide an emergency breaking capability; and cabling over each gimbal axis by means of cable follow-up consisting of 13 signal and 15 power flat band cable loops. Test results of disturbance torque characteristics are presented.
A program was conducted to design and develop an advanced-concept motor specifically created for propulsion of electric vehicles with increased range, reduced energy consumption, and reduced life-cycle costs in comparison with conventional systems. The motor developed is a brushless, dc, rare-earth cobalt, permanent magnet, axial air gap inductor machine that uses an ironless stator. Air cooling is inherent provided by the centrifugal-fan action of the rotor poles. An extensive design phase was conducted, which included analysis of the system performance versus the SAE J227a(D) driving cycle. A proof-of-principle model was developed and tested, and a functional model was developed and tested. Full generator-level testing was conducted on the functional model, recording electromagnetic, thermal, aerodynamic, and acoustic noise data. The machine demonstrated 20.3 kW output at 1466 rad/s and 160 dc. The novel ironless stator demonstated the capability to continuously operate at peak current. The projected system performance based on the use of a transistor inverter is 23.6 kW output power at 1466 rad/s and 83.3 percent efficiency. Design areas of concern regarding electric vehicle applications include the inherently high windage loss and rotor inertia.
Current spacecraft design relies upon microprocessor control; however, motors usually require extensive additional electronic circuitry to interface with these microprocessor controls. An improved control technique that allows a smart brushless motor to connect directly to a microprocessor control system is described. An actuator with smart motors receives a spacecraft command directly and responds in a closed loop control mode. In fact, two or more smart motors can be controlled for synchronous operation.
A brushless dc tachometer is disclosed that includes a high strength toroidal permanent magnet for providing a uniform magnetic field in an air gap, an annular pole piece opposite the magnet, and a pickup coil wound around the pole piece and adapted to rotate about the axis of the pole piece. The pickup coil is rotated by an input shaft to which the coil is coupled with the friction clip. The output of the coil is conducted to circuitry by a twisted wire pair. The input shaft also activates a position transducing potentiometer.
Mathematical models capable of simulating the transient, steady state, and faulted performance characteristics of various brushless dc machine-PSA (power switching assembly) configurations were developed. These systems are intended for possible future use as primemovers in EMAs (electromechanical actuators) for flight control applications. These machine-PSA configurations include wye, delta, and open-delta connected systems. The research performed under this contract was initially broken down into the following six tasks: development of mathematical models for various machine-PSA configurations; experimental validation of the model for failure modes; experimental validation of the mathematical model for shorted turn-failure modes; tradeoff study; and documentation of results and methodology.
Design features and test results of an oil-free compressor developed for Spacelab Mission-4 Refrigerator/Freezer are detailed. The compressor has four identical pistons activated by a common eccentric shaft, operated by a brushless dc motor at 1300 rpm. The stroke of each piston is 0.28 cm, with the piston ends connected to the shaft by means of sealed needle bearings, eliminating the ned for oil. The mass flow rates produced by the compressor are by over 100 percent higher compared to the original Amfridge unit. Test results show that the compressor can meet the Spacelab refrigerator/freezer requirements.
Compressor pistons moved by eccentric shaft need no lubricants. Compressor has shaft, middle section is eccentric in relation to end sections. Driven by brushless dc motor, shaft turns inner races of set of four cam bearings. Outer cam-bearing races in turn actuate four pistons spaced equally apart, around and along shaft. Each outer bearing race held in position by pressure exerted on it by piston. Because no frictional motion between piston and outer bearing race, lubricant between them unnecessary. Cam bearings themselves contain potted internal lubricant. Originally proposed for use in space, new compressor for refrigerators or freezers does not depend on pool of oil for lubricating its pistons. Operated in any orientation.
Consideration is given to the design, fabrication, and testing of a magnetically suspended flywheel system for energy storage applications in space. The device is the prototype of a system combining passive suspension of the flywheel plate by samarium cobalt magnets and active control in the radial direction using eight separate magnetic coils. The bearing assembly was machined from a nickel-iron alloy, and the machine parts are all hydrogen annealed. Slots in the magnetic plate allow four independent quadrants for control. The motor/generator component of the system is a brushless dc-permanent magnetic/ironless engine using electronic communication. The system has been tested at over 2500 rpm with satisfactory results. The system characteristics of the flywheel for application in low earth orbit (LEO) are given in a table.
New way of mounting magnets in permanent-magnet, electronically commutated, brushless dc motors. Magnets wedge shaped, tapering toward center of rotor. Oppositely tapered pole pieces, electron-beam welded to rotor hub, retain magnets against centrifugal force generated by spinning rotor. To avoid excessively long electron-beam welds, pole pieces assembled in segments rather than single long bars.
This paper describes four noncontacting measurement technologies that can be used in a turbopump condition monitoring system. The isotope wear analyzer, fiberoptic deflectometer, brushless torque-meter, and fiberoptic pyrometer can be used to monitor component wear, bearing degradation, instantaneous shaft torque, and turbine blade cracking, respectively. A complete turbopump condition monitoring system including these four technologies could predict remaining component life, thus reducing engine operating costs and increasing reliability.
A "smart" hand for remote manipulator not only senses forces acting on it and detects presence of objects in immediate vicinity but also processes sensory data and controls its gripping claws. Hand reduces computational load on control computer of manipulator system. Includes wrist body and two opposing jaws with sets of claws that mesh with each other. Jaws of hand open as wide as 8.8 cm. Brushless dc motor operates claws through bevel-gear drive train and pair of ball screws. Maximum grip force 540 N, or about 120 lb.
A strategy is presented for the design and construction of a large master/slave-controlled, five-finger robotic hand. Each of the five fingers will possess four independent axes each driven by a brushless DC servomotor and, thus, four degrees-of-freedom. It is proposed that commercially available components be utilized as much as possible to fabricate a working laboratory model of the device with an anticipated overall length of two-to-four feet (0.6 to 1.2 m). The fingers are to be designed so that proximity, tactile, or force/torque sensors can be imbedded in their structure. In order to provide for the simultaneous control of the twenty independent hand joints, a multilevel master/slave control strategy is proposed in which the operator wears a specially instrumented glove which produces control signals corresponding to the finger configurations and which is capable of conveying sensor feedback signals to the operator. Two dexterous hand master devices are currently commercially available for this application with both undergoing continuing development. A third approach to be investigated for the master control mode is the use of real-time image processing of a specially patterned master glove to provide the respective control signals for positioning the multiple finger joints.
Using manipulators with a fixed configuration for specific tasks is appropriate when the task requirements are known beforehand. However, in less predictable situations, such as an outdoor construction site or aboard a space station, a manipulator system requires a wide range of capabilities, probably beyond the limitations of a single, fixed-configuration manipulator. To fulfill this need, researchers have been working on a Reconfigurable Modular Manipulator System (RMMS). Researchers have designed and are constructing a prototype RMMS. The prototype currently consists of two joint modules and four link modules. The joints utilize a conventional harmonic drive and torque motor actuator, with a small servo amplifier included in the assembly. A brushless resolver is used to sense the joint position and velocity. For coupling the modules together, a standard electrical connector and V-band clamps for mechanical connection are used, although more sophisticated designs are under way for future versions. The joint design yields an output torque to 50 ft-lbf at joint speeds up to 1 radian/second. The resolver and associated electronics have resolutions of 0.0001 radians, and absolute accuracies of plus or minus 0.001 radians. Manipulators configured from these prototype modules will have maximum reaches in the 0.5 to 2 meter range. The real-time RMMS controller consists of a Motorola 68020 single-board computer which will perform real time servo control and path planning of the manipulator. This single board computer communicates via shared memory with a SUN3 workstation, which serves as a software development system and robot programming environment. Researchers have designed a bus communication network to provide multiplexed communication between the joint modules and the computer controller. The bus supports identification of modules, sensing of joint states, and commands to the joint actuator. This network has sufficient bandwidth to allow servo sampling rates in excess of 500 Hz.