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ac bidirectional motor controller

Test data are presented and the design of a high-efficiency motor/generator controller at NASA-Lewis for use with the Space Station power system testbed is described. The bidirectional motor driver is a 20 kHz to variable frequency three-phase ac converter that operates from the high-frequency ac bus being designed for the Space Station. A zero-voltage-switching pulse-density-modulation technique is used in the converter to shape the low-frequency output waveform.

Schreiner, K.↗

Performance testing of a high frequency link converter for Space Station power distribution system

The testing of a brassboard version of a 20-kHz high-frequency ac voltage link prototype converter dynamics for Space Station application is presented. The converter is based on a three-phase six-pulse bridge concept. The testing includes details of the operation of the converter when it is driving an induction machine source/load. By adapting a field orientation controller (FOC) to the converter, four-quadrant operation of the induction machine from the converter has been achieved. Circuit modifications carried out to improve the performance of the converter are described. The performance of two 400-Hz induction machines powered by the converter with simple V/f regulation mode is reported. The testing and performance results for the converter utilizing the FOC, which provides the capability for rapid torque changes, speed reversal, and four-quadrant operation, are reported.

Sul, S. K.↗

Cheaper Synthesis Of Multipole-Brushless-dc-Motor Current

Circuit converts output of single two-phase shaft-angle resolver to that of multi-speed three-phase shaft-angle resolver. Converter circuit applicable to generation of multispeed, multiphase shaft-angle-resolver signals from single two-phase shaft-angle resolver. Combination of converter circuit and single two-phase shaft-angle resolver offer advantages in cost, weight, size, and complexity. Design readily adaptable to two-phase motor.

Alhorn, Dean C.↗

High-frequency ac power distribution in Space Station

A utility-type 20-kHz ac power distribution system for the Space Station, employing resonant power-conversion techniques, is presented. The system converts raw dc voltage from photovoltaic cells or three-phase LF ac voltage from a solar dynamic generator into a regulated 20-kHz ac voltage for distribution among various loads. The results of EASY5 computer simulations of the local and global performance show that the system has fast response and good transient behavior. The ac bus voltage is effectively regulated using the phase-control scheme, which is demonstrated with both line and load variations. The feasibility of paralleling the driver-module outputs is illustrated with the driver modules synchronized and sharing a common feedback loop. An HF sinusoidal ac voltage is generated in the three-phase ac input case, when the driver modules are phased 120 deg away from one another and their outputs are connected in series.

Tsai, Fu-Sheng↗

Power Processing for a Conceptual Project Prometheus Electric Propulsion System

NASA has proposed a bold mission to orbit and explore the moons of Jupiter. This mission, known as the Jupiter Icy Moons Orbiter (JIMO), would significantly increase NASA s capability to explore deep space by making use of high power electric propulsion. One electric propulsion option under study for JIMO is an ion propulsion system. An early version of an ion propulsion system was successfully used on NASA's Deep Space 1 mission. One concept for an ion thruster system capable of meeting the current JIMO mission requirement would have individual thrusters that are 16 to 25 kW each and require voltages as high as 8.0 kV. The purpose of this work is to develop power processing schemes for delivering the high voltage power to the spacecraft ion thrusters based upon a three-phase AC distribution system. In addition, a proposed DC-DC converter topology is presented for an ion thruster ancillary supply based upon a DC distribution system. All specifications discussed in this paper are for design convenience and are speculative in nature.

Scina, Joseph E., Jr.↗

Transistorized PWM inverter-induction motor drive system

This paper describes the development of a transistorized PWM inverter-induction motor traction drive system. A vehicle performance analysis was performed to establish the vehicle tractive effort-speed requirements. These requirements were then converted into a set of inverter and motor specifications. The inverter was a transistorized three-phase bridge using General Electric power Darlington transistors. The description of the design and development of this inverter is the principal object of this paper. The high-speed induction motor is a design which is optimized for use with an inverter power source. The primary feedback control is a torque angle control with voltage and torque outer loop controls. A current-controlled PWM technique is used to control the motor voltage. The drive has a constant torque output with PWM operation to base motor speed and a constant horsepower output with square wave operation to maximum speed. The drive system was dynamometer tested and the results are presented.

Peak, S. C.↗

A versatile power converter for high-frequency link systems

A single-phase HF link appears to be an attractive alternative to the dc link commonly used in power conversion systems. Here, a power converter suitable for one-step conversion of the single-phase HF link voltage to the three-phase LF voltages typically required for interfacing with system sources and loads is proposed. The converter utilizes zero-voltage switching principles to minimize switching losses and an easy-to-implement technique of pulse-density modulation for the control of the amplitude, frequency, and waveshape of the synthesized LF signals. Adaptation of the proposed topology for power conversion to single-phase ac and dc voltage or current outputs is shown to be straightforward. The feasibility of the proposed power circuit and the control technique has been experimentally verified.

Sood, Pradeep K.↗

Design and test of electromechanical actuators for thrust vector control

New control mechanisms technologies are currently being explored to provide alternatives to hydraulic thrust vector control (TVC) actuation systems. For many years engineers have been encouraging the investigation of electromechanical actuators (EMA) to take the place of hydraulics for spacecraft control/gimballing systems. The rationale is to deliver a lighter, cleaner, safer, more easily maintained, as well as energy efficient space vehicle. In light of this continued concern to improve the TVC system, the Propulsion Laboratory at the NASA George C. Marshall Space Flight Center (MSFC) is involved in a program to develop electromechanical actuators for the purpose of testing and TVC system implementation. Through this effort, an electromechanical thrust vector control actuator has been designed and assembled. The design consists of the following major components: Two three-phase brushless dc motors, a two pass gear reduction system, and a roller screw, which converts rotational input into linear output. System control is provided by a solid-state electronic controller and power supply. A pair of resolvers and associated electronics deliver position feedback to the controller such that precise positioning is achieved. Testing and evaluation is currently in progress. Goals focus on performance comparisons between EMA's and similar hydraulic systems.

Cowan, J. R.↗

Improved transistorized AC motor controller for battery powered urban electric passenger vehicles

An ac motor controller for an induction motor electric vehicle drive system was designed, fabricated, tested, evaluated, and cost analyzed. A vehicle performance analysis was done to establish the vehicle tractive effort-speed requirements. These requirements were then converted into a set of ac motor and ac controller requirements. The power inverter is a three-phase bridge using power Darlington transistors. The induction motor was optimized for use with an inverter power source. The drive system has a constant torque output to base motor speed and a constant horsepower output to maximum speed. A gear shifting transmission is not required. The ac controller was scaled from the base 20 hp (41 hp peak) at 108 volts dec to an expanded horsepower and battery voltage range. Motor reversal was accomplished by electronic reversal of the inverter phase sequence. The ac controller can also be used as a boost chopper battery charger. The drive system was tested on a dynamometer and results are presented. The current-controlled pulse width modulation control scheme yielded improved motor current waveforms. The ac controller favors a higher system voltage.

Peak, S. C.↗

Development and performance of pulse-width-modulated static inverter and converter modules

Pulse-width-modulated inverter and converter modules are being developed for modular aerospace electrical power systems. The modules, rate 2.5 kilowatts per module and 10-minute - 150-percent overload, operate from 56 volts dc. The converter module provides two output voltages: a nominal link voltage of 200 volts dc when used with the inverter, and 150 volts dc to a load bus when used separately. The inverter module output is 400-hertz, sinusoidal, three-phase, 120/208 volts. Tests of breadboard models with standard parts and integrated circuits show rated power efficiencies of 71.4 and 85.1 percent and voltage regulation of 5 and 3.1 percent for inverter and converter modules, respectively. Sine-wave output distortion is 0.74 percent.

Pittman, P. F.↗

Experimental observation of electrochemical rate limitations affecting sodium ion-electron recombination at electrodes of the alkali metal thermoelectric converter at T about 1200 K

This paper considers a model of the internal impedances of thin porous Mo and W alkali metal thermoelectric converter (AMTEC), in which the kinetic parameters associated with the reaction of the beta-double-prime alumina solid electrolite (BASE)/porous metal/gas three-phase boundary can be evaluated. Impedance data in the frequency range 0.01-100,000 Hz were collected over a range of AMTEC cell operating voltages for small-area thin porous Mo and W electrodes, yielding apparent charge transfer resistances at a series of cell potentials/currents. The ohmic resistance in the AMTEC cell could be broken down and characterized with three parameters: the BASE ionic resistance, the electrode film sheet resistance, and the contact/lead resistance, all of which could be calculated or measured independently and used to calculate power curves in good agreement with observed power curves. It is shown that these calculations can be used to predict the properties of electrodes with optimized parameters or to detect enhanced transport modes.

Williams, R. M.↗

Design of power electronics for TVC and EMA systems

The EMA systems proposed for future space transportation applications are high power systems operating at voltages up to 270 Vdc and at current levels on the order of hundreds of amperes. The position of the actuator is controlled by modulating the flow of energy from the source to an electric motor with an inverter. Hard-switching of the semiconductor devices in the inverter results in considerable device switching stresses and losses and in the generation of substantial amounts of EMI. Both of these can be reduced by employing zero-voltage-switching (ZVS) techniques in the inverter. This project has focused on the development of a ZVS inverter for the Marshall Space Center EMA prototypes, which utilize brushless dc motors to convert electrical energy to mechanical energy. An inverter which permitted zero-voltage switching and a quasi-PWM operation was selected for study and implementation. A waveshaping circuit is added to the front of a standard three-phase inverter to achieve the desired switching properties. This circuit causes the input voltage of the three-phase inverter to ring to zero where it is clamped for a short period of time. During this zero-voltage period, any of the semiconductor switches in the three-phase inverter are switched on or off at zero voltage resulting in a reduction in switching losses and EMI. The operation of this waveshaping circuit and its interaction with the three-phase inverter are described. The different circuit modes were analyzed using equivalent circuits. Based on this analysis, design relationships were developed for calculating component values for the circuit elements in the waveshaping circuit. Waveforms of various voltages and currents in the waveshaping circuit were plotted and used to determine the ratings of the semiconductors in the waveshaping circuit. The implementation of this inverter are described. Block diagrams for the overall control system and the waveshaping circuit control are presented and discussed. The current control scheme employed in the controller is also described.

Nelms, R. Mark↗

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.↗

Concurrent CO2 Control and O2 Generation for Advanced Life Support

The electrochemical reduction of carbon dioxide (CO2) using ceramic oxygen generators (COGs) is well known and widely studied, however, conventional devices using yttria-stabilized zirconia (YSZ) electrolytes operate at temperatures greater than 700 C. Operating at such high temperatures increases system mass compared to lower temperature systems because of increased energy overhead to get the COG up to operating temperature and the need for heavier insulation and/or heat exchangers to reduce the COG oxygen (O2) output temperature for comfortable inhalation. Recently, the University of Florida developed novel ceramic oxygen generators employing a bilayer electrolyte of gadolinia-doped ceria and erbia-stabilized bismuth for NASA's future exploration of Mars. To reduce landed mass and operation expenditures during the mission, in-situ resource utilization was proposed using these COGs to obtain both lifesupporting oxygen and oxidant/propellant fuel, by converting CO2 from the Mars atmosphere. The results showed that oxygen could be reliably produced from CO2 at temperatures as low as 400 C. These results indicate that this technology could be adapted to CO2 removal from a spacesuit and other applications in which CO2 removal was an issue. The strategy proposed for CO2 removal for advanced life support systems employs a catalytic layer combined with a COG so that it is reduced all the way to solid carbon and oxygen. Hence, a three-phased approach was used for the development of a viable low weight COG for CO2 removal. First, to reduce the COG operating temperature a high oxide ion conductivity electrolyte was developed. Second, to promote full CO2 reduction while avoiding the problem of carbon deposition on the COG cathode, novel cathodes and a removable catalytic carbon deposition layer were designed. Third, to improve efficiency, a pre-stage for CO2 absorption was used to concentrate CO2 from the exhalate before sending it to the COG. These subsystems were then integrated into a single CO2 removal system. This paper describes our progress to date on these tasks.

Paul, Heather L.↗

Development of a uninterrupted power system: ac and dc to dc converter

This program covered the design, fabrication and testing of an advanced development model uninterrupted power system. The input and output requirements imposed on the power processor were specified such that the unit is electrically interchangeable with existing power systems used by the Federal Aviation Administration in installations which have a history of failure due to electrical transient conditions. Input power is from either of two single-phase ac power sources or batteries with electronic selection and transfer between power sources. Battery reconditioning is automatic when either ac source is present. The output power is rated at 84OW; the nominal output is 24V at 35A. Within the 84OW limit, the regulated output voltage is adjustable from 22V to 30Vdc. Protection against continuous overloading or short circuit is provided. The unit is packaged in a standard 19-inch rack mount configuration with 7-inch panel height. Controls are on the front panel with power input and output through connectors on the rear surface. Cooling is by free convection from fin areas located on the side and rear panels. The packaged unit weighs 52.8 lbs., which can be reduced significantly if a three-phase ac power source is used.

Cronin, D. L.↗

High power density dc-to-dc converters for aerospace applications

Three dc-to-dc converter topologies aimed at high-power high-frequency applications are introduced. Major system parasitics, namely, the leakage inductance of the transformer and the device output capacitance are efficiently utilized. Of the three circuits, the single-phase and three-phase versions of the dual active bridge topology demonstrate minimal stresses, better utilization of the transformer, bidirectional, and buck-boost modes of operation. All circuits operate at a constant switching frequency, thus simplifying design of the reactive elements. The power transfer characteristics and soft-switching regions on the Vout-Iout plane are identified. Two coaxial transformers with different cross-sections were built for a rating of 50 kVA. Based on the single-phase dual active bridge topology, a 50 kW, 50 kHz converter operating at an input voltage of 200 Vdc and an output voltage of 1600 Vdc was fabricated. Characteristics of current-fed output make the dual active bridge topologies amenable to paralleling and hence extension to megawatt power levels. Projections to a 1 MW system operating from a 500 Vdc input, at an output voltage of 10 kVdc and a switching frequency of 50 kHz, using MOS-controlled thyristors, coaxially wound transformers operating at three times the present current density with cooling, and multilayer ceramic capacitors, suggests an overall power density of 0.075 to 0.08 kg/kW and an overall efficiency of 96 percent.

Divan, Deepakraj M.↗

Method and apparatus for pulse width modulation control of an AC induction motor

An inverter is connected between a source of DC power and a three-phase AC induction motor, and a micro-processor-based circuit controls the inverter using pulse width modulation techniques. In the disclosed method of pulse width modulation, both edges of each pulse of a carrier pulse train are equally modulated by a time proportional to sin .THETA., where .THETA. is the angular displacement of the pulse center at the motor stator frequency from a fixed reference point on the carrier waveform. The carrier waveform frequency is a multiple of the motor stator frequency. The modulated pulse train is then applied to each of the motor phase inputs with respective phase shifts of 120.degree. at the stator frequency. Switching control commands of electronic switches in the inverter are stored in a random access memory (RAM) and the locations of the RAM are successively read out in a cyclic manner, each bit of a given RAM location controlling a respective phase input of the motor. The DC power source preferably comprises rechargeable batteries and all but one of the electronic switches in the inverter can be disabled, the remaining electronic switch being part of a flyback DC-DC converter circuit for recharging the battery.

Geppert, Steven↗

Pulse width modulation inverter with battery charger

An inverter is connected between a source of DC power and a three-phase AC induction motor, and a microprocessor-based circuit controls the inverter using pulse width modulation techniques. In the disclosed method of pulse width modulation, both edges of each pulse of a carrier pulse train are equally modulated by a time proportional to sin .theta., where .theta. is the angular displacement of the pulse center at the motor stator frequency from a fixed reference point on the carrier waveform. The carrier waveform frequency is a multiple of the motor stator frequency. The modulated pulse train is then applied to each of the motor phase inputs with respective phase shifts of 120.degree. at the stator frequency. Switching control commands for electronic switches in the inverter are stored in a random access memory (RAM) and the locations of the RAM are successively read out in a cyclic manner, each bit of a given RAM location controlling a respective phase input of the motor. The DC power source preferably comprises rechargeable batteries and all but one of the electronic switches in the inverter can be disabled, the remaining electronic switch being part of a flyback DC-DC converter circuit for recharging the battery.

Slicker, James M.↗