Tip-Clearance Actuation With Magnetic Bearings for High-Speed Compressor Stall Control

Magnetic bearings are widely used as active suspension devices in rotating machinery, mainly for active vibration control purposes. The concept of active tip clearance control suggests a new application of magnetic bearings as servo-actuators to stabilize rotating stall in axial compressors. This paper presents a first-of-a-kind feasibility study of an active stall control experiment with a magnetic bearing servo-actuator in the NASA Glenn high-speed single-stage compressor test facility. Together with CFD and experimental data a two-dimensional, incompressible compressor stability model was used in a stochastic estimation and control analysis to determine the required magnetic bearing performance for compressor stall control. The resulting requirements introduced new challenges to the magnetic bearing actuator design. A magnetic bearing servo-actuator was designed which fulfilled the performance specifications. Control laws were then developed to stabilize the compressor shaft. In a second control loop, a constant gain controller was implemented to stabilize rotating stall. A detailed closed loop simulation at 100% corrected design speed resulted in a 2.3% reduction of stalling mass flow which is comparable to results obtained in the same compressor by Weigl et al. (1998) using unsteady air injection. The design and simulation results presented here establish the viability of magnetic bearings for stall control in aero-engine high-speed compressors. Furthermore the paper outlines a general design procedure to develop magnetic bearing servo-actuators for high-speed turbomachinery.United States. National Aeronautics and Space Administration (Grant NAG3-1457

Stabilization of Compressor Surge Using Gain-Scheduled Controller

Gain scheduling is a control method that is used in nonlinear systems to optimize their controlled performance and robustness over a wide range of operating conditions. It is one of the most commonly used controller design approaches for nonlinear systems. In this control technique, the controller consists of a collection of linear controllers, each of which provides satisfactory closed-loop stability and performance for a small operating region, and combined they guarantee the stability of the system along the entire operating range. The operating region of the system is determined by a scheduling signal, also known as the scheduling variable, which may be either exogenous or endogenous with respect to the plan. A good design of the gain-scheduled controller requires a suitable selection of the scheduling variables to properly reflect the dynamics of the system. In this thesis, we apply the gain scheduling control method to the control of compression systems with active magnetic bearings (AMBs). First, a gain-scheduled controller is designed and tested for the rotor levitation control of the AMB system. The levitation controller is designed to guarantee robust rotor levitation over a wide range of rotating speeds. We show through numerical simulation that the rotor vibration is contained in the presence of uncertainties introduced by speed dependent gyroscopic forces. Next, we implement the gain scheduling control method to the active stabilization of compressor surge in a compression system using the AMBs as actuators. Recently, Yoon et al. [1] showed that AMBs can be used to stabilize the surge instability in a compression system. In this thesis, we demonstrate that gain scheduling control can effectively extend the stable operating region of the compression system beyond the limits presented in [1]. For the stabilization of surge, a gain-scheduled controller was obtained by combining six linear controllers that together they cover the full operating range of the compression system. We were able to demonstrate through numerical simulation that the designed surge controller is effective in suppressing the instability down to a throttle valve opening of 12%, and in the presence of random flow disturbance and actuator saturation. An observer-based technique was implemented to achieve a bumpless and smooth transfer when switching between the linear controllers

Active Control of an Axial Flow Compressor via Pulsed Air Injection

This paper presents the use of pulsed air injection to control the onset of rotating stall in a low-speed, axial flow compressor. By measuring the unsteady pressures near the rotor face, a control algorithm determines the magnitude and phase of the first mode of rotating stall and controls the injection of air in the front of the rotor face. Experimental results show that this technique slightly extends the stall point of the compressor and eliminates the hysteresis loop normally associated with rotating stall. A parametric study is used to determine the optimal control parameters for suppression of stall. Analytic results---using a low-dimensional model developed by Moore and Greitzer combined with an unsteady shift in the compressor characteristic to model the injectors---give further insights into the operation of the controller. Based on this model, we show that the behavior of the experiment can be explained as a change in the bifurcation behavior of the system under nonlinear feedback. A higher fidelity simulation model is then used to further verify some of the specific performance characteristics that are observed in experiments

Modelling and Quasilinear Control of Compressor Surge and Rotating Stall Vibrations

An unsteady nonlinear and extended version of the Moore-Greitzer model is developed to facilitate the synthesis of a quasilinear stall vibration controller. The controller is synthesised in two steps. The first step defines the equilibrium point and ensures that the desired equilibrium point is stable. In the second step, the margin of stability at the equilibrium point is tuned or increased by an appropriate feedback of change in the mass flow rate about the steady mass flow rate at the compressor exit. The relatively simple and systematic non-linear modelling and linear controller synthesis approach adopted in this paper clearly highlights the main features on the controller that is capable of inhibiting compressor surge and rotating stall vibrations. Moreover, the method can be adopted for any axial compressor provided its steady-state compressor and throttle maps are known

Nonlinear Control and Modeling of Rotating Stall in an Axial Flow Compressor

This thesis focuses on understanding the use of air injection as a means of controlling rotating stall in an axial flow compressor, involving modeling, dynamical systems analysis, and experimental investigations. The first step towards this understanding was the development of a low order model for air injection control, the starting point of which was the Moore and Greitzer model for axial flow compressors. The Moore and Greitzer model was extended to include the effects of air injection and bifurcation analysis was performed to determine how the closed loop system dynamics are different from those of the open loop system. This low order model was then used to determine the optimal placement of the air injection actuators. Experimental work focused on verifying that the low order model, developed for air injection actuation, qualitatively captured the behavior of the Caltech compressor rig. Open loop tests were performed to determine how the placement of the air injectors on the rig affected the performance of the compressor. The positioning of the air injectors that provided the greatest control authority were used in the development of air injection controllers for rotating stall. The controllers resulted in complete elimination of the hysteresis associated with rotating stall. The use of a throttle actuator for the control of the surge dynamics was investigated, and then combined with an air injection controller for rotating stall; the resulting controller performed quite well in throttle disturbance rejection tests. A higher order model was developed to qualitatively match the experimental results with a simulation. The results of this modeling effort compared quite well with the experimental results for the open loop behavior of the Caltech rig. The details of how the air injection actuators affect the compressor flow were included in this model, and the simulation predicted the same optimal controller that was developed through experimentation. The development of the higher order model also included the investigation of systematic methods for determining the simulation parameters. Based on experimental measurements of compression system transients, the open loop simulation parameters were identified, including values for the compressor performance characteristic in regions where direct measurements were not possible. These methods also provided information on parameters used in the modeling of the pressure rise delivered by the compressor under unsteady flow conditions

Control of rotating stall in a low-speed axial flow compressor using pulsed air injection: modeling, simulations, and experimental validation

Previous results in the use of pulsed air injection for active control of rotating stall have suggested that air injectors have the effect of shifting the steady state compressor characteristic. In this paper we analyze the effect of a compressor characteristic actuation scheme for the three state Moore Greitzer compression system model. It is shown that closed loop feedback based on the square magnitude of the first rotating stall mode can be used to decrease the hysteresis region associated with the transition from unstalled to stalled and back to unstalled operation. The compressor characteristic shifting idea is then applied to a higher fidelity distributed model in which the characteristic shifting has phase content in addition to the magnitude content captured by the three state model. The optimal phasing of the air injection relative to the sensed position of the stall cell is determined via simulation and the results found to agree with those obtained via an experimental parametric study on the Caltech low-speed axial flow compressor

Analytic Parameterization of Stabilizing Controllers for the Moore-Greitzer Compressor Model

This work presents an extension, simplification and application of a design procedure for dynamic output feedback design for systems with nonlinearities satisfying quadratic constraints (QC). Our method was motivated by the challenges of output feedback control design for the three-state Moore-Greitzer (MG) compressor model. The classical three-state MG model is a nonlinear dynamical system that is widely used in stall/surge analysis and control design. First, we find the parameter set of the stabilizing dynamic output feedback controllers for the surge subsystem by using conditions for stability of a transformed system and the associated matching conditions. Second, we choose the optimal control parameters from the stabilizing set with respect to different desired criteria. We show the set of parameters of the stabilizing controllers for the surge subsystem and the set of parameters of the stabilizing controllers with extended integral part for MG compressor. We present simplified sufficient conditions for stabilization, new constraints for the corresponding parameters and examples of optimal problem for the surge subsystem of the Moore-Greitzer compressor model. We discuss the degree of robustness and clarify an alternative proof of stability of the closed-loop system with the surge subsystem and the stabilizing dynamic output feedback controller without an integral state. In addition, we show the derivation of a quadratic function by using CVX

Model Analysis and Nonlinear Control of Air Compressors

RÉSUMÉ Pendant des décennies, les turbines à gaz ont été des dispositifs importants et fiables dans les domaines de la production d'énergie, de l'industrie pétrochimique, et de l'aéronautique. Ces machines utilisent les compresseurs centrifuges et axiaux qui se dégradent en présence d’instabilités aérodynamiques telles que le pompage et le décrochage tournant. Ces dernières limitent la performance et peuvent causer des sollicitations mécaniques importantes, une réduction de la durée de vie, du bruit et des vibrations. De plus, dans les compresseurs axiaux à vitesse variable (CAVV), les variations de vitesse affectent la stabilité des systèmes et peuvent entraîner le pompage et le décrochage tournant. Cela limite le taux de variation de vitesse et pénalise la performance. Le travail présenté dans cette thèse dresse premièrement l'analyse de bifurcation du modèle des CAVVs afin d’étudier l'impact de la dynamique de la vitesse sur la stabilité de points de fonctionnement efficaces. Ici, le taux de variation de vitesse (accélération) est défini comme un nouveau paramètre du modèle et une analyse détaillée de bifurcation numérique est fournie. Les résultats des simulations dans le domaine temporel valident non seulement l'analyse de bifurcation, mais élargissent aussi nos connaissances sur la réponse transitoire du modèle, qui est d’une importance majeure. L'analyse réalisée révèle que les variations de vitesse peuvent mener à un décrochage tournant entièrement développé ainsi qu’au décrochage temporaire mentionné précédemment. Les résultats montrent que les instabilités développées dépendent fortement du taux d'accélération. L'impact des autres paramètres du modèle, les vitesses initiale et finale, et la contribution des modes du décrochage sont également étudiés. Au niveau du contrôle, malgré toutes les réalisations présentées, la conception d’une commande robuste même pour des systèmes de compression axiaux à vitesse constante demeure encore un problème difficile. Ici, deux méthodes de commande non linéaires: le contrôle par modes glissants et le contrôle par passivité sont proposées pour résoudre ce problème de stabilité. Ces deux approches traitent de tous les aspects difficiles du sujet qui apparaissent dans la littérature : l'impact des perturbations externes, le manque de connaissance précise des paramètres du modèle, et l'absence d’un retour d’état complet.---------- ABSTRACT For decades, gas turbines have been important, widespread, and reliable devices in the field of power generation, petrochemical industry, and aeronautics. They employ centrifugal and axial compressors which suffer from aerodynamic instabilities, namely, surge and rotating stall. These performance limiting instabilities can cause component stress, lifespan reduction, noise, and vibration. Furthermore, in variable speed axial compressors (VSACs), speed variations affect the system stability and can lead to surge and rotating stall. This limits the rate of speed variations and results in important performance penalties. The present work firstly addresses the bifurcation analysis of VSACs’ model to investigate the impact of speed dynamics on the stability of efficient operating points. Here, the rate of speed variations (acceleration rate) is defined as a new parameter of the model and a detailed numerical bifurcation analysis is provided. The results of time-domain simulations not only validate the results of bifurcation analysis, but also broaden our knowledge about the transient response of the model, which is a matter of importance as well. The analysis reveals that speed variations can lead to a fully developed rotating stall as well as the previously reported temporary stall developments. The results show that the developed instabilities depend to a great extent on the acceleration rate. The impact of other key issues such as throttle gain, viscosity factor, initial speed, final speed, and the contribution of stall modes are also explored. From the control point of view, despite reported achievements, robust control design for compression systems remains a challenging problem. In this work, at first, two nonlinear approaches are proposed to tackle the stability problem of constant-speed axial compressors (CSACs). The first approach is a robust passivity-based control and the second one is a second order sliding mode control. The approaches tackle the challenging problems being addressed in the literature such as: the impact of external perturbations, the lack of detailed parameters knowledge, and the absence of full-state feedback. They drive the control from pressure and mass flow measurements and use throttle and close-coupled valve actuations. Finally, this study reports that these methods can be used in the case of VSACs by applying the required modifications to simultaneously control speed and instabilities. This simultaneous control design has been an open problem and the proposed method can improve the performance of VSACs