NASA helicopter transmission system technology program

The purpose of the NASA Helicopter Transmission System Technology Program is to improve specific mechanical components and the technology for combining these into advanced drive systems to make helicopters more viable and cost competitive for commerical applications. The history, goals, and elements of the program are discussed

Hysteresis Bearingless Slice Motors with Homopolar Flux-biasing

We present a new concept of bearingless slice motor that levitates and rotates a ring-shaped solid rotor. The rotor is made of a semi-hard magnetic material exhibiting magnetic hysteresis, such as D2 steel. The rotor is radially biased with a homopolar permanent-magnetic flux, on which the stator can superimpose two-pole flux to generate suspension forces. By regulating the suspension forces based on position feedback, the two radial rotor degrees of freedom are actively stabilized. The two tilting degrees of freedom and the axial translation are passively stable due to the reluctance forces from the bias flux. In addition, the stator can generate a torque by superimposing six-pole rotating flux, which drags the rotor via hysteresis coupling. This six-pole flux does not generate radial forces in conjunction with the homopolar flux or two-pole flux, and therefore the suspension force generation is in principle decoupled from the driving torque generation. We have developed a prototype system as a proof of concept. The stator has 12 teeth, each of which has a single-phase winding that is individually driven by a linear transconductance power amplifier. The system has four reflectivetype optical sensors to differentially measure the two radial degrees of freedom of the rotor. The suspension control loop is implemented such that the phase margin is 25° at the cross-over frequency of 110 Hz. The prototype system can levitate the rotor and drive it up to about 1730 r/min. The maximum driving torque is about 2.7 mNm

Rotorcraft transmissions

Highlighted here is that portion of the Lewis Research Center's helicopter propulsion systems program that deals with drive train technology and the related mechanical components. The major goals of the program are to increase life, reliability, and maintainability, to reduce weight, noise, and vibration, and to maintain the relatively high mechanical efficiency of the gear train. The current activity emphasizes noise reduction technology and analytical code development, followed by experimental verification. Selected significant advances in technology for transmissions are reviewed, including advanced configurations and new analytical tools. Finally, the plan for transmission research in the future is presented

Design of a high-speed superconducting bearingless machine for flywheel energy storage systems

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Special section on high speed electrical machines and drives

The use of high-speed electrical machines and drives is in continuous evolution for a number of engineering applications, including electrical spindles for milling cutters and grinding, turbochargers, electrical turbo-compounding systems, aeroengine spools, helicopter and racing engines, and fuel pumps. The academic and industrial interests in this topic are growing very fast, pushing their research toward improvements in the involved technologies with a significant impact in many application areas. One of the main advantages of high-speed machines and drives is the reduction of system weight for a given power conversion. This is particularly desirable in all transportation applications where a weight reduction directly results in reduced fuel consumption and emissions. The electric transportation system is one of main topics with a significant push for advancing high-speed technologie

Rotors on Active Magnetic Bearings: Modeling and Control Techniques

In the last decades the deeper and more detailed understanding of rotating machinery dynamic behavior facilitated the study and the design of several devices aiming at friction reduction, vibration damping and control, rotational speed increase and mechanical design optimization. Among these devices a promising technology is represented by active magnetic actuators which found a great spread in rotordynamics and in high precision applications due to (a) the absence of all fatigue and tribology issues motivated by the absence of contact, (b) the small sensitivity to the operating conditions, (c) the wide possibility of tuning even during operation, (d) the predictability of the behavior. This technology can be classified as a typical mechatronic product due to its nature which involves mechanical, electrical and control aspects, merging them in a single system. The attractive potential of active magnetic suspensions motivated a considerable research effort for the past decade focused mostly on electrical actuation subsystem and control strategies. Examples of application areas are: (a) Turbomachinery, (b) Vibration isolation, (c) Machine tools and electric drives, (d) Energy storing flywheels, (e) Instruments in space and physics, (f) Non-contacting suspensions for micro-techniques, (g) Identification and test equipment in rotordynamics. This chapter illustrates the design, the modeling, the experimental tests and validation of all the subsystems of a rotors on a five-axes active magnetic suspension. The mechanical, electrical, electronic and control strategies aspects are explained with a mechatronic approach evaluating all the interactions between them. The main goals of the manuscript are: • Illustrate the design and the modeling phases of a five-axes active magnetic suspension; • Discuss the design steps and the practical implementation of a standard suspension control strategy; • Introduce an off-line technique of electrical centering of the actuators; • Illustrate the design steps and the practical implementation of an online rotor selfcentering control technique. The experimental test rig is a shaft (Weight: 5.3 kg. Length: 0.5 m) supported by two radial and one axial cylindrical active magnetic bearings and powered by an asynchronous high frequency electric motor. The chapter starts on an overview of the most common technologies used to support rotors with a deep analysis of their advantages and drawbacks with respect to active magnetic bearings. Furthermore a discussion on magnetic suspensions state of the art is carried out highlighting the research efforts directions and the goals reached in the last years. In the central sections, a detailed description of each subsystem is performed along with the modeling steps. In particular the rotor is modeled with a FE code while the actuators are considered in a linearized model. The last sections of the chapter are focused on the control strategies design and the experimental tests. An off-line technique of actuators electrical centering is explained and its advantages are described in the control design context. This strategy can be summarized as follows. Knowing that: a) each actuation axis is composed by two electromagnets; b) each electromagnet needs a current closed-loop control; c) the bandwidth of this control is depending on the mechanical airgap, then the technique allows to obtain the same value of the closed-loop bandwidth of the current control of both the electromagnets of the same actuation axis. This approach improves performance and gives more steadiness to the control behavior. The decentralized approach of the control strategy allowing the full suspensions on five axes is illustrated from the design steps to the practical implementation on the control unit. Furthermore a selfcentering technique is described and implemented on the experimental test rig: this technique uses a mobile notch filter synchronous with the rotational speed and allows the rotor to spin around its mass center. The actuators are not forced to counteract the unbalance excitation avoiding saturations. Finally, the experimental tests are carried out on the rotor to validate the suspension control, the off-line electrical centering and the selfcentering technique. The numerical and experimental results are superimposed and compared to prove the effectiveness of the modeling approach

Analysis of a Shaftless Semi-Hard Magnetic Material Flywheel on Radial Hysteresis Self-Bearing Drives

Flywheel Energy Storage Systems are interesting solutions for energy storage, featuring advantageous characteristics when compared to other technologies. This has motivated research effort focusing mainly on cost aspects, system reliability and energy density improvement. In this context, a novel shaftless outer-rotor layout is proposed. It features a semi-hard magnetic FeCrCo 48/5 rotor coupled with two bearingless hysteresis drives. The novelty lies in the use of the semi-hard magnetic material, lending the proposed layout advantageous features thanks to its elevated mechanical strength and magnetic properties that enable the use of bearingless hysteresis drives. The paper presents a study of the proposed layout and an assessment of its energetic features. It also focuses on the modeling of the radial magnetic suspension, where the electromagnets providing the levitating forces are modeled through a one-dimensional approach. The Jiles–Atherton model is used to describe the magnetic hysteresis of the rotor material. The proposed flywheel features a mass of 61.2 kg, a storage capability of 600 Wh at the maximum speed of 18,000 rpm and achieves an energy density of 9.8 Wh/kg. The performance of the magnetic suspension is demonstrated to be satisfactory and the influence of the hysteresis of the rotor material is highlighted

Rotorcraft research testing in the National Full-Scale Aerodynamics Complex at NASA Ames Research Center

The unique capabilities of the National Full-Scale Aerodynamics Complex (NFAC) for testing rotorcraft systems are described. The test facilities include the 40- by 80-Foot Wind Tunnel, the 80- by 120-Foot Wind Tunnel, and the Outdoor Aerodynamic Research Facility. The Ames 7- by 10-Foot Subsonic Wind Tunnel is also used in support of the rotor research programs conducted in the NFAC. Detailed descriptions of each of the facilities, with an emphasis on helicopter rotor test capability, are presented. The special purpose rotor test equipment used in conducting helicopter research is reviewed. Test rigs to operate full-scale helicopter main rotors, helicopter tail rotors, and tilting prop-rotors are available, as well as full-scale and small-scale rotor systems for use in various research programs. The test procedures used in conducting rotor experiments are discussed together with representative data obtained from previous test programs. Specific examples are given for rotor performance, loads, acoustics, system interactions, dynamic and aeroelastic stability, and advanced technology and prototype demonstration models

NASA transmission research and its probable effects on helicopter transmission design

Transmissions studied for application to helicopters in addition to the more conventional geared transmissions include hybrid (traction/gear), bearingless planetary, and split torque transmissions. Research is being performed to establish the validity of analysis and computer codes developed to predict the performance, efficiency, life, and reliability of these transmissions. Results of this research should provide the transmission designer with analytical tools to design for minimum weight and noise with maximum life and efficiency. In addition, the advantages and limitations of drive systems as well as the more conventional systems will be defined

MPTC for PMSMs of EVs with Multi-Motor Driven System Considering Optimal Energy Allocation

© 1965-2012 IEEE. This paper presents a compound propulsion system with a high-speed permanent-magnet synchronous motor (PMSM) and two in-wheel motors for electric vehicles (EVs). In this paper, the longitudinal dynamic model of EVs is first presented. Then traction distribution ratio \alpha is introduced to express the traction distribution between the front and the rear axles. Moreover, the function of power consumption concerned with the traction distribution ratio \alpha is established. Therefore, the \alpha that minimizes the power consumption function is selected as the optimal traction distribution ratio. To improve the performance of motor controllers, the model predictive torque control (MPTC) method is employed for high-speed and in-wheel motor drives. Experimental comparison with field-oriented control (FOC) shows the advantages of MPTC in dynamic response. Finally, experimental comparisons and hardware-in-loop (HiL) tests are presented to verify the MPTC method and the proposed energy allocation method, respectively