Design study for a magnetically supported reaction wheel

Results are described of a study program in which the characteristics of a magnetically supported reaction wheel are defined. Tradeoff analyses are presented for the principal components, which are then combined in several reaction wheel design concepts. A preliminary layout of the preferred configuration is presented along with calculated design and performance parameters. Recommendations are made for a prototype development program

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

Small Engine Component Technology (SECT) studies

A study was conducted to identify component technology requirements for small, expendable gas turbine engines that would result in substantial improvements in performance and cost by the year 2000. A subsonic, 2600 nautical mile (4815 km) strategic cruise missile mission was selected for study. A baseline (state-of-the-art) engine and missile configuration were defined to evaluate the advanced technology engines. Two advanced technology engines were configured and evaluated using advanced component efficiencies and ceramic composite materials; a 22:1 overall pressure ratio, 3.85 bypass ratio twin-spool turbofan; and an 8:1 overall pressure, 3.66 bypass ratio, single-spool recuperated turbofan with 0.85 recuperator effectiveness. Results of mission analysis indicated a reduction in fuel burn of 38 and 47 percent compared to the baseline engine when using the advanced turbofan and recuperated turbofan, respectively. While use of either advanced engine resulted in approximately a 25 percent reduction in missile size, the unit life cycle (LCC) cost reduction of 56 percent for the advanced turbofan relative to the baseline engine gave it a decisive advantage over the recuperated turbofan with 47 percent LCC reduction. An additional range improvement of 10 percent results when using a 56 percent loaded carbon slurry fuel with either engine. These results can be realized only if significant progress is attained in the fields of solid lubricated bearings, small aerodynamic component performance, composite ceramic materials and integration of slurry fuels. A technology plan outlining prospective programs in these fields is presented

Advanced gearbox technology

An advanced 13,000 HP, counterrotating (CR) gearbox was designed and successfully tested to provide a technology base for future designs of geared propfan propulsion systems for both commercial and military aircraft. The advanced technology CR gearbox was designed for high efficiency, low weight, long life, and improved maintainability. The differential planetary CR gearbox features double helical gears, double row cylindrical roller bearings integral with planet gears, tapered roller prop support bearings, and a flexible ring gear and diaphragm to provide load sharing. A new Allison propfan back-to-back gearbox test facility was constructed. Extensive rotating and stationary instrumentation was used to measure temperature, strain, vibration, deflection and efficiency under representative flight operating conditions. The tests verified smooth, efficient gearbox operation. The highly-instrumented advanced CR gearbox was successfully tested to design speed and power (13,000 HP), and to a 115 percent overspeed condition. Measured CR gearbox efficiency was 99.3 percent at the design point based on heat loss to the oil. Tests demonstrated low vibration characteristics of double helical gearing, proper gear tooth load sharing, low stress levels, and the high load capacity of the prop tapered roller bearings. Applied external prop loads did not significantly affect gearbox temperature, vibration, or stress levels. Gearbox hardware was in excellent condition after the tests with no indication of distress

Small, high-speed bearing technology for cryogenic turbo-pumps

The design of 20-mm bore ball bearings is described for cryogenic turbo-machinery applications, operating up to speeds of 120,000 rpm. A special section is included on the design of hybrid bearings. Each hybrid bearing is composed of a ball bearing in series with a conventional pressurized fluid-film journal bearing. Full details are presented on the design of a test vehicle which possesses the capability of testing the above named bearings within the given speed range under externally applied radial and axial loads

A review of physics-based models in prognostics: application to gears and bearings of rotating machinery

Health condition monitoring for rotating machinery has been developed for many years due to its potential to reduce the cost of the maintenance operations and increase availability. Covering aspects include sensors, signal processing, health assessment and decision-making. This article focuses on prognostics based on physics-based models. While the majority of the research in health condition monitoring focuses on data-driven techniques, physics-based techniques are particularly important if accuracy is a critical factor and testing is restricted. Moreover, the benefits of both approaches can be combined when data-driven and physics-based techniques are integrated. This article reviews the concept of physics-based models for prognostics. An overview of common failure modes of rotating machinery is provided along with the most relevant degradation mechanisms. The models available to represent these degradation mechanisms and their application for prognostics are discussed. Models that have not been applied to health condition monitoring, for example, wear due to metal–metal contact in hydrodynamic bearings, are also included due to its potential for health condition monitoring. The main contribution of this article is the identification of potential physics-based models for prognostics in rotating machinery

Development of small bore, high speed tapered roller bearing

The performance of four rolling bearing configurations for use on the input pinion shaft of a proposed commercial helicopter transmission was evaluated. The performance characteristics of a high speed tapered roller bearing operating under conditions comparable to those existing at this input pinion shaft were defined. The tapered roller bearing shaft support configuration was developed for the gearbox using commercially available bearing designings. The configuration was optimized and interactive thermomechanically system analyzed. Automotive pinion quality tapered roller bearings were found to be reliable under load and speed conditions in excess of those anticipated in the helicopter transmission. However, it is indicated that the elastohydrodynamic lubricant films are inadequate

Residual stress field of HIPed silicon nitride rolling elements

The residual stress field of HIPed Si3N4 rolling elements were studied. Two kinds of HIPed Si3N4 ball blanks self-finished at different nominal lapping loads ranging from 1.3 to 10.87 kgf/ball and four kinds of commercially finished 1/2 in (12.7 mm) HIPed Si3N4 balls before, during and after RCF tests were investigated. The experimental results showed that in the finishing process of HIPed Si3N4 rolling elements. the surface and subsurface compressive residual stress induced is proportional to the lapping load applied. There was initially a high compressive residual stress layer on the HIPed Si3N4 ball blanks and this layer is mostly removed during the finishing process. During the rolling contact fatigue process of HIPed Si3N4 rolling elements, the residual stresses on the rolling track will change dramatically as RCF proceeds

Identification and proposed control of helicopter transmission noise at the source

Helicopter cabin interiors require noise treatment which is expensive and adds weight. The gears inside the main power transmission are major sources of cabin noise. Work conducted by the NASA Lewis Research Center in measuring cabin interior noise and in relating the noise spectrum to the gear vibration of the Army OH-58 helicopter is described. Flight test data indicate that the planetary gear train is a major source of cabin noise and that other low frequency sources are present that could dominate the cabin noise. Companion vibration measurements were made in a transmission test stand, revealing that the single largest contributor to the transmission vibration was the spiral bevel gear mesh. The current understanding of the nature and causes of gear and transmission noise is discussed. It is believed that the kinematical errors of the gear mesh have a strong influence on that noise. The completed NASA/Army sponsored research that applies to transmission noise reduction is summarized. The continuing research program is also reviewed