High Speed flywheel and test rig design for rural energy storage

There is considerable growth in the renewable energy sector to contribute to sustainable development, environmental conservation and most importantly to provide affordable energy to isolated rural communities of sub-Saharan Africa. Renewable energy sources such as solar and wind require energy storage since the source of energy is intermittent. Electrochemical batteries especially from lead acid are commonly used to store energy in Solar Home Systems (SHS) for rural electrification in sub-Saharan Africa. Disadvantages such as low efficiencies, low life cycle costs, high maintenance, comparatively short life and serious environmental and human toxicity effects exist. Since recycling is not widespread, replacement costs are high, as are the resultant environmental damage and health hazards from lead and sulphuric acid. In this thesis, an electromechanical flywheel energy storage device is proposed as an alternative to a lead acid battery in order to increase efficiency, life expectancy, increased high depth of discharge, low life cycle cost and elimination of adverse environmental effects. Due to income and service skill constraints in rural areas, the proposed, high speed flywheel systems (for long time energy storage) will require the use of low cost configurations and topologies, special considerations on the flywheel rotor profile design, robust electrical machines, simple power electronics and a low cost bearing set. Low loss magnetic bearings are also possible but were limited by time while also making their maintenance complex especially in rural areas. Conventional high strength composite materials used in flywheel rotor manufacture for high speed operation are expensive. Therefore there is a need to develop techniques to profile the rotor shape so as to improve on material usage and exhibit lower mechanical stresses. A robust electrical machine topology for high speed operation and a simple drive system are investigated to ensure simple assembly, low cost and low maintenance. vii The various flywheel components were designed using analytical and numerical methods. Two techniques were used to develop two optimal profiles for the flywheel rotor structure. Partial differential equations and analytical solutions were employed to develop the profiles. Analytical equations were used to design the electrical machine, drive, bearing system and other accessories. The final electromechanical battery prototype consisted of a composite flywheel rotor made from E-glass fibre materials, double rotor Axial Flux Permanent Magnet (AFPM) machine and a drive system using Brushless DC (BLDC) mode of operation. The system was designed for 300Wh of energy storage for the delivery of 100W and 500W of power and an operating speed range of 8,000 rpm-25,000 rpm. The design and development of the flywheel energy storage system and test rig using locally available materials was investigated. Experiments were conducted for speeds up to 6,000 rpm. The electromechanical battery was able to store a maximum of 77Wh of energy. The shortfall of the system to meet its design specifications was investigated and found to have been caused by vibrations resulting from prototyping issues. A thermal model was developed to predict the temperature rise in the system which showed a good correlation with the experimental results

Modelling and detection of faults in axial-flux permanent magnet machines

The development of various topologies and configurations of axial-flux permanent magnet machine has spurred its use for electromechanical energy conversion in several applications. As it becomes increasingly deployed, effective condition monitoring built on reliable and accurate fault detection techniques is needed to ensure its engineering integrity. Unlike induction machine which has been rigorously investigated for faults, axial-flux permanent magnet machine has not. Thus in this thesis, axial-flux permanent magnet machine is investigated under faulty conditions. Common faults associated with it namely; static eccentricity and interturn short circuit are modelled, and detection techniques are established. The modelling forms a basis for; developing a platform for precise fault replication on a developed experimental test-rig, predicting and analysing fault signatures using both finite element analysis and experimental analysis. In the detection, the motor current signature analysis, vibration analysis and electrical impedance spectroscopy are applied. Attention is paid to fault-feature extraction and fault discrimination. Using both frequency and time-frequency techniques, features are tracked in the line current under steady-state and transient conditions respectively. Results obtained provide rich information on the pattern of fault harmonics. Parametric spectral estimation is also explored as an alternative to the Fourier transform in the steady-state analysis of faulty conditions. It is found to be as effective as the Fourier transform and more amenable to short signal-measurement duration. Vibration analysis is applied in the detection of eccentricities; its efficacy in fault detection is hinged on proper determination of vibratory frequencies and quantification of corresponding tones. This is achieved using analytical formulations and signal processing techniques. Furthermore, the developed fault model is used to assess the influence of cogging torque minimization techniques and rotor topologies in axial-flux permanent magnet machine on current signal in the presence of static eccentricity. The double-sided topology is found to be tolerant to the presence of static eccentricity unlike the single-sided topology due to the opposing effect of the resulting asymmetrical properties of the airgap. The cogging torque minimization techniques do not impair on the established fault detection technique in the single-sided topology. By applying electrical broadband impedance spectroscopy, interturn faults are diagnosed; a high frequency winding model is developed to analyse the impedance-frequency response obtained

Development of a microfabricated silicon motor-driven compression system

Thesis (Ph.D.)--Massachusetts Institute of Technology, Dept. of Aeronautics and Astronautics, 2000.Includes bibliographical references (p. 237-243).by Luc G. Fréchette.Ph.D

Design and initial testing of a high speed 45 kW switched reluctance drive for aerospace application

This paper presents innovative research towards the development of a 45 kW high speed switched reluctance drive as an alternative starter-generator for future aero-engines. To perform such a function the machine had to be designed with a very wide constant power-speed range. During engine-start/motoring mode, a peak torque demand of 54 Nm at 8 krpm was met, whilst in generating mode, 19.2-32 krpm, the machine was designed to deliver a constant power of 45 kW. The key enabling feature of the design lies in the novel rotor structure developed so as to allow for such a wide speed range. The results presented, are those measured during the initial testing phase and validate the system design and performance in the low-speed region with the machine operated in starting-mode. The measured machine power density is at 9.8 kW/ltr, whilst the global system efficiency is at 82%

SIRM 2017

This volume contains selected papers presented at the 12th International Conference on vibrations in rotating machines, SIRM, which took place February 15-17, 2017 at the campus of the Graz University of Technology. By all meaningful measures, SIRM was a great success, attracting about 120 participants (ranging from senior colleagues to graduate students) from 14 countries. Latest trends in theoretical research, development, design and machine maintenance have been discussed between machine manufacturers, machine operators and scientific representatives in the field of rotor dynamics. SIRM 2017 included thematic sessions on the following topics: Rotordynamics, Stability, Friction, Monitoring, Electrical Machines, Torsional Vibrations, Blade Vibrations, Balancing, Parametric Excitation, and Bearings. The papers struck an admirable balance between theory, analysis, computation and experiment, thus contributing a richly diverse set of perspectives and methods to the audience of the conference

APPLICATION OF NONLINEAR SYSTEM FREQUENCY ANALYSIS AND DESIGN TO VIBRATION ISOLATION AND ENERGY HARVESTING

Vibration is naturally present in the environment including engineering systems and structures. The presence of vibration can be beneficial or destructive, depending on the nature of the affected system and also the level of vibration. Vibrations at dangerously high levels can be reduced by the addition of some energy dissipation elements (dampers) or/and energy storage elements (springs). Energy dissipation elements, such as dampers, dissipate some of these destructive mechanical vibrations as heat. However, mechanical spring systems absorb and store this mechanical vibration energy as potential energy. Nonlinear analysis is primarily applied in system analysis and design of engineering systems. Many methods are available to perform this purpose including averaging method, perturbation method, harmonic balance and the recently developed Output frequency response function (OFRF). The studies presented in this thesis focus on the application of nonlinear system frequency domain analysis and design to vibration isolation and energy harvesting systems. The OFRF method is the analytical and design tool adopted for all studies presented in this thesis. This method is chosen due to its advantage over other methods. This is because the OFRF reveals a significant relationship between the system output spectrum and the parameters that define the system nonlinearities. Therefore, it can facilitate a systematic analysis, design and optimisation process which other approaches are unable to realize. The first study considered in this thesis is a frequency domain analysis, design and optimisation of a vehicle suspension system which is illustrative of a vibration isolation system. In this study, the suspension system is analysed and designed based on a performance criterion. The main aim of the study is to minimise the transmitted vibration force to a tolerable level. At the specified level, some of the vibration energy is dissipated as heat by the damping system. However, this energy can be harvested into electricity, a process known as energy harvesting. This leads to subsequent studies in this thesis. The next study considers a vibration energy harvester system with nonlinear cubic damping characteristic. In this study, a concept is investigated, using the OFRF method, which increases the average power harvested by the harvesting device compared to an equivalent linear harvester. An extension of this study is further considered with the addition of a nonlinear hardening stiffness element to primarily broaden the operational bandwidth of the harvesting device. A final study is then considered where a dual-function system is investigated. The primary function of the system is vibration isolation while its secondary function is energy harvesting. The system is therefore called a dual-function vibration isolation and energy harvester system. This system is optimised for the best dual-function performance subject to existing constraints. For all the systems considered in this thesis, nonlinearities have been integrated into the existing systems to improve their performance, correspondingly, based on a selected criterion. In addition, the OFRF method has been employed in the analysis, design and optimisation of all the systems considered

Extended analytical charge modeling for permanent-magnet based devices : practical application to the interactions in a vibration isolation system

This thesis researches the analytical surface charge modeling technique which provides a fast, mesh-free and accurate description of complex unbound electromagnetic problems. To date, it has scarcely been used to design passive and active permanent-magnet devices, since ready-to-use equations were still limited to a few domain areas. Although publications available in the literature have demonstrated the surface-charge modeling potential, they have only scratched the surface of its application domain. The research that is presented in this thesis proposes ready-to-use novel analytical equations for force, stiffness and torque. The analytical force equations for cuboidal permanent magnets are now applicable to any magnetization vector combination and any relative position. Symbolically derived stiffness equations directly provide the analytical 3 £ 3 stiffness matrix solution. Furthermore, analytical torque equations are introduced that allow for an arbitrary reference point, hence a direct torque calculation on any assembly of cuboidal permanent magnets. Some topics, such as the analytical calculation of the force and torque for rotated magnets and extensions to the field description of unconventionally shaped magnets, are outside the scope of this thesis are recommended for further research. A worldwide first permanent-magnet-based, high-force and low-stiffness vibration isolation system has been researched and developed using this advanced modeling technique. This one-of-a-kind 6-DoF vibration isolation system consumes a minimal amount of energy (Ç 1W) and exploits its electromagnetic nature by maximizing the isolation bandwidth (> 700Hz). The resulting system has its resonance > 1Hz with a -2dB per decade acceleration slope. It behaves near-linear throughout its entire 6-DoF working range, which allows for uncomplicated control structures. Its position accuracy is around 4mum, which is in close proximity to the sensor’s theoretical noise level of 1mum. The extensively researched passive (no energy consumption) permanent-magnet based gravity compensator forms the magnetic heart of this vibration isolation system. It combines a 7.1kN vertical force with <10kN/m stiffness in all six degrees of freedom. These contradictory requirements are extremely challenging and require the extensive research into gravity compensator topologies that is presented in this thesis. The resulting cross-shaped topology with vertical airgaps has been filed as a European patent. Experiments have illustrated the influence of the ambient temperature on the magnetic behavior, 1.7h/K or 12N/K, respectively. The gravity compensator has two integrated voice coil actuators that are designed to exhibit a high force and low power consumption (a steepness of 625N2/W and a force constant of 31N/A) within the given current and voltage constraints. Three of these vibration isolators, each with a passive 6-DoF gravity compensator and integrated 2-DoF actuation, are able to stabilize the six degrees of freedom. The experimental results demonstrate the feasibility of passive magnet-based gravity compensation for an advanced, high-force vibration isolation system. Its modular topology enables an easy force and stiffness scaling. Overall, the research presented in this thesis shows the high potential of this new class of electromagnetic devices for vibration isolation purposes or other applications that are demanding in terms of force, stiffness and energy consumption. As for any new class of devices, there are still some topics that require further study before this design can be implemented in the next generation of vibration isolation systems. Examples of these topics are the tunability of the gravity compensator’s force and a reduction of magnetic flux leakage

Development of Magnetic Shape Memory Alloy Actuators for a Swashplateless Helicopter Rotor

Actuator concepts utilizing NiMnGa, ferromagnetic shape memory alloy are investigated for potential use on a smart rotor for trailing edge flap actuation. With their high energy density, large dynamic stroke, and wide operating bandwidth, ferromagnetic shape memory alloys (FSMA) like NiMnGa, seem like attractive candidates for smart rotor actuators, potentially able to fulfill the requirements for both primary rotor control and vibration suppression. However, because of the recent discovery of the material, current experimental data and analytical tools are limited. To rectify these shortcomings, an extensive set of detailed experiments were conducted on samples of NiMnGa to characterize the response of the alloy for a wide variety of mechanical and magnetic loading conditions. Measurements of the material performance parameters such as power density, damping properties, magneto-mechanical coupling, and transduction efficiency were included. Once characterized, the experimental data were used to develop a series of analytical tools to predict the behavior of the material. A model, developed in parallel to thermal shape memory alloy models is proposed to predict the quasi-static stress-strain behavior. A simple, low frequency, parameter based model was also developed to predict the alloy's dynamic strain response. A method for developing conceptual actuators utilizing NiMnGa as the actuation element was proposed. This approach incorporates experimental data into a process that down-selects a series of possible actuator configurations to obtain a single configuration optimized for volumetric and weight considerations. The proposed actuator was designed to deliver 2 mm of stroke and 60 N of force at an actuation frequency of 50 Hz. However, to generate the 1.0 T magnetic field, the actuator mass was determined to be 2.8 kg and required a minimum of 320 Watts of power for operation. The mass of the NiMnGa element was only 18.3 g. It was concluded that although the NiMnGa alloy was capable of meeting the trailing edge flap actuation requirements, the material is not suitable in its present form for this application because of weight and power consumption issues. The magnetic field requirements must be reduced to improve the utility of the material for rotorcraft applications