Multigrid for structures analysis

In structural dynamics the equations are usually expressed as finite elements. Neighbor elements need not be connected. The process of condensing a fine model into a coarse model and interpolating the low-frequency solution to the fine model is studied

Piezoelectric pushers for active vibration control of rotating machinery

The active control of rotordynamic vibrations and stability by magnetic bearings and electromagnetic shakers have been discussed extensively in the literature. These devices, though effective, are usually large in volume and add significant weight to the stator. The use of piezoelectric pushers may provide similar degrees of effectiveness in light, compact packages. Tests are currently being conducted with piezoelectric pusher-based active vibration control. Results from tests performed on NASA test rigs as preliminary verification of the related theory are presented

"Fan-Tip-Drive" High-Power-Density, Permanent Magnet Electric Motor and Test Rig Designed for a Nonpolluting Aircraft Propulsion Program

A scaled blade-tip-drive test rig was designed at the NASA Glenn Research Center. The rig is a scaled version of a direct-current brushless motor that would be located in the shroud of a thrust fan. This geometry is very attractive since the allowable speed of the armature is approximately the speed of the blade tips (Mach 1 or 1100 ft/s). The magnetic pressure generated in the motor acts over a large area and, thus, produces a large force or torque. This large force multiplied by the large velocity results in a high-power-density motor

Stability of the Tilt Modes of an Actively Controlled Flywheel Analyzed

Applications of strongly gyroscopic rotors are becoming important, including flywheels for terrestrial and space energy storage and various attitude control devices for spacecraft. Some of these applications, especially the higher speed ones for energy storage, will have actively controlled magnetic bearings. These bearings will be required where speeds are too high for conventional bearings, where adequate lubrication is undesirable or impossible, or where bearing losses must be minimized for efficient energy storage. Flywheel rotors are highly gyroscopic, and above some speed that depends on the bandwidth of the feedback system, they always become unstable in an actively controlled magnetic bearing system. To assess ways to prevent instability until speeds well above the desired operating range, researchers at the NASA Lewis Research Center used a commercial controls code to calculate the eigenvalues of the tilt modes of a rigid gyroscopic rotor supported by active magnetic bearings. The real part of the eigenvalue is the negative of the damping of the mode, and the imaginary part is approximately equal to the mode s frequency

Permanent Magnetic Bearing for Spacecraft Applications

A permanent, totally passive magnetic bearing rig was designed, constructed, and tested. The suspension of the rotor was provided by two sets of radial permanent magnetic bearings operating in the repulsive mode. The axial support was provided by jewel bearings on both ends of the rotor. The rig was successfully operated to speeds of 5500 rpm using an air impeller. Radial and axial stiffnesses of the permanent magnetic bearings were experimentally measured and then compared to finite element results. The natural damping of the rotor was measured and a damping coefficient was calculated

Cross-Axis Proportional Gains Used to Control Gyroscopic Effects in a Magnetic- Bearing-Supported Flywheel

For magnetic-bearing-supported high-speed machines with significant gyroscopic effects, it is necessary to stabilize both forward and backward tilt whirling modes. Instability or the low damping of these modes can prevent the attainment of desired shaft speeds. Previous work elsewhere showed that cross-axis derivative gain in the magnetic bearing control law can improve the stability of the forward whirl mode, but it is commonly recognized that derivative gains amplify high-frequency noise and increase the required control effort. At the NASA Glenn Research Center, it has been shown previously that a simple cross-axis proportional gain can add stability (without adding noise) to either forward whirl or backward whirl, depending on the sign of the gain, but that such a gain destabilizes the other mode. It has been predicted by Glenn analysis that both modes can be stabilized by cross-axis proportional gains by utilizing the large-frequency separation of the two modes at speeds where the gyroscopic effects are significant. We use a modal controller that decouples the tilt and center-of-mass-translation modes. Only the tilt modes exhibit speed-dependent gyroscopic effects. The key to controlling them by the present method is to stabilize the backward whirl tilt mode with the appropriate sign of cross-axis proportional gain in the control law, but to include a low-pass filter on that gain term to restrict its effect only to the low-frequency backward-whirl mode. A second cross-axis term with the opposite sign and a high-pass filter stabilizes the forward whirl, which can have a frequency one or two orders of magnitude higher than the backward whirl, permitting very independent action of the two terms. Because the physical gyroscopic torques are proportional to the spinning speed of the shaft, it is convenient to gain-schedule the cross-axis control terms by making them proportional to shaft speed. This has the added benefit of avoiding a somewhat awkward zero-speed splitting of the tilt-mode eigenvalues

Feed-forward control of gear mesh vibration using piezoelectric actuators

This paper presents a novel means for suppressing gear mesh-related vibrations. The key components in this approach are piezoelectric actuators and a high-frequency, analog feed-forward controller. Test results are presented and show up to a 70-percent reduction in gear mesh acceleration and vibration control up to 4500 Hz. The principle of the approach is explained by an analysis of a harmonically excited, general linear vibratory system

High-Temperature Switched-Reluctance Electric Motor

An eight-pole radial magnetic bearing has been modified into a switched-reluctance electric motor capable of operating at a speed as high as 8,000 rpm at a temperature as high as 1,000 F (=540 C). The motor (see figure) is an experimental prototype of starter-motor/generator units that have been proposed to be incorporated into advanced gas turbine engines and that could operate without need for lubrication or active cooling. The unique features of this motor are its electromagnet coils and, to some extent, its control software. Heretofore, there has been no commercial-off-the-shelf wire capable of satisfying all of the requirements for fabrication of electromagnet coils capable of operation at temperatures up to 1,000 F (=540 C). The issues addressed in the development of these electromagnet coils included thermal expansion, oxidation, pliability to small bend radii, micro-fretting, dielectric breakdown, tensile strength, potting compound, thermal conduction, and packing factor. For a test, the motor was supported, along with a rotor of 18 lb (.8-kg) mass, 3-in. (.7.6-cm) diameter, 21-in. (.53-cm) length, on bearings packed with high-temperature grease. The motor was located at the mid span of the rotor and wrapped with heaters. The motor stator was instrumented with thermocouples. At the time of reporting the information for this article, the motor had undergone 14 thermal cycles between room temperature and 1,000 F (.540 C) and had accumulated operating time >27.5 hours at 1,000 F (=540 C). The motor-controller hardware includes a personal computer equipped with analog-to-digital input and digital-to-analog output cards. The controller software is a C-language code that implements a switched-reluctance motor-control principle: that is, it causes the coils to be energized in a sequence timed to generate a rotating magnetic flux that creates a torque on a scalloped rotor. The controller can operate in an open- or closed-loop mode. In addition, the software has been modified to enable the simultaneous operation of the prototype motor or another, similar apparatus as both a motor and a magnetic bearing. Combined bearing/motor operation has been demonstrated at room temperature but had not yet been demonstrated at high temperature at the time of reporting the information for this article

Stability Limits of a PD Controller for a Flywheel Supported on Rigid Rotor and Magnetic Bearings

Active magnetic bearings are used to provide a long-life, low-loss suspension of a high-speed flywheel rotor. This paper describes a modeling effort used to understand the stability boundaries of the PD controller used to control the active magnetic bearings on a high speed test rig. Limits of stability are described in terms of allowable stiffness and damping values which result in stable levitation of the nonrotating rig. Small signal stability limits for the system is defined as a nongrowth in vibration amplitude of a small disturbance. A simple mass-force model was analyzed. The force resulting from the magnetic bearing was linearized to include negative displacement stiffness and a current stiffness. The current stiffness was then used in a PD controller. The phase lag of the control loop was modeled by a simple time delay. The stability limits and the associated vibration frequencies were measured and compared to the theoretical values. The results show a region on stiffness versus damping plot that have the same qualitative tendencies as experimental measurements. The resulting stability model was then extended to a flywheel system. The rotor dynamics of the flywheel was modeled using a rigid rotor supported on magnetic bearings. The equations of motion were written for the center of mass and a small angle linearization of the rotations about the center of mass. The stability limits and the associated vibration frequencies were found as a function of nondimensional magnetic bearing stiffness and damping and nondimensional parameters of flywheel speed and time delay

High-Temperature, High-Load-Capacity Radial Magnetic Bearing

A radial heteropolar magnetic bearing capable of operating at a temperature as high as 1,000 F (=540 C) has been developed. This is a prototype of bearings for use in gas turbine engines operating at temperatures and speeds much higher than can be withstood by lubricated rolling-element bearings. It is possible to increase the maximum allowable operating temperatures and speeds of rolling-element bearings by use of cooling-air systems, sophisticated lubrication systems, and rotor-vibration- damping systems that are subsystems of the lubrication systems, but such systems and subsystems are troublesome. In contrast, a properly designed radial magnetic bearing can suspend a rotor without contact, and, hence, without need for lubrication or for cooling. Moreover, a magnetic bearing eliminates the need for a separate damping system, inasmuch as a damping function is typically an integral part of the design of the control system of a magnetic bearing. The present high-temperature radial heteropolar magnetic bearing has a unique combination of four features that contribute to its suitability for the intended application: 1. The wires in its electromagnet coils are covered with an insulating material that does not undergo dielectric breakdown at high temperature and is pliable enough to enable the winding of the wires to small radii. 2. The processes used in winding and potting of the coils yields a packing factor close to 0.7 . a relatively high value that helps in maximizing the magnetic fields generated by the coils for a given supplied current. These processes also make the coils structurally robust. 3. The electromagnets are of a modular C-core design that enables replacement of components and semiautomated winding of coils. 4. The stator is mounted in such a manner as to provide stable support under radial and axial thermal expansion and under a load as large as 1,000 lb (.4.4 kN)