TEXAS A

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• TEXAS AM CENTER FOR SPACE POWER
• AT NORTHRUP GRUMMAN
• 01 AUGUST 2006
• PRESENTATION II - RELATED CAPABILITIES
• Dr. Alan Palazzolo, Clinton Johnson
• Erwin Thomas

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• Background
• The Vibration Control and Electromechanics Lab
  VCEL at TAMU was Founded by Dr. Palazzolo in
  1986.
• Specialty Areas Magnetic Bearings for Flywheels
  and Turbomachinery, High Temperature (1,000F
  Magnetic Bearings and Motors), Rotordynamics,
  Machinery and Structural Vibration Control,
  Active Vibration Control, Bearing and Seal
  Analysis
• Sponsors Include TAMU Center for Space Power,
  NASA Glenn, NASA Marshall, Office of Naval
  Research, TAMU Turbomachinery Research
  Consortium, US Flywheels, Optimal Energy
  (Flywheels), Rockwell Scientific,Korean Institute
  of Metals and Materials

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• Achievements (General)
• 50 Archival Journal Publications
• 6M Funded Research
• 1 US Patent Magnetic Bearing Controller for High
  Power Density Flywheels
• 1 US Patent Pending Redundant / Fault Tolerant
  Magnetic, Homopolar Magnetic Bearings
• 1 RD 100 Award High Temperature Magnetic
  Bearing (1,000 F)

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• Achievements (Flywheel Magnetic Bearing Related)
• Supplied Magnetic Bearing Digital Controller and
  Commissioning Services for Initial Startup of 40
  krpm and 60 krpm (DEV-1) Flywheels at US
  Flywheels Inc.
• Designed and Built Magnetic Bearings for NASA
  Glenn G2 Flywheels
• Designed Magnetic Bearings for NASA Glenn G3
  Flywheel
• Supplied Magnetic Bearing Design, Digital
  Controller, Commissioning Services and Power
  Electronics for Optimal Energy Magnetic Bearing
  Flywheel
• Supplied a Digital Controller, Commissioning
  Services and Power Electronics for Univ. of
  Texas Train Flywheel
• Designed and Built PLM (Preload Loss Monitor)
  Flywheel Module Including the Magnetic Bearings
  and Controller / Power Electronics / Sensor
  System. Successfully Spun at 42,000 rpm on the
  ground and at 0, 1 and 2 gs in the NASA Zero
  Gravity Plane.

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Left DEV-1 , Top Right G2 (581 Watt-Hours),
Bottom Right G3 (2136 Watt- Hours)
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• Recent Publications
• Kenny, A. and Palazzolo, A., Single
  Plane Radial, Magnetic Bearings Biased with Poles
  Containing Permanent Magnets, ASME J. of
  Mechanical Design, March 2003, Vol. 125, pp.
  178-185.
• Minihan, T., Lei, S., Sun, G. and
  Palazzolo, A., Large Motion Tracking Control for
  Thrust Magnetic Bearings With Fuzzy Logic,
  Sliding Mode, and Direct Linearization, Journal
  of Sound and Vibration, 263 (2003), 549-567.
• Sun, G., Palazzolo, A., Provenza, A. and
  Montague, G., Detailed Ball Bearing Model for
  Magnetic Suspension Auxiliary Service, J. of
  Sound and Vibration, Vol. 269, Issues 3-5, 22
  January 2004, pp. 933-963.
• Kenny, A., Palazzolo, A., Montague, G.
  and Kascak, A., Theory and Test Correlation for
  Laminate Stacking Factor Effect on Homopolar
  Magnetic Bearing Stiffness, ASME J. of
  Engineering for Gas Turbines and Power, Vol. 126,
  January 2004, pp. 142-146.
• Li, Ming Hsiu, Palazzolo,A., Kenny, A.,
  Provenza, A., Beach,R., Kascak,A., Fault
  Tolerant Homopolar Magnetic Bearings,
  IEEE Trans. On Magnetics, Vol. 40, No. 5, Sept.
  2004, pp. 3308 3318.
• Provenza, A., Montague, G., Jansen,
  M., Palazzolo, A., and Jansen, R., High
  Temperature Characterization of a Radial Magnetic
  Bearing for Turbomachinery, J. of Engineering
  for Gas Turbines and Power. , v 127, n 2, April,
  2005, p 437-444

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SOLID MODEL of PLM FLYWHEEL MODULE
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Flywheel Radial Magnetic Bearing
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3D Electromagnetic Finite Element Model of G2
Bearing
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G2 Magnetic Bearing Design Correlation
Contour Plot of Gap Flux Density When Rotor
Offset .004 in from center Air Gap .016 to
.024 inch.
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Magnetic Bearing Control Diagram Showing CDMs
for Fault Tolerant Control (FTC)
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Rotor Displacements in the Radial and
Axial Directions This example illustrates the FTC
operation. Both bearings have the same failure
combination, pole 1-2-3-4 failure. The power
amplifier (PA) failures initiate at 0.1 (s), and
the time delay for swapping CDMs is 20 (ms).
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Currents in Combo Bearing
During Pole 1-2-3-4- Failure
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Sensor Development Test Rig in Vacuum Vessel
(55,000 rpm)
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• G2 Magnetic Bearing Stiffness Measurements
• Using a linear force model the bearing forces can
  be modeled as where j signifies the corresponding
  bearing (i.e. j CB, RB), And i signifies the
  ith coordinate direction. Where

Magnetic bearing levitation force diagram
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• G2 Magnetic Bearing Design Correlation

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G2 Magnetic Bearing Correlation Summary
G2 Radial Bearing Parameters G2 Radial Bearing Parameters G2 Radial Bearing Parameters G2 Radial Bearing Parameters G2 Radial Bearing Parameters
  Predicted Value Predicted Value Measured Value Measured Value
Position Stiffness -6.16 lbs/mil -6.8 lbs/mil
Current Stiffness 8.8 lbs/Amp 10.4 lbs/Amp
Load Capacity 70 lbs 85 lbs
Bias Flux Density --- Tesla 0.82 Tesla
Pole Inductance 1.35 mH 1.2 mH
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G2 Combo Bearing Parameters G2 Combo Bearing Parameters G2 Combo Bearing Parameters G2 Combo Bearing Parameters G2 Combo Bearing Parameters
  Predicted Value Predicted Value Measured Value Measured Value
Position Stiffness -6.9 lbs/mil -8.3 lbs/mil
Current Stiffness 9.3 lbs/Amp 8.5 lbs/Amp
Load Capacity 74 lbs 90 lbs
Bias Flux Density 0.82 Tesla --- Tesla
Pole Inductance 1.35 mH --- mH
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PLM Flywheel Mounted on Bottom of Spin Pit
Lid
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Empty Spin Pit and Pit With PLM Flywheel
Enclosed