ALBERT

Description: The development and use of a large Magnetic Suspension and Balance System (MSBS) in wind tunnels is examined, discussing NASA-sponsored research to develop a large MSBS, and the 2 MSBS already in use. The MSBS holds the model in an arbitrary position in the wind tunnel test section and measures the forces and moments acting on the model. Technologies for building a large MSBS have been developed, and research is being done to reduce building costs. Magnetic suspension is advantageous because it completely eliminates interference from mechanical support systems such as stings or struts and it allows for easy rotation and translation of the model. Advances allowing operation at higher temperatures, probably using liquid nitrogen instead of liquid helium may reduce the cost of MSBS operation. A large MSBS would require power controllers with capacity up to 10 MW, efficiency approaching 98 percent and the ability to reverse the sign of both voltage and current. Technologies include the electro-magnetic position sensor, model positioning sensing, digital controller, and a precalibrated resistance strain-gage balance.

Description: As part of a NASA effort to develop the technology and techniques required to demonstrate the magnetic suspension of objects over wide ranges of attitudes, a small-scale demonstration project was undertaken. The objectives here are to suspend a cylindrical element containing a permanent magnet core, to demonstrate stability and control in five degrees-of-freedom, and to permit controlled rotation of the model in one degree-of-freedom over the full range of 360 deg. Further constraints are that all suspension and control electromagnets are to be behind a flat plane, located some distance from the model. Since this is a ground-based experiment and in order to maintain generality, the plane is chosen to be horizontal with the model levitated above the plane by repulsive forces.

Description: The ability to get good experimental data in wind tunnels is often compromised by things seemingly beyond our control. Inadequate Reynolds number, wall interference, and support interference are three of the major problems in wind tunnel testing. Techniques for solving these problems are available. Cryogenic wind tunnels solve the problem of low Reynolds number. Adaptive wall test sections can go a long way toward eliminating wall interference. A magnetic suspension and balance system (MSBS) completely eliminates support interference. Cryogenic tunnels, adaptive wall test sections, and MSBS are surveyed. A brief historical overview is given and the present state of development and application in each area is described.

Description: The classification of magnetic suspension devices into small-gap and large-gap categories is addressed. The relative problems of position sensing, control systems, power supplies, electromagnets, and magnetic field or force analysis are discussed. The similarity of all systems from a controls standpoint is qualified. Some applications where large-gap technology is being applied to systems with a physically small air-gap are mentioned. Finally, the applicability of some other suspension approaches, such as electrodynamic or superconducting are briefly addressed.

Description: This paper will briefly review previous work in wind tunnel Magnetic Suspension and Balance Systems (MSBS) and will examine the handful of systems around the world currently known to be in operational condition or undergoing recommissioning. Technical developments emerging from research programs at NASA and elsewhere will be reviewed briefly, where there is potential impact on large-scale MSBSS. The likely aerodynamic applications for large MSBSs will be addressed, since these applications should properly drive system designs. A recently proposed application to ultra-high Reynolds number testing will then be addressed in some detail. Finally, some opinions on the technical feasibility and usefulness of a large MSBS will be given.

Description: Static modelling of magnetic bearings is often carried out using magnetic circuit theory. This theory cannot easily include nonlinear effects such as magnetic saturation or the fringing of flux in air-gaps. Modern computational tools are able to accurately model complex magnetic bearing geometries, provided some care is exercised. In magnetic suspension applications, the magnetic fields are highly three-dimensional and require computational tools for the solution of most problems of interest. The dynamics of a magnetic bearing or magnetic suspension system can be strongly affected by eddy currents. Eddy currents are present whenever a time-varying magnetic flux penetrates a conducting medium. The direction of flow of the eddy current is such as to reduce the rate-of-change of flux. Analytic solutions for eddy currents are available for some simplified geometries, but complex geometries must be solved by computation. It is only in recent years that such computations have been considered truly practical. At NASA Langley Research Center, state-of-the-art finite-element computer codes, 'OPERA', 'TOSCA' and 'ELEKTRA' have recently been installed and applied to the magnetostatic and eddy current problems. This paper reviews results of theoretical analyses which suggest general forms of mathematical models for eddy currents, together with computational results. A simplified circuit-based eddy current model proposed appears to predict the observed trends in the case of large eddy current circuits in conducting non-magnetic material. A much more difficult case is seen to be that of eddy currents in magnetic material, or in non-magnetic material at higher frequencies, due to the lower skin depths. Even here, the dissipative behavior has been shown to yield at least somewhat to linear modelling. Magnetostatic and eddy current computations have been carried out relating to the Annular Suspension and Pointing System, a prototype for a space payload pointing and vibration isolation system, where the magnetic actuator geometry resembles a conventional magnetic bearing. Magnetostatic computations provide estimates of flux density within airgaps and the iron core material, fringing at the pole faces and the net force generated. Eddy current computations provide coil inductance, power dissipation and the phase lag in the magnetic field, all as functions of excitation frequency. Here, the dynamics of the magnetic bearings, notably the rise time of forces with changing currents, are found to be very strongly affected by eddy currents, even at quite low frequencies. Results are also compared to experimental measurements of the performance of a large-gap magnetic suspension system, the Large Angle Magnetic Suspension Test Fixture (LAMSTF). Eddy current effects are again shown to significantly affect the dynamics of the system. Some consideration is given to the ease and accuracy of computation, specifically relating to OPERA/TOSCA/ELEKTRA.

Description: The current status of wind tunnel magnetic suspension and balance system development is briefly reviewed. Technical work currently underway at NASA Langley Research Center is detailed, where it relates to the ultra-high Reynolds number application. The application itself is addressed, concluded to be quite feasible, and broad design recommendations given.

Description: Classical design methods involved in magnetic bearings and magnetic suspension systems have always had their limitations. Because of this, the overall effectiveness of a design has always relied heavily on the skill and experience of the individual designer. This paper combines two approaches that have been developed to aid the accuracy and efficiency of magnetostatic design. The first approach integrates classical magnetic circuit theory with modern optimization theory to increase design efficiency. The second approach uses loss factors to increase the accuracy of classical magnetic circuit theory. As an example, an axial magnetic thrust bearing is designed for minimum power.