ALBERT

Description: This article 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% 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.

Description: In structural analysis the amount of computational time necessary for a solution is proportional to the number of degrees of freedom times the bandwidth squared. In implicit time analysis, this must be done at each discrete point in time. If, in addition, the problem is nonlinear, then this solution must be iterated at each point in time. If the bandwidth is large, the size of the problem that can be analyzed is severely limited. The multi-grid method is a possible algorithm which can make this solution much more computationally efficient. This method has been used for years in computational fluid mechanics. It works on the fact that relaxation is very efficient on the high frequency components of the solution (nearest neighbor interactions) and not very good on low frequency components of the solution (far interactions). The multi-grid method is then to relax the solution on a particular model until the residual stops changing. This indicates that the solution contains the higher frequency components. A coarse model is then generated for the lower frequency components to the solution. The model is then relaxed for the lower frequency components of the solution. These lower frequency components are then interpolated to the fine model. In computational fluid mechanics the equations are usually expressed as finite differences.

Description: This paper contains a summary of the experience of the authors in the field of electromechanical modeling for rotating machinery - active vibration control. Piezoelectric and magnetic bearing actuator based control are discussed.

Description: 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.

Description: 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.

Description: 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.

Description: With growing concerns about global warming, there is a need to develop pollution-free aircraft. One approach is to use hydrogen-fueled aircraft that use fuel cells or turbogenerators to produce electric power to drive the electric motors that turn the aircraft s propulsive fans. Hydrogen fuel would be carried as a liquid, stored at its boiling point of 20.5 K (-422.5 F). Conventional electric motors, however, are too heavy for aircraft propulsion. We need to develop high-power, lightweight electric motors (highpower- density motors). One approach is to increase the conductivity of the wires by cooling them with liquid hydrogen (LH2). This would allow superconducting rotors with an ironless core. In addition, the motor could use very pure aluminum or copper, substances that have low resistances at cryogenic temperatures. A preliminary design of a 450-hp LH2-cooled electric motor was completed and is being manufactured by a contractor. This motor will be tested at the NASA Glenn Research Center and will be used to test different superconducting materials such as magnesium diboride (MgB2). The motor will be able to operate at speeds of up to 6000 rpm.

Description: Active stall control is a current research area at the NASA Glenn Research Center that offers a great benefit in specific fuel consumption by allowing the gas turbine to operate beyond the onset of stall. Magnetic bearings are being investigated as a new method to perform active stall control. This enabling global aviation safety technology would result in improved fuel efficiency and decreased carbon dioxide emissions, as well as improve safety and reliability by eliminating oil-related delays and failures of engine components, which account for 40 percent of the commercial aircraft departure delays. Active stall control works by perturbing the flow in front of the compressor stage such that it cancels the pressure wave, which causes the compressor to go into stall. Radial magnetic bearings are able to whirl the shaft so that variations in blade tip leakage would flow upstream causing a perturbation wave that could cancel the rotating stall cell. Axial or thrust magnetic bearings cannot be used to cancel the surge mode in the compressor because they have a very low bandwidth and thus cannot modulate at a high enough frequency. Frequency response is limited because the thrust runner cannot be laminated. To improve the bandwidth of magnetic thrust bearings, researchers must use laminations to suppress the eddy currents. A conical magnetic bearing can be laminated, resulting in increased bandwidth in the axial direction. In addition, this design can produce both radial and thrust force in a single bearing, simplifying the installation. The proposed solution combines the radial and thrust bearing into one design that can be laminated--a conical magnetic bearing. The new conical magnetic bearing test rig, funded by a Glenn fiscal year 2002 Director's Discretionary Fund, was needed because none of the existing rigs has an axial degree of freedom. The rotor bearing configuration will simulate that of the main shaft on a gas turbine engine. One conical magnetic bearing replaces the ball bearing in front of the compressor, and the second replaces the roller bearing behind the burner. The rig was made operational to 10,000 rpm under Smart Efficient Components funding, and both position and current adaptive vibration control have been demonstrated. Upon program completion, recommendations will be made as to the efficacy of the conical magnetic bearing for active stall control.

Description: 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.

Description: This paper describes the development of effective and reliable minimum-weight and minimum-envelope vibration dampers for cryogenic turbines. To meet this objective, a high speed test rig was designed and fabricated, which is currently used to test a curved beam type damper. The operation, capacity, structural characteristics, measurement system, and safety features of the cryogenic damper test rig are discussed.