1 / 21

Gregory D. Buckner Assistant Professor Department of Mechanical and Aerospace Engineering

Electromechanics: Integrating 19 th Century Theory with 21 st Century Technology – Applications to Aerospace Systems. Gregory D. Buckner Assistant Professor Department of Mechanical and Aerospace Engineering September 4, 2003. GDB 090403-1. PRESENTATION OVERVIEW. Electromechanics

cili
Download Presentation

Gregory D. Buckner Assistant Professor Department of Mechanical and Aerospace Engineering

An Image/Link below is provided (as is) to download presentation Download Policy: Content on the Website is provided to you AS IS for your information and personal use and may not be sold / licensed / shared on other websites without getting consent from its author. Content is provided to you AS IS for your information and personal use only. Download presentation by click this link. While downloading, if for some reason you are not able to download a presentation, the publisher may have deleted the file from their server. During download, if you can't get a presentation, the file might be deleted by the publisher.

E N D

Presentation Transcript


  1. Electromechanics: Integrating 19th Century Theory with 21st Century Technology – Applications to Aerospace Systems Gregory D. Buckner Assistant Professor Department of Mechanical and Aerospace Engineering September 4, 2003 GDB 090403-1

  2. PRESENTATION OVERVIEW • Electromechanics • What is Electromechanics? • Bridging 19th Century Theory with 21st Century Technology • Electromechanics Research at NCSU • EM Research Laboratory • Active Magnetic Bearings • Automated Chatter Prediction on HSM Centers • Semi-Active Vehicle Suspensions • Other Projects • Conclusions GDB 090403-2

  3. WHAT IS ELECTROMECHANICS? • Electromechanics explores the interactions of electric and magnetic fields (electromagnetism) and how these interactions can be harnessed to produce mechanical work • An inherently multi-disciplinary engineering field • The design, analysis, and control of electric machines: GDB 090403-3

  4. WHAT IS ELECTROMECHANICS? • Electromechanics is a “mature” engineering discipline • Principles unchanged since the 19th century (Maxwell’s equations) • The design of many industrial machines (motors, generators) has changed little in the past 25 years • Once a core component of the Electrical Engineering curriculum, now few engineering undergraduates are exposed GDB 090403-4

  5. WHAT IS ELECTROMECHANICS? • Electromechanics  Mechatronics (though the two are highly related and complimentary) GDB 090403-5

  6. WHAT IS ELECTROMECHANICS? • Recent advancements in technology have renewed interest and extended applications • Materials • High-energy permanent magnets • “Smart materials” – SMAs, MR fluids, magnetostrictives, etc. • Superconductors, hi-mu alloys • Manufacturing Processes • Precision machining – DTMs, ultramills • MEMS fabrication - silicon micromachining, LIGA, etc. • Computational Advancements • Microcontrollers • Design software – FEA, BEM • Simulation software – MATLAB, Simulink • Control algorithms – adaptive and intelligent control GDB 090403-6

  7. ELECTROMECHANICS RESEARCH AT NCSU • Electro-Mechanics Research Lab (EMRL) • Research focus: development and transfer of enabling technologies (a bridge between 19th century theory and 21st century technology) • Over $1.2M in research grants • $725K federal: NSF CISE, NSF DMII, NASA NIA, DOE NNP • $450K industrial: Ethicon (J&J), Gillette, Vulcancraft, Carrera, AO Smith, Hyster/Yale • $35K non-profit: Doris Duke, NCIIA • Supported 26 student researchers • 6 PhD (4 current) • 11 Masters (2 current) • 9 Undergraduate (2 current) • Resulted in 21 papers, 5 patent disclosures GDB 090403-7

  8. ELECTROMECHANICS RESEARCH AT NCSU • Intelligent Controllers for Active Magnetic Bearings • Sponsor: NSF (CISE) • Research Objective: Develop self-learning (“intelligent”) AMB controllers that will enable the development of practical flywheel battery systems for automotive and aerospace applications NASA Graphics from website GDB 090403-8

  9. ELECTROMECHANICS RESEARCH AT NCSU • Intelligent Controllers for Active Magnetic Bearings • Motivation: Flywheels for space applications • Motor when solar panels are active • Generate when panels are inactive • AMBs provide non-contacting support, reduce friction and wear, and eliminate lubrication concerns • Have higher power and energy densities than batteries • Longer life! NASA Graphics from website • CONs • AMBs are inherently unstable, highly nonlinear • Gyroscopic and bending effects, model uncertainty GDB 090403-9

  10. ELECTROMECHANICS RESEARCH AT NCSU • Intelligent Controllers for Active Magnetic Bearings • Approach: • Artificial neural networks are used to characterize (“learn”) model uncertainty • These intelligent uncertainty bounds are fused with robust control synthesis • Resulting controller adapts for improved performance, responds to parameter variations • This fusion of intelligent and robust control is both innovative and applicable to a wide range of problems GDB 090403-10

  11. ELECTROMECHANICS RESEARCH AT NCSU • Intelligent Controllers for Active Magnetic Bearings • Results: • This intelligent approach has been successfully applied to single-input, single-output magnetic bearings • Application to a 5-axis, flexible rotor AMB test rig is underway GDB 090403-11

  12. ELECTROMECHANICS RESEARCH AT NCSU • Integrated Chatter Prediction on High Speed Machining Centers • Sponsor: Vulcancraft, Inc. • Research Objectives: • Increase High Speed Machining (HSM) productivity by predicting the onset of regenerative chatter on milling centers • Design non-contacting EM actuators, sensors, and algorithms for modal testing of HSM centers Boeing Graphics from website GDB 090403-12

  13. ELECTROMECHANICS RESEARCH AT NCSU • Integrated Chatter Prediction on High Speed Machining Centers • Motivation: • HSM advantages: • Very high material removal rates (MRR) in aluminum • Tooth passing frequency approaches or exceeds first natural frequency • Parts simultaneously lighter, stronger, cheaper • Embraced by aircraft industry • HSM disadvantages: • Limited by unstable self-induced vibration… ‘regenerative chatter’ • Poor part surface finish • Tool wear/breakage GDB 090403-13

  14. ELECTROMECHANICS RESEARCH AT NCSU • Integrated Chatter Prediction on High Speed Machining Centers • Approach: • Develop non-contating EM actuator, tool, displacement sensor • Use modal testing to identify the combined tool/toolholder/spindle dynamics • Use RCSA to identify the toolholder/spindle dynamics • Combined response for any tool can be computed GDB 090403-14

  15. ELECTROMECHANICS RESEARCH AT NCSU • Integrated Chatter Prediction on High Speed Machining Centers • Results: • Developed non-contacting EM actuator, displacement sensor, tool • Currently validating RCSA to identify toolholder/spindle dynamics GDB 090403-15

  16. ELECTROMECHANICS RESEARCH AT NCSU • Optimization and Control of MR Dampers for Semi-Active Vehicle Suspensions • Sponsor: Carrera, Inc. (Atlanta) • Research Objectives: • optimize the electromechanics of a commercial semi-active shock absorber • develop and demonstrate real-time actuation and control to improve ride quality and vehicle handling GDB 090403-16

  17. ELECTROMECHANICS RESEARCH AT NCSU • Optimization and Control of MR Dampers for Semi-Active Vehicle Suspensions • Motivation: • Ride quality and vehicle handling represent design tradeoffs • Off-road suspensions require large displacements, peak forces • Active vehicles suspensions are COMPLEX, expensive, durability is questionable • Semi-active suspensions, particularly MR dampers, have fewer moving parts, are cheaper, more durable GDB 090403-17

  18. ELECTROMECHANICS RESEARCH AT NCSU • Optimization and Control of MR Dampers for Semi-Active Vehicle Suspensions • Results: • Carrera’s Magneshock was redesigned using FEA for optimal EM performance • Efficiency, damping characteristics were significantly improved • FL controllers were developed and demonstrated on a vehicle equipped with Magneshocks • Ride quality was significantly improved vs. passive shocks GDB 090403-18

  19. ELECTROMECHANICS RESEARCH AT NCSU • Other Ongoing Research Projects • AMBs for Tool Deflection Compensation in Precision Milling Operations • Sponsor: NSF (DMII) • Co-I: Dr. Tom Dow, NCSU Precision Engineering Center • Development of a Low-Frequency MEMS Vibration Sensor • Sponsor: DOE (NNP Fellowship) • Collaborator: Dr. Angus Kingon, NCSU Thin Films Lab GDB 090403-19

  20. ELECTROMECHANICS RESEARCH AT NCSU • Other Ongoing Research Projects • Reliability Analysis and Life Prediction of Aircraft Structures • Sponsor: NASA (NIA) • Co-I: Dr. Mohammad Noori, NCSU MAE • Technology Development for Robot-Assisted Cardiac Surgery • Sponsor: CardioVations (J&J) • Collaborator: Dr. Randolph Chitwood, ECU Brody School of Medicine GDB 090403-20

  21. ELECTROMECHANICS RESEARCH AT NCSU • Conclusions • Electromechanics research at NCSU focuses on the development and transfer of enabling technologies (a bridge between 19th century theory and 21st century technology) • A broad range of research projects are underway, funded by federal agencies and industries and conducted at the EMRL • Aerospace applications are obvious in many of these projects • Ideas for specific NIA projects are being explored GDB 090403-21

More Related