8
429 Shock and Vibration Testing of an AMB Supported Energy Storage Flywheel * Lawren ce HAWKIN S**, Bri an MURPH Y ** *, Jo seph ZIERER *** and Ri chard HAYE S* ** Shock and v ibration testing of an Active Magnetic Beari ng (AMB ) supported energy sto rage fl ywheel is presente d. The flywheel is under de velopment at the Uni versity of T exas-Center for Electromechani cs (UT - CEM ) for application in a transit bus. T he fl ywheel is gim ba l mount ed to reduce the gyr oscopic forces transm it· ted to the magnetic bearings during pitchi ng a nd rolling motio ns of the bus. The system was placed on a hydraulic ter ra in simula tor and driven thro ugh p itch, roll a nd shock motions equivalent to 150% of maximum ex pected bus frame values. Although the AMB control appro ach was origina ll y developed specifically to ensure roto r- dynamic stabil ity, rel ative r otor/housing motion was typically less than half of the backup bear ing clearance under a ll test ed conditions. Test res ults are presented and compared to anal ytical predictions f or the 35 000 rpm no mina l operati ng speed. The impact of the AMB control algorithm is discussed relative to the input forcing func- tion. Key Words: Magneti c Bear ings, Flywheel En ergy Storage, Mag netic Bear ing Sh oc k Response, Flywheel Ha ttery L Introduc tion UT-CEM is developing a fl ywheel energy storage system, or fl ywheel batte ry (F WB), for use in a power -a veraging role in a hybrid electric bus. Several aspec ts of this project have been de tailed in the litera- t ure. Hayes<' 1 , described the FWB design consid era - tions and low speed test ing. Hawkins< 21 described the mag netic bearings, control approac h and backup bear- ings for th is system. Hawk ins< 31 described stator power consumption measurements with and without ada ptive synchronous cancell at ion. Murphy(· ll de- sc r ibed the co nsid erations of vehicle/ fl ywheel dyna mi cs that led to th e choices of the or ie ntat ion of the FWB in the vehicle, the sizing the m agnetic bear- ings, and the gimbal mo unti ng of the flywheel housing to the vehi cl e frame. Thi s paper d escr ibes sh ock and vibrat ion test ing of t he FWB, including the test facility, development of • Received 27th Se ptember. 2002 (No. 02-51 :1 4) •• Calnetix, Inc .. 12880 Mo01·e Street, Ce rritos, Califor- nia 90703, USA. E- mail: larry@calnetix.com ... Center for Electromechanics, Univ ersity of Texas. Mail Stop R7000, Austin, T exas 78712, USA JS!V I f: frtlemational Journal r eq uirements, and test results. Thi s is the first controlled, large m ot ion vi bration test of a magnetic bearing supported fl ywheel batte ry that is large enough to be used f or vehicular power averaging. The goal of this ph ase of the development was to design, f ab ricate , and perform shock and vi brat ion t esting on a complete mechanica l sk id for the vehic ular flywheel battery. The sk id int egrates the FWB, a gimba l mount, gimbal axis dampers, vib ra tion i solation, nec- essary auxil iar y su bsystems, and electrical co nnec- tions i nto a pack age that is compat ible with the Northr op -Grumman Adva nced T echn ology Transit Bus (AT TB). T esting was accomplished with the fl ywheel sk id mounted on a fully programmable fo ur corn er terrain simul at or. Th e test pl an was designed to eval uate suitability of the flywheel skid for the transit bus app lication and test conditions were devel- oped to exceed the expected loads for the A TTB . 2. Flywheel Battery Ch a r acteristics The fl ywheel r otor, which can oper ate at up to 40 000 rpm, spins on m agnet ic bearings with a nominal design capac ity of 3 g in all di rections. Th is load capacity meets the r equ irem ents imposed by typical Ser ies C, Vo l. - lll, 1\o. 2,

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429

Shock and Vibration Testing of an AMB Supported Energy Storage Flywheel*

Lawrence HAWKIN S**, Bri an MURPHY ***,

Joseph ZIERER *** and Richard HAYES* **

Shock and vibration testing of an Active Magnetic Bearing (AMB) suppor ted energy storage flywheel is presented. The flywheel is under development at the University of Texas- Center for Electromechanics (UT-CEM) for application in a transit bus. T he flywheel is gimbal mounted to reduce the gyroscopic forces transmit· ted to the magnetic bearings during pitching and rolling motions of the bus. The system was placed on a hydraulic ter ra in simulator and driven through pitch, roll and shock motions equivalent to 150% of maximum expected bus frame values. Although the AMB control approach was originall y developed specifically to ensure rotor­dynamic stability, relative rotor/housing motion was typically less than half of the backup bearing clearance under all tested conditions. Test results are presented and compared to analytical predictions for the 35 000 rpm nomina l operating speed. The impact of the AMB control algorithm is discussed relative to the input forcing func­tion.

Key Words: Magnetic Bearings, Flywheel Energy Storage, Magnetic Bearing Shock Response, Flywheel Hattery

L Introduction

UT-CEM is developing a flywheel energy st orage system, or flywheel battery (FWB), for use in a power-averaging role in a hybrid electric bus. Several aspects of this project have been detailed in the litera­ture. Hayes<'1, described the FWB design considera­tions and low speed test ing. Hawkins<21 described the magnetic bearings, control approach and backup bear­ings for this system. Hawkins<31 described stator power consumption measurements with and without adaptive synchronous ca ncellation. Murphy(·ll de­scr ibed the considerations of vehicle/ flywheel dynamics that led to the choices of the orientation of the FWB in the vehicle, the sizing the magnetic bear­ings, and the gimbal mounting of the flywheel housing to the vehicle frame.

This paper describes shock and vibration testing of the FWB, including the test facility, development of

• Received 27th September. 2002 (No. 02-51:14) •• Calnetix, Inc .. 12880 Mo01·e Street , Cerritos, Califor­

nia 90703, USA. E- mail: [email protected] ... Center for Electromechanics, University of Texas . Mai l Stop R7000, Aust in, Texas 78712, USA

JS!VI f: frtlemational Journal

requirements, and test results. This is the first controlled, large motion vibration test of a magnetic bearing supported flywheel battery that is large enough to be used for vehicular power averaging. T he goal of this phase of the development was to design, fabricate, and perform shock and vibration testing on a complete mechanical skid for the vehicular flywheel battery. The skid integrates t he FWB, a gimbal mount, gimbal axis dampers, vibra tion isolation, nec­essary auxil iary subsystems, and electrical connec­tions into a package that is compatible with the Northrop-Grumman Advanced T echnology Transit Bus (AT TB). T esting was accomplished with the flywheel skid mounted on a fully programmable four corner terrain s imulator. The test plan was designed to evaluate suitability of the flywheel skid for the transit bus application and test conditions were devel­oped to exceed the expected loads for the A TTB.

2. Flywheel Battery Characteristics

The flywheel rotor, which can operate at up to 40 000 rpm, spins on magnetic bear ings with a nominal design capacity of 3 g in all directi ons. This load capacity meets the requirements imposed by typical

Ser ies C, Vol. -lll, 1\o. 2 , 200~

430

operating conditions on a transit bus, but to increase the load margin and tolerance to excessive loads, a number of additional precautions were taken. F irst, isolat ion mounts ·were insta lled between the flywheel housing and the mounting system. This attenua tes the vibration transmitted to the flywheel by approximate­ly SO% and is most important during the type of axial shock loading tha t occurs when hitting a pothole, curb, or other suspension bottoming event. Second, by using a gimbal mount wi th appropr iate dampi ng the gyroscopic forces transmitted to t he magne tic bear ­ings during pi tching and rolling of the A T T B are minimized as well. T hese loads are associated with brak ing. turning or changing inclination of the bus. F inally, in the event that the magnetic bearings a re overloaded, ceramic rolling element backup bearings provide a low fr ict ion interface between the rotor and stator. These would be used in the event of severe operating condit ions such as : l ) passing through drainage troughs at 30 mph or greater , 2 ) t raffic accidents, or 3) other conditions that cause the vehi­cle suspension to bottom.

T ables l and 2 summarize FWB and magnetic bear ing characteristics. T he tests reported here were performed on the titanium lest flywheel. When testi ng

Table 1 Fly~Yhccl battery characteristics

Titanium Composite Test Flywheel

Flywheel Nom Spin Speed, rad/s 4,190 3,665

(llJm) (40,000) (35,000)

MIG Power, kW Continuous 110 110 Peak !50 150

Rotor Mass, kg 52 59 (Ibm) (1 14) (129)

Polar Inertia, kg-m" 0.284 0.793 (lbm-in2

) (9691 .(27042._ Transverse Inertia, kg-m2 1.122 1.375

(lbm-in2) (3825) ( 4689)_

Rigid Bodv loflt 0.25 0.58 Bearing Soan, Ill (in) 0.508 (20) 0.508 (20)

Table 2 Magnetic bearing characteristics

Bearing Combo Radial Combo Bearing Bearing Bearing (Radial) (Axial)

Brg Ref Name Brg I Brg2 Thrust Load Capacity, N 1115 670 2230

(lbf) (250) (150) J 50Ql Force Constant, N/A !56 94 303

(lbf/ A) (35) (21 ) (68)

Neg. Stiffness, N/mm 1751 963 3502 (lbf/in) (10,000) (5500) (20,000)

Air Gap, mm 0 .508 0.508 0.508 (in) (.020) (.020) (.020)

Max Current A 7.1 7.1 7.4

St>r iPs C. Vol. 4 6 . No. 2. 200:\

was completed, the test flywheel was machined down and a composite flywheel pressed on, producing the higher energy capacity needed for the A TTB applica­tion. T he final configuration is shown in Fig. 1.

3. Design Considerat ions for Vehicula r FWB Bearing Loads

T he interaction between vehicle and flywheel dynamics produces many sources of bear ing loads not present in a stationary application. These loads were discussed in detai l by Murphy1'', and are summarized below.

3. 1 Shock loads Shock event s, such as potholes, arc common

occurrences in vehicles and are characterized by their brief and transient nature. Shock inputs arc partially fi ltered by the vehicle suspension, which will have r igid body natural frequencies of a few herlz. ·with a

5 0

~ 1i -0.5

" < - 1

-1.5

Radial Bearing (Brg 2)

Motor/Generator

Composite ~-t+-~-- Flywheel Rotor

Combo Bear ing (Brg 1)

Fig. 1 Flywheel battery cross-section

3

Bus Frame Vertical Acceleration at Rear Axle

3.5

Fig. 2 Ver tical acceleration measurement on ATTB rear floor, 4.5 m/s (10 mph) over 0.1 m (4 .0 in) half round speed breaker

]SMC ln!Pmolionol Journal

vertical spin axis, the shock loads will be born largely by the thrust bearing. Fil,rure 2 shows vert ical bus frame acceleration measurements made on a bus traveling over a 0.1 m (4 in) half round speed breaker at 4.5 m/s (10 mph). Other measurements made on an Austin, Texas city transit bus traveling around town produced similar and lower accelerations.

3. 2 Vibration loads Vibration is distinguished from shock in that the

input and response attain steady state amplitudes that are maintained for an appreciable length of time. Sources are cobblestone roads and general road roughness. However, much of this is at higher frc· quencies that are generally filtered by the tires and suspension of the vehicle. The expected contribution to the bearing loads is on the order of a few tenths of a g.

3. 3 Maneuvering loads Vehicle maneuvering refers to the net rigid body

motion of the vehicle, i.e. any event that changes the vehicle linear momentum such as braking, acceleral· ing, or turning. The corresponding linear accelera· tions lead directly to loads on the F\'VB bearings ; however, such loads arc limited to several tenths of a g due to tire adhesion.

3. 4 Gyrodynamic loads Gyrodynamic or gyroscopic loads are produced

when the flywheel spin axis is changed, usually due to maneuvering. A spinning flywheel has a relatively large angular momentum so changing its spin ax is requires significa nt torque, which must be produced by the magnetic bearings. The required torque. T is:

T = lrws& ( 1 )

where 1 P is the polar moment of inertia, ws is the spin speed, and (J is the turning rate of the spin axis. T he associated bearing loads, Fb, are approximately :

FB= T/b ( 2)

vvhere b is the bearing span. \Vhen the flywheel design was initiated, the expected maximum turning rate for the bus was 6.7 degrees/sec (0.1 17 rad/ s). For the composite flywheel, spinning at 35 000 rpm, this gener· ates a bearing load of 669 N (150 lb) at each bearing. For the titanium test flywheel the same turning rate results in a bearing load of 274 N (54 lb) at the same 35 000 rpm spin speed.

3. 5 Rotating mass imbalance loads Rotating mass imbalance produces synchronous

bearing loads that depend on the mass imbalance and the dynamics of the rotor/ bearing system. Although the FWH rotor is well balanced the resul ting bearing loads can still be a significant fraction of bearing capacity. An advantage of using magnetic bearings is that adaptive synchronous cancellation can be used to nearly eliminate bearing loading due to mass imbal·

}Sii'II:; lnl!'m alional }oumal

431

ance. T his has been demonstrated by many authors, and was described for this flywheel by Hawkins(3).

3. 6 Design considerations Of the five loading sources mentioned above,

th ree of them, shock, gyrodynamic, and mass imbal· ance, require design consideration to mitigate the loads. The shock loads a re reduced by using elas· tomeric shock isolators between the gimbal mounting frame and the housing. The mass imbalance loads are reduced as ment ioned above by using adaptive syn­chronous cancellation. Reducing the gyrodynamic loads require more significant efforts. First, the flywheel is oriented vertically so that yawing (turn· ing) of the bus does not require a change in angular momentum of the flywheel, and thus no bearing reac· tions. During turns the vehicle will also roll (tilt) somewhat, which will still result in bearing reactions if the flywheel hous ing is firmly attached to the frame. Also, acceleration, deceleration, and grade changes (entering or leaving a hill) will result in pitch (front to back) motion of the vehicle, again with bearing reaction loads required to move the flywheel. An a lternative to r igidly mount ing the flywheel housing to the bus is to mount it in a two-axis gimbal, allowing the FWB to pi tch and roll somewhat freely relative to the bus.

A two-axis gimbal was designed to support the FWB along with a mounting frame used to attach the system to the vehicle. A restoring force is required to give the flywheel a home position that is nominally vertical so that it doesn't drift too far from vertical. This restoring force is provided using gravity, by placing the rotor CG about 20 mm (0.75 in) below the gimbal pivot point. Viscous damping is provided by a rotary damper in the gimbal bearings and is adjust­able to a limited extent.

4. Test Setup

An ex1stmg four-corner terrain simulator was modified to make it suitable for testing with the ATTB flywheel. The terrain simulator setup is shown in Fig. 3. The flywheel battery is at the top of the picture, supported in the two-axis gimbal. The gim· bal frame is mounted to a support skid through elas­tomeric isolation mounts. T he skid, which wi ll later be mounted to the frame of the A TTB, is bolted to the table top of the terrain simulator. T his system uti­lizes three hydraulic cylinders to simulate the pitch, roll and shock seen on a transit bus. Each of the hydraul ic cylinders has a 0.254 m (10 inch) stroke and a 13 380 N (3 000 lb) capacity. A programmable con· troller controls table motion, and inputs and responses were measured with a Zonic signal analyzer and digital data recorder.

Series (, Vol. 46, No. 2 , 200:~

432

Fig. 3 F lywheel batter y system mounted on terrain simulator

Liquid dielectric inclinometers were used as pitch and roll sensors on both the gimbal table and on the FWB. T his type of sensor has the advantage of providing an absolute angle (an angle relative to an inertial reference frame), but they have low ban­dwidth compared to other available angle sensors that measure relative angles.

5. Pitch and Roll Testing-

During testing the flywheel skid was mounted on the terrain simulator, and operated at speeds up to 3.) 000 rpm . T he fi rst test series involved pitch and roll testing to determine the effects of a variety of maneu­vers on the flywheel system. The test matrix included a variety of input amplitudes and rates. The goal was to validate that the flyv.rheel isolation, gimbal and magnetic bearings could act together to prevent back­up bearing impacts during the full range of expected motion.

T he nominal input for the terrain simul ator was developed based on information provided by N orlh­rop- Grumman. the DOT White Book, and bus frame vibration measurements conducted by UT -CEM. The associated bus maneuvers are listed in Table 3. To verify operation under more aggressive conditions, the nominal amplitude and rate values were increased by 50%. These values are shown in Table 3 and repre­sent the approximate maximum rates anticipated under all conditions. The terrain s imulator appl ied these rates and amplitudes over a 225 second period to generate the simulated bus test rout e. The response of the gimbal table versus time is shown in Fig. 4,

Table 3 Simulator table input. rates and angles a ppl ied for aggressive ma neuver ( P = Pitch. N = Roll)

Label Description for 150% x l50%x Nominal Maneuver Angle Rate

(deg) (deg/s) AI Accelerate to 35 mph P= -0.36 036

LCI 35 mph lane change R= -3.0 4.5 LC2 35 mph lane change R= 3.0 6

Bl Brake to 20 mph P= 0.75 0.75 RTI Gentle right tw'n R= -3.0 3 HI Dip down into culvert P= 3.0 0.7 H2 Pitch up exiting culvt P= -3.0 1.5

LTl Hard left tum R=6.0 6 H3 7% hill at20 mph P= -6.0 6

LT2 Gentle left turn R=3.0 1.5 B2 Hard brake to stop P= 0.75 0.75 A2 Accelerate to 20 nl]Jh P= -0.36 3.6

RT2 Gentle right tw'n R= -3.0 1.5 LCJ 20 mph lane change R= -6.0 6 A3 Accelerate to 35 mph P= -0.36 0.36 H4 5.4% hill at 35 mph P= -4.6 9.3 B3 Hard brake to stop P= 0.75 0.75

Flywheel & Table Response to 150% Simulated Test Route at 35,000 rpm

6

4

~ 2 "' g, 0 "C

-; ·2 c, c -4 ~

-6

-8

LT1 ~

LC2 H1 ': LT/(

t ~ )_\i~ l'c.B2 1\

-;:;v l1 v A2 1\ [,1 A3 83

LC1 RTt H2 IR~2~ LC3 H4

H3

0 50 100 150 200 250

Time (seconds)

I - Table Prtch - · ··Table Roll I

Fig. 4 T errain simulator table mot ion, 150% of maximum expected inputs

along with annota tions of the specific maneuvers from Table:~. The gimbal t able response does not precisely match the terrain simulator input because of the low bandwidth of the pitch and roll sensors (0.5 Hz)_

Figure 5 shows the displacement orbit at Lhe non thrust end radial magnetic bearing position sensor for the entire 225 second t est. T he peak relative displace­ment is about 0.18 mm (0.007 in) . T his peak displace­ment occurred during the H4 maneuver (Table 3), an 8.1% hi ll (L;) * 5.4), which had the highest program­med slew rate of 9.3 degrees/sec. T he absolute response ra tes of the gimbal table and the FWB during the H4 maneuver are shovvn in Fig_ 6. T he measured table angular velocity is near to the pro­grammed value. and the flywheel response is about 65% lower at about 2.7 degrees/sec. This reduced response angle should directly result in a 65% rcduc-

I I o I

02 - ----~---- -- ---: ----- ---- - ~--- - - ----- -:----- ----~-- --

015

E 0 1 E

~005 E "' ~ 0 c:. "' -o-005 "' x :. -0 1

-015

-02

. ' ' ' ' t I I I I I I I I

' ' ••• - ~ • -- -- - ---- t • - •• ---- - - ... . --- - • •• - - .,. -- ---- - • - . - - --I I I I

' ' ' ' ' ' ' '

. . ---- -· ---- --- --··- .. -.-- ---------- ... . ··- -- --- ·-. - ~ .. . -. ' . . . ' ' . . -0 25 ~~"-'-'-'"-'-'-'-'-'-'-'-'-'-'=~,_=~==~="-'':-"':'--'-'-'-='

-0 2 0 02 X ax1s displacement, mm

Fig. 5 Displacement orbit at non- thrust end radial posit ion sensor throughout the test

Flywheel & Table Pitch Rate 0

9 f''

8 I \

7 I I \

6 I \

5 I

I \ 4

I \ I 3

I '\ ~/ / '\ 2 I I/ \ / I..---I \'-

1 f I '---~ - - v

0

197.0 197.5 198.0 198.5 Time (sec)

- Flywheel - Table 1

Fig. 6 Simulator table and FWB r esponse to 150% of maximum expected inputs (deg/ scc)

t ion in the necessary bearing reactions during the maneuver.

A two second time s lice from the H4 maneuver is shown in Fig. 7. I<adial displacement. x· , from the non- thrust end position sensor is shown in the upper figure and radial reaction load, Ft>, at the non-thrust end bearing is shown in t he lower. T he loads are calculated from the measured coi l current. fc, and displacement as follows :

F b=Kff c+Knx Values for the bearing force constant, Kf, and the nega tive stiffness, Kn are given in T able 2. Both data sets were low pass fi ltered at 75 Hz to take out the synchronous response. In Fig. 7, two spil<es (most noticeable on displacement) occur about 0.5 seconds apar t (197.7 sec and 198.2 sec) . T hese spikes corre-

}S/V/ /,· fntPma t irma/ Journal

433

Rod tal Dtsplacement at Non-ThtUSI End Beanng, H4 Ttme Slice 035,--.---,---.---.---.--.---~--.--.--~

. . . . . ' ' ' . . ' ' . 03 ······:-····· j·· ··-·1······ i· ·····:······j--- .. · ~·······i ·· · ··- ~- ....

MalllCieard~Ce 0 2~4 mm; : ~ : ~ : ~ o 25 .•..• . : .. ···. : .. ····r· ···· ~ ..... - ~ ...... ~-··· ··

1

. ...... : ... . .. : .... .

. ' . ' ' I 02 ··-··-:·····-:···-·-·:-·-···r····-:··-···)·······j····-·-:-···-·r ··-! o 15 ····-·!····-+··-··:···· ·r····-L .... ;. ···]·-·····f-·-·+···· ~ 01 .. .. .. i- .. ( ••• •( . ~ .... .L. .... ;. ···1······+······: .....

. . .

q97 197 2 197 4 197 6 197 8 T1me. sec

Radtal Load at Non-Thrust End Beanng, H4 Ttme Shce

700~~~=;~~~==~~~==~~ Loa~ Capacity 670iN , ; . : ; ,

600 .... - . i·· .. -. ~ - ·- ... ·i· .... --~ · ..... i .. ---. ~ -- · ... ~- ..... -~- .... ·i- .... : : : : : : : : . . . . . ' . . .

500 ••.•. ' ; ..... - : ....... ; ..•.. - -~.- .••. ; •••.. • ; ..... • ~- •••.• -~ .. - .. -~ ...•. 2. : • : : : : : • : -o' : : ' : • : : : (15 ' • ' • ' • • ' •

3 400 . --... i .. .... {. ---- .. ; ..... --~ - - ... -f.·- .. -~ -- - -- - ~- ... ·--~- .. -- .:.- -.--g> : : : : : • : : : ~ : : : : : : : Ql • • ' • • • 0 '

~ 3(X) ··---- ~ ------~ -- - - ---;--··- -· r -- --·;···--- ~ - --- ~---·--·;.·- -- - -~--- --

-g : : : : ' ' ' 0: 200 ••..•. : ..•. •• ; . ..•.• +-

' . . . . . . . . . . . : .... -- :· ----. ·;·.. -- ~ ;-- -.- --. : ..... -:--. . ' ' . . . . ' . . . . ' . . . .

o~~~~--~~~~~--~~~--~~~~ 197 197 2 197 4 197 6 197 8 198 198 2 198 4 198 6 198 8 199

T1me. sec

Fig. 7 !\ on-thrm;t end bearing radial position (top) and rad ial loads (bottom) during maneuver H4

spond to the star t and end of the simulated hill. At the start of the hill the terrain simulator begins changing the pi tch from 0 to 4.65 degrees over a 0.5 second per iod (9.:~ degrees/sec) . T he impulse at the start and end of the maneuver causes the displacement spikes. This is an unintent ional consequence of the test appa­ratus dynamics ; however. similar impulses might be expected to occur along with many of the real world events in Table 3. The response during the period where the pitch is be ing steadily changed does not show a significant change in displacement , but does show a load increase of approximately 75 to 100 N. Per Eq. ( 2 ) , the load would be approximately 333 N (75 Jbf) if the flywheel were not gi mba led. T his correlates reasonably well with the angle rate difference in Fig. 6.

6. Shock Testing

The terrain simulator was also used to perform vertical shock testing, to determine the ver tical accel­eration that could be tolerated before impacting the backup bearings. Figure 8 shows the results from one

S,rie8 C, Vol. !J.{>, No.2, :wo:~

434

:§ 1 c .e Eo .. ;;

~ - 1

-2

Vertical Shock Test 2.4 9 Input ~------------------------------~ 0 3

0.2

-0.2 A).ial Olsplacoment

~Vertical Table Acce~ration -3 J...._ ______________________________ ----1. -0.3

0 0.05 0.1 0.15 0.2 0.25 0.3 Time (seconds)

Fig. 8 Axial shock test results showing 2.4 g input, FWB response. and relative rot/ hsg displacement

of the tests. T he table acceleration, FWB accelera­tion, and relative rotor / housing displacement are shown in the figure. T he simulator input acceleration is 2.4 g at 100 Hz, the highest input level that could be used without the rotor hitting the backup bearings. The associated FWB response was about 0.8 g (65% reduction) at the 15Hz natural frequency of the FWD mass on the isolator stiffness of 2.2 MN /m (12 500 lbf/ in) . Relative rotor/housing displacement is just below the backup bearing clearance of 0.25 mm (0.010 in).

Although the 2.4 g input is well below the acceler­ation level measured in an actual bus (Fig. 2), it is desirable to consider improvements and to consider the influence of the higher system mass planned for the composite flywheel. A simple 3 degree- of- free­dom model was created for this purpose. The simu­lator table, FWB housing a nd FWB rotor masses were connected by discrete stiffness and damping elements to represent the isolators and axial magnetic bearing. The results, shown in Fig. 9, provide a reasonable match to the data from Fig. 8, although the predicted accelera tion of the FWB housing is somewhat low. The t wo biggest sources of error in the model are : 1 ) the simpl icity of the model compared to the test system, and 2 ) the stiffness and damping of the isolators, which varies with preload. The model is adequate to serve its intended purpose of trading-off potential system changes. Since the crit ical parame­ter for the trade study is axial displacement, the isolator stiffness and damping were increased by 20% from nominal to match the predicted displacement to the tested value. The model was then used to predict relative rotor housing response due to a 2.4 g input with three var iations : 1 ) increase net magnetic bear­ing stiffness by 50% (15% increase in compensa tor gain) , increase FWB housing and rotor mass to corre­spond to the values expected for the composite sys-

Series C, Vo l. 4 6 , No. 2, 2003

Vertical Shock Analysis 2.4 9 Input

-2

0.2

e 0.1 E.

-0.2

-3 ~----------------------------~ -0.3

0 0.05 0.1 0.15 0.2 0.25 0 3

Time (seconds)

Fig. 9 Three dof analysis of axial shock test showing input, FWB response. and rei. displacement

Impact of System Changes on Shock Displacement Response

.o 25o: ---:o=-'os'=·--~o:'-:1:--0::-'-:15---:0:-':2:----::-0~25:---o::':3:----::-o~35:-----::'o 4

Time (sec)

Fig. 10 Predicted displacement response for various system changes

tem, and 3 ) increase both magnetic bearing stiffness and FWB housing and rotor mass. The results from t hese three variations are compared to the nominal model in Fig. 10. Increasing the stiffness alone attenu­ates the peak response by 35%, increasing the mass reduced the peak response by about 20%, and the combination of the two decreases the peak response by over 50%.

7. Conclusions

The reported testing has verified the suitability of the flywheel battery skid system for field testing in a transit bus. T he gimbal support reduced the flywheel bearing loads by about 65%. T he shock isolators reduced the transmitted axial shock by 65%. Most importantly, the control of the flywheel on the mag­netic bearings is maintained for shock and vibration levels well in excess of the values that are expected in the transit bus.

}Silff~ fnlemational }oumrrl

Acknowledgements

T his work was completed under funding provided by the US Dept. of Trans. (DOT) through the South· ern Coalition for Advanced Transportation (SCAT) and by the Houston Metropoli tan Transit Authority (HMTA).

References

( I ) Hayes, R.J. . Kajs, J.P .. Thompson, R.C. and Beno, J.H .. Design and Testing of a Flywheel Battery for a Transit Bus. SAE 01-1159, (1999) .

( 2) Hawkins, L.A .. Murphy, B.T. and Kajs, J.P .. Analysis and T esting of a Magnetic Bearing

iSM/:_' fnlnnatiorutl ./oumal

435

Energy Storage Flywheel wi th Gain-Scheduled. MIMO Cont rol, ASME 2000-GT-405, Presented at ASME IGTI Conference. Munich, Germany, May 8- I l , (2000) .

( 3) Hawkins, L.A. and F lynn, M., Influence of Control Strategy on Measured Actuator Power Consump· tion in an Energy Storage Flywheel with Mag· netic Bearings, Proc. of the 6th Inti. Symp. on Magnetic Suspension T ech .. Turin, Italy, October 7- ll. (2001) .

( 4) Murphy, B.T., Beno, J.H. and Bresie, D.A., Bear­ing Loads in a Vehicular Flywheel Battery, PR-224, SAE Int. Congress and Exp., Detroit, Mi· chigan, USA, February, 24-27, ( 1997) .

Series C, Vol. -1-6, No. 2. 2003

436

JSME International Journal

Information for Authors 1. Originality

Papers submitted must be original, and previously unpub­

lished.

2. Language and Units The language of the Journal is English and the units used

are Sl.

3. Receiving Date The date of receipt of the manuscript is the date of its

arrival at the society's office.

4. Acceptance Acceptance or rejection of submitted papers will be based

on and determined by the refereeing standards of the

Journal's editorial committee.

5. Responsibility of Contents The respons ibility for the contents of published articles

rests solely with the authors and not the society.

6. Page Charge A charge of ¥10,000 (or equivalent US$) per printed

page will be invoiced to the author or the author's

designated institution. 50 reprints will be provided to the

lead author following publication and receipt of payment.

7. Length of Paper The manuscript should be prepared in 6500-9000 words

including figures and tables (approximately 6-8 pages in

printed form).

8. Manuscript Please type manuscripts using A4 (21 em X 30 em) or 8.5

inch X II inch sheets.

One typed page should contain 26 lines with approximate­

ly 65 characters per line. When this guideline is followed,

three type-written pages will make up one printed page.

Sample Layout : I st page: Title, names of authors, affiliation and address,

key words and mailing address

2nd page: Abstract of less than !50 words 3rd page and following pages: Text

The text should be arranged in the following manner:

Introduction, Materials and Methods, Results, Discus­

sions, Acknowledgments, References, Figure Legends and

Tables.

9. Style Use short paragraphs wherever possible. Express ideas

clearly, and avoid using jargon. Abbreviations should be

explained in the text. If many abbreviations are used, a

table of abbreviations should be included.

10. Mathematical Expressions All mathematical expressions should be numbered in

parentheses and typed. Symbols not available on the

typewriter should be carefully inserted.

11. Figures Drawings for figures must be submitted on separate

sheets, drawn in black India ink and carefully lettered and

also the lettering be proportionate so that it does not

become illegible or unclear after reduction by the printers.

The appropriate placement of each figure in the text

should be indicated in the margin and equations be contained to one column in width.

12. References References lists should be typed, double- spaced, on a

separate sheet following this example :

( 1 ) Fuller, E.W. and Stoessel, R. F., Factory Automa­tion, Mech. Eng., Vo l. 109, No.3 (1987), p. 42-

45.

( 2) Akasaka, T., Shibuya, K . and Shinjuku, T., Auto­

motive Electronics, Trans. Jpn. Soc. Mech. Eng., (in Japanese), Vol. 53, No. 785, A ( !987), p. 340-

346.

13. Copyright Copyright of the materials publ ished m the Journal

belongs to the JSME.

14, Submission of Manuscripts Please send three copies of your manuscript to:

JSME International Jo urnal Editorial Board

! Shinanomachi-Rengakan Bui lding, Shinanomachi 35,

! Shinjuku-ku, Tokyo l60-00!6, Japan