Effects of rotating inlet distortion on multistage compressor stability

In multi-spool engines, rotating stall in an upstream compressor will impose a rotating distortion on the downstream compressor, thereby affecting its stability margin. In this paper experiments are described in which this effect was simulated by a rotating screen upstream of several multistage low-speed compressors. The measurements are complemented by, and compared with, a theoretical model of multistage compressor response to speed and direction of rotation of an inlet distortion. For co-rotating distortions (i.e., distortions rotating in the same direction as rotor rotation), experiments show that the compressors exhibited significant loss in stability margin and that they could be divided into two groups according to their response. The first group exhibited a single peak in stall margin degradation when the distortion speed corresponded to roughly 50% of rotor speed. The second group showed two peaks in stall margin degradation corresponding to distortion speeds of approximately 25-35% and 70-75% of rotor speed. These new results demonstrate that multistage compressors can have more than a single resonant response. Detailed measurements suggest that the two types of behavior are linked to differences between the stall inception processes observed for the two groups of compressors and that a direct connection thus exists between the observed forced response and the unsteady flow phenomena at stall onset. For counter-rotational distortions, all the compressors tested showed minimal loss of stability margin. The results imply that counter-rotation of the fan and core compressor, or LP and HP compressors, could be a worthwhile design choice. Calculations based on the two-dimensional theoretical model show excellent agreement for the compressors which had a single peak for stall margin degradation. We take this first-of-a-kind comparison as showing that the model, though simplified, captures the essential fluid dynamic features of the phenomena. Agreement is not good for compressors which had two peaks in the curve of stall margin shift versus distortion rotation speed. The discrepancy is attributed to the three-dimensional and short length scale nature of the stall inception process in these machines; this includes phenomena that have not yet been addressed in any model.

Superconducting micro-bearings

This paper presents research into superconducting Micro-Bearings for MEMS systems. Advanced silicon processing techniques developed for the Very Large Scale Integration (VLSI) industry have been exploited in recent years to enable the production of micro-engineered moving mechanical systems. These devices commonly known as Micro-ElectroMechanical Systems (MEMS) have many potential advantages. In many respects the effect of scaling a machine from macro-sized to micro-sized are either neutral or beneficial. However in one important respect the scaling produces a severely detrimental effect. That respect is in the tribology and the subsequent wear on the high speed rotating machines. This leads to very short device lifetimes. This paper presents results obtained from a MEMS motor supported on superconducting bearings. The bearings are self-positioning, relying on, the Meissner effect to provide a levitation force which moves the rotor into position and flux pinning to provide stability thereafter. The rotor is driven by a simple electrostatic type motor in which photo resist is used to pattern the motor poles directly onto the rotor. © 2005 IEEE.

Tribological properties of mems materials measured on a small-scale device

Micro-electro-mechanical systems, MEMS, is a rapidly growing interdisciplinary technology within the general field of Micro-Systems Technology which deals with the design and manufacture of miniaturised machines with major dimensions at the scale of tens, to perhaps hundreds, of microns. Because they depend on the cube of a representative dimension, component masses and inertias rapidly become small as size decreases whereas surface and tribological effects, which often depend on area, become increasingly important. Although MEMS components and their areas of contact are small, tribological conditions, measured by contact pressures or acceptable wear rates, are demanding and technical and commercial success will require careful measurement and precise control of surface topography and properties. Fabrication of small numbers of MEMS devices designed to test potential material combinations can be prohibitively expensive and thus there is a need for small scale test facilities which mimic the contact conditions within a micro-machine without themselves requiring processing within a full semiconductor foundry. The talk will illustrate some initial experimental results from a small-scale experimental device which meets these requirements, examining in particular the performance of Diamond-Like-Carbon coatings on a silicon substrate. Copyright © 2005 by ASME.

Power losses in small inverter-fed induction motors

This paper presents the results of experimental and simulation investigations of the breakdown of losses in a small inverter fed induction motor. Factors that are considered include the impact of skew, excitation voltage waveform shape and PWM switching frequency. Detailed finite element simulations of the motor performance are carried out for the various conditions, with simulation results compared to calorimetric test results. © 2005 IEEE.

Monitoring tunnel deformation induced by close-proximity bored tunneling using distributed optical fiber strain measurements

The paper describes the use of optical fiber Brillouin Optical Time Domain Reflectometry (BOTDR) to monitor the strain distribution in an existing tunnel while a twin tunnel was bored at close-proximity. The twin circular bored tunnels between Serangoon and Bartley stations on the new Circle Line Stage 3 subway in Singapore were constructed at close-proximity to avoid underpinning the foundations of adjacent buildings. The minimum clear separation of the two tunnels is 2.3m (0.4 times the tunnel diameter). The Outer Tunnel was constructed first, followed by the Inner Tunnel, with the earth-pressure balance tunnel boring machines maintained at a minimum of 100m apart. In this trial application of BOTDR, the strain distribution along the Outer Tunnel was measured, in order to monitor its deformation due to the boring of the Inner Tunnel at close-proximity. The aim of the trial application was to determine the practicality of this monitoring method for future use in 'live' tunnels. This paper compares the measurements obtained from optical fiber BOTDR with conventional methods of tunnel monitoring and describes preliminary installation and workmanship guidelines derived from lessons learnt during this trial. © 2007 ASCE.

AC losses of superconducting racetrack coil in various magnetic conditions

High-temperature superconductors have created the opportunity for a step change in the technology of power applications. Racetrack superconducting coils made from YBCO coated conductors have been used in several engineering applications including SMES, rotor or stator windings of electric machines. AC loss is one of the most important factors that determine the design and performance of superconducting devices. In this paper, a numerical model is developed to calculate the AC losses in superconducting racetrack coils in different magnetic conditions. This paper first discusses the AC losses of the coils in self-field or external field only. It then goes to investigate the AC losses of the coils being exposed to AC ripple field and a DC background field. Finally, the AC losses of the coils carrying DC current and being exposed to AC field are calculated. These two scenarios correspond to using superconducting coils as the rotor field winding of an electric machine. © 2010 IEEE.

Optimisation of fuel usage and steam availability in the power and steam plant of a paper mill

This paper presents the results of a project aimed at minimising fuel usage while maximising steam availability in the power and steam plant of a large newsprint mill. The approach taken was to utilise the better regulation and plant wide optimisation capabilities of Advanced Process Control, especially Model Predictive Control (MPC) techniques. These have recently made their appearance in the pulp and paper industry but are better known in the oil and petrochemical industry where they have been used for nearly 30 years. The issue in the power and steam plant is to ensure that sufficient steam is available when the paper machines require it and yet not to have to waste too much steam when one or more of the machines suffers an outage. This is a problem for which MPC is well suited. It allows variables to be kept within declared constraint ranges, a feature which has been used, effectively, to increase the steam storage capacity of the existing plant. This has resulted in less steam being condensed when it is not required and in significant reductions in the need for supplementary firing. The incidence of steam being dump-condensed while also supplementary firing the Combined Heat & Power (CHP) plant has been reduced by 95% and the overall use of supplementary firing is less than 30% of what it was. In addition the plant runs more smoothly and requires less operator time. The yearly benefit provided by the control system is greater than £200,000, measured in terms of 2005 gas prices.

Unstable behavior of low and high speed compressors

By far the greater part of our understanding about stall and surge in axial compressors comes from work on low-speed laboratory machines. As a general rule, these machines do not model the compressibility effects present in high-speed compressors and therefore doubt has always existed about the application of low-speed results to high-speed machines. In recent years interest in active control has led to a number of studies of compressor stability in engine type compressors. This paper presents new data from an eight-stage fixed geometry engine compressor and compares this with low-speed laboratory data.

Design method of an innovative motor for an intra-aortic ventricular assist device

A permanent-magnet motor has been designed for an innovative axial-flow ventricular assist device (VAD), to be placed in the descending aorta, intended to offload the left ventricle and augment renal perfusion in patients with congestive heart failure (CHF). For this application, an intra-aortic impeller with a built-in permanent magnet rotor is driven by an extraaortic stator working in synchronism with the natural heart. To meet this need, a two-dimensional analytical model has been developed in the MATLAB environment to estimate machine parameters; finite element analysis (FEA) has been used to refine the results. A prototype blood pump equipped with an innovative motor designed from the procedure above has been tested in a mock loop representing the human circulatory system. The performance of VAD incorporating the motor is presented. © 2009 IEEE.

Operating charts for the brushless doubly-fed machine (BDFM)

The Brushless Doubly-Fed Machine (BDFM) is an electrical machine that allows brushless operation in many applications where the Doubly-Fed Induction Generator (DFIG) is currently used. In recent years work on BDFM control means that the machine can now be run stably across its working range. However, little work has been done to define the working area in which BDFM can safely be operated without exceeding its material and stability limits. This paper sets out the theoretical backing for an operating chart of an ideal BDFM similar to that of the synchronous machine. It goes on to show that though the ideal chart gives the right form, non-ideal parameters (especially the finite magnetizing inductances) significantly effect the locations of the limits. Some preliminary experimental data obtained for a 225 frame size machine support the form of the chart. Finally it is shown how the operating chart can be used to chose appropriately sized converters for the BDFM. © 2009 IEEE.

The Brushless Doubly-Fed Machine vector model in the rotor flux oriented reference frame

The paper presents the vector model of the Brushless Doubly-Fed Machine (BDFM) in the rotor flux oriented reference frame. The rotor flux oriented reference frame is well known in the standard AC machines analysis and control. Similar benefits can be sought by employing this method for the BDFM The vector model is implemented in MATLAB/SIVIULINK to simulate the BDFM dynamic performance under different operating conditions. The predictions from the vector model are compared to those from the coupled circuit model in simulation. The results are shown for the cascade mode of operation. © 2008 IEEE.

Force ripple compensation in a tubular linear generator for marine renewable generation

Tubular permanent magnet linear generators are a promising generator technology for use in marine renewables. One aspect of their design relates to the conditions necessary for achieving a smooth thrust response from the generator, free from cogging and periodic variations due to spatial harmonics of the flux cutting the generator coils. This paper presents an experimental and finite element study of the sources of thrust ripple in a prototype linear generator for marine generation. A simple self-commutated control scheme is shown, which uses linear Hall-effect sensors and look-up-table based feed-forward compensation to derive the excitation currents required to drive the machine with constant force. Details of the controller's FPGA based implementation are given, including its strategy for detecting sensor failure. © 2011 IEEE.

The single-phase brushless doubly-fed machine as a generator for wind turbines

This paper proposes a single-phase variant of the Brushless Doubly-Fed Machine, the Single-Phase BDFM, SPB. Like the BDFM it is a variable speed generator which requires a converter rated at only a fraction of the machine rating, using structure with no brushes. Unlike the BDFM, most of its power is delivered directly into a single-phase grid connection. As such it is a potential replacement for PM generators in small-ish wind turbines, potentially with a much lower cost. In this paper we give details of its operation, with reference to results from the first prototype SPB. We also suggest how it may be controlled, again with experimental results. © 2011 IEEE.

Product life trade-offs: what if products fail early?

Increasing product life allows the embodied emissions in products to be spread across a longer period but can mean that opportunities to improve use-phase efficiency are foregone. In this paper, a model that evaluates this trade-off is presented and used to estimate the optimal product life for a range of metal-intensive products. Two strategies that have potential to save emissions are explored: (1) adding extra embodied emissions to make products more sturdy, increasing product life, and (2) increasing frequency of use, causing early product failure to take advantage of improvements in use-phase efficiency. These strategies are evaluated for two specific case studies (long-life washing machines and more frequent use of vehicles through car clubs) and for a range of embodied and use-phase intensive products under different use-phase improvement rate assumptions. Particular emphasis is placed on the fact that products often fail neither at their design life nor at their optimal life. Policy recommendations are then made regarding the targeting of these strategies according to product characteristics and the timing of typical product failure relative to optimal product life.

A Videogrammetric As-Built Data Collection Method for Digital Fabrication of Sheet Metal Roof Panels

A roofing contractor typically needs to acquire as-built dimensions of a roof structure several times over the course of its build to be able to digitally fabricate sheet metal roof panels. Obtaining these measurements using the exiting roof surveying methods could be costly in terms of equipment, labor, and/or worker exposure to safety hazards. This paper presents a video-based surveying technology as an alternative method which is simple to use, automated, less expensive, and safe. When using this method, the contractor collects video streams with a calibrated stereo camera set. Unique visual characteristics of scenes from a roof structure are then used in the processing step to automatically extract as-built dimensions of roof planes. These dimensions are finally represented in a XML format to be loaded into sheet metal folding and cutting machines. The proposed method has been tested for a roofing project and the preliminary results indicate its capabilities.