Project ShowcasesBy: Xiaojun Li PhD candidate, Texas A&M universityContact: tonylee2016@gmail.com

Applications:• Power grid frequency regulation• Renewable energy source storage• Backup power (UPS) for data centers and hospitals• And many more

Features:• Patented next-generation shaft-less high strength steel flywheel

with double energy density to convectional flywheel.• Magnetic levitation and vacuum sealed operation chamber give

minimal power loss.• A 12,000 lbs flywheel levitated by a single combo-magnetic

bearing.• Energy storage of 100kw-hr and power rate of 100kw

Project#1: Shaft-less Flywheel Introduction

Road Map1. Design stage

• Flywheel stress and fatigue analysis and design using FEA (Ansys Mechanical)

• Magnetic bearing design, analysis and optimization using FEA• Motor design and analysis using FEA (Ansys Maxwell)• Electro-mechanical System dynamics simulation by Matlab• Real time MIMO feedback control system designed by

Dspace2. Small scale prototype assembly and test (150 lbs)

• Successful fabrication and test of all functions3. Full scale prototype assembly test (12,000 lbs)

• Flywheel testing facility finished with vacuum chamber• Full fabrication and successful levitation

3D electromagnetic simulation

Cutaway view of Flywheel Test CenterCAD model of the full scale flywheel assembly.

Real-time control and monitor system

Full-scale test rig after assembledRelated Publications:

Li, X., Palazzolo, A., Mcmullen, P., and Wang, Z., 2015, “SHAFT-LESS ENERGY STORAGE FLYWHEEL,” Proceedings of the ASME 2015 9th International Conference on Energy Sustainability.

Applications:• monitor and analysis of rotating machines• Machinery/structure modal test, alignment and balancing• Intelligent Machinery diagnosis

Features:

• Rotordynamics and Vibration data acquisition, analysis and display.• Modal testing, foundation identification and 3d animation.• Weight least square balancing, hole splitting.• Fuzzy logic and artificial neural network based machinery diagnosis.:• Reverse indicator based cold/hot alignment.

Project#2: LVTRC: rotor-dynamics DAQ

LVTransFunc

LVBalancing LVAlignmentRotordynamics /LVTRCMain

LVExpertsSys

LVTRC Software Package

Digital Event Recorder

Raw data & Even Angel signal Info Orbit PlotFFT Spectrum

Bode PlotPolar Plot Advanced Waterfall Plot

Combined Orbit&Centerline

Plot

Harmonic & Sub-harmonic

Monitoring Plot

Gear Mesh Monitoring

Dual Keyphasor Support

Differential Channel Support

Manual Input Module

Alarm and shut down relays

Improved Signal Inetgration

Help Options For Easy Usability

Foundation Identification

Modal Testing

Modal Motion Animation

Comprehensive User Manual

Report format Generator

Data array export for excel

Database manipulation

Weighted Least/Least Square balancing

Display of residual Vibration

Torsional vibration

Sensor/manual input

Cold/hot alignment

Graphical display

Sine/ chirp waveform

Modal shaker output

Trial weightestimator

Instant screen capture

Whirl Direction indicator

Full Spectrum Analyzer

Ball Bearing FaultDectation

Octave Band Noise Monitor

--Functions--

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Sine/ chirp waveform

Health Monitoring Expert System

Fuzzy Logic Experts System

--Functions--

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Nonsynchronous whirl orbit

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Reverse indicator method

--Features--

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Modal Shape Measurement

Transfer function Measurement

--Features--

Multiple input & output

1D/2D/3D multiple point mode shape

animation

Transfer Function display

Detailed Software Structure and Functionality

Demonstration of the software features:Advanced Rotor-dynamic vibration monitoring:Full Spectrum Monitor with Whirl Direction Indicator

1 2 3 4

In the hope of observing oil-whirl or other possible nonsynchronous vibration, the test rig includes an over-hung disc rested on a shaft with another disc, on a transparent fluid-film bearing and a ball bearing. The shaft is driven by a 1hp motor capable of 10,000 rpm connected through a flexible coupling.

Figure 3 Lateral Hardware Set-up (1-over-hung disc, 2- transparent fluid-film bearing, 3- disc, 4- ball bearing and coupling)A set of X and Y eddy current probes are installed on the fluid film bearing. The tachometer is mounted on the motor side.

Sub-synchronous vibration

sub-synchronous vibration signal captured by the software

rotor whirling direction indicated by the code

Code Features

• Full spectrum based X and Y• Real-time peak identification• Real-time whirl direction identification

Torsional Vibration Monitor

Resonance

Modal test