2012 Advisory Panel Electromechanical System Solutions

1. 2012 Advisory PanelElectromechanical System Solutions Joe Beno Center for Electromechanics The University of Texas at Austin 12/4/2012

2. Introduction • Electromechanical System Solutions • Synergistic combination of electromechanical hardware (actuators, motors, generators); controls and related software; sensors and related software; communication and related software; transducers; power electronics; processors; materials science; and all interconnections. • Key applications • Almost any electrically powered device or system that moves itself or something else under its own power. • This talk focuses on motion control systems, actuation systems, robotic systems and anything else not covered by other talks.

3. Key Challenges – Get Ahead of the Wave (or at least ride it!) • Exploit advances in all related fields, especially computation, analysis and power electronics. • Improve Integration and Systems Engineering. • Identify commercially viable products and commercially viable new science. Mechatronics: New engineering discipline that emerged in ~2000. CEM vision also includes material science and systems engineering. At Universities the disciplines of Electrical Engineering, Computer Science, Mechanical Engineering and Material Sciences are still largely represented by separate departments – after 40 years CEM still needed to focus on cross discipline applications. Source: Lyshevski textbook on Mechatronics

4. Significant Recent Programs Hobby Eberly Telescope • 20 ton robot to move optical package along trajectories to within ~5 microns in real time.

5. Significant Recent Programs HET Tracker Video

6. Significant Recent Programs • Giant Magellan Telescope Azimuth and Elevation Drives Design Study • New class of super large telescopes • Operational in ~2020 in Atacama Desert, Chile • 7 Large mirrors, viewing area 80 ft in diameter • Long circular track (~60 m); permanent magnet direct drive solution • 4 forcer heads per track, ~6,700 lbf total • Integrate with GMT control system • Less than 2% force ripple (desire close to 0.1%) • Must stay with 2o C of ambient • Minimize size and weight

7. Significant Recent Programs GMT Azimuth Drive Design Tour Video

8. Significant Recent Programs • Oshkosh 90,000 lb Airport Rescue and Firefighting (ARFF) Active Suspension System • 2.5x to 4x increase in vehicle per wheel mass compared to previous vehicles • Required hybrid power train development: 10 Farad Cap storage, 200 kW peak power, 48 kW avg power • 6 actuators, each with 17,300 lbf peak and 6,600 lbf continuous • 3.5x force and 2x speed (7 m/s wheel vertical speed) of previous suspension actuators • Result: 3x increase in cross country speed • Result: Greatly improved handling and safety – eliminates roll on high g turns

9. Significant Recent Programs ARFF Highlights Video

10. Significant Recent Programs • NASA Vibration Isolation System • Isolates electronics racks on heavy lift vehicle launch platforms (e.g., space shuttle mobile launch platform). • Disturbance rejection up to 2 kHz (high bandwidth actuators) • 2.75 ton payload • Vertical velocity primarily less than 1 m/s • Actuator stroke ~6 inches • Very low friction system • Developed new “voice-coil” actuator

11. Significant Recent Programs NASA Vibration Isolation Video

12. Recent and Ongoing Smaller Scale EM System Examples • High Temperature Superconducting Magnetic Bearings for Ultra Low Loss Flywheel Systems • Aggregate Screen Actuator (sifts and separates gravel by size; 100 Hz, 3250 lbf, homopolar actuator with PM bias) • Canfield Joint as Gimbal Replacement System for Satellite Reaction Wheels (~2 kg) • Small programs with potential to expand CEM expertise and applications

13. Key CEM Strength – Modeling and Simulation

14. Key CEM Strength – Culture of Model Verification

15. System Design Power Electronics Mechanical Advantage Power Source Auxiliaries Geared Actuator Weight vs. Gear Ratio Key CEM Strength – Balanced System Design High Peak-to-AverageDual Motor Controller ~3 MW Flywheel Battery & Power Electronics Active Suspension Alternator

16. Key CEM Strength – Multidisciplinary Analysis EM FEA of Coil Circuit of Screen Actuator x x Specifications X axis,140 turns @ 12 Amps per coil M19 Laminations 0.063 in, 1.5 deep Air gap 0.100 in @ 14 in diameter O.D. 20 in, I.D. 8 in 0 Hz Neumman Boundary Conditions

17. Key CEM Strength – Effective Use of Energy Storage Flywheel Mechanical Springs PM (Potential Energy) Caps; Ultra-Caps Batteries

18. How To Develop $3M to $5M New Annual Funding for EM Systems Identify and Develop New Opportunities • CEM traditional customer’s budgets are declining. Their response: keep current staff and reduce/eliminate external contracts (Army R&D centers/labs, NASA, ONR) • One exception: Small Business Innovative Research (SBIR) and Small Business Technology Transfer (STTR) programs: established by Congress and must be externally contracted to small businesses • Some military system procurements surviving • More focused on application of existing technology, more production oriented, less research • More focused on OEM’s • DOE: Doing energy research (a CEM strength), but has major cost share requirements • Impact: • Must develop new customers (DARPA, industry) • Must team with industry more for military procurements • Must team with industry more for SBIR/STTR’s (small contracts with opportunities for expanding CEM areas of expertise) • Must team with industry more for DOE opportunities • CEM program mangers must expand outreach to industry and new customers (travel)

19. How To Develop $3M to $5M New Annual Funding for EM Systems Identify and Exploit New/Emerging Technology • CEM uniqueness is applied R&D through advanced prototype hardware • Usually (but not always) exploits basic R&D or new products from other organizations • Example: Toray T1000G fiber critical to increased flywheel energy density that was significant motivation for government sponsors to fund CEM flywheel research in the 1990’s and early 2000’s. • Example: Emerging permanent magnet materials and improved processing/controls critical to development active magnetic bearings that was significant motivation for government sponsors to fund CEM flywheel research in the 1990’s and early 2000’s. • Example: Emerging COTS motor generators, advanced analysis capabilities, new processing/controls technology critical to CEM active suspension program from 1993 to ~2005. • Has been a major source of CEM innovation in the past. • Impact: • CEM must expand outreach efforts to identify new/emerging technology • CEM must expand awareness of relevant R&D developments and their potential before industry and other R&D organizations

20. How To Develop $3M to $5M New Annual Funding for EM Systems Develop New Areas of CEM Expertise • Active funded areas of R&D grow old and funding wanes. • Newness and excitement wears off. • Upcoming government and industry leaders want to make their own mark. • Sometimes, after sufficiently long lulls, R&D area re-emerges • New technology expands possibilities • Other options don’t pay off and they wear out their welcome • Impact: • CEM must continually develop new areas of expertise • Past examples: flywheel energy storage systems, active suspension systems, oil and gas support areas (subject of later talk); telescope movement control systems • How to establish a new area of expertise? • Get smart through equivalent of IR&D • Team with other experts • Establish a presence through papers, conferences, meetings, outreach.

21. How To Develop $3M to $5M New Annual Funding for EM Systems Required Resources • One 3 day trip per month (~$1,800 average travel cost per trip) • Cultivating new sponsors, joint planning/budgeting/proposing activities with industry members, visiting government agencies, attending meetings, and attending 2-3 conferences per year • 0.5 days planning and arranging trip, preparing briefings, etc. • 1 day follow-up from trip • 2 hrs per day when not on travel for white papers, responding to budget requests, maintaining contact and presence with sponsors and team members, searching for funding opportunities, etc. • 3 major proposal efforts per year (4 PI man-days and 4 engineering support man-days each) • Total: ~$9.5K / month • My current B&P budget: $1,670/month (not enough to cover one average trip if I use vacation time to cover my labor cost). • If successful, UT will earn $1M to $1.6M in overhead and CEM will receive $290K to $500K direct funding for admin, lab services, software, etc. per year after the building year.

22. Near Term Focus • Re-energize flywheel energy storage programs • After having plateaued for ~20 years, Carbon Nanotubes (CNT) offer 30-50% improvement in energy density in near term to reinforce existing carbon fibers and 1 to 2 orders of magnitude in long term to replace existing carbon fibers • Team with organizations with appropriate CNT expertise • Exploit SBIRs/STTRs to get started and build technology and “presence” • Will significantly outperform other forms of energy storage (e.g., Li batteries) • Cost will be an issue • After having plateaued for ~20 years, magnetic bearings are poised to make major step in efficiency through use of High Temperature Superconducting (HTS) Trapped Field Magnets (TFM) • Also exploits advancements in COTS cryo-cooling technology • Builds on CEM recognized expertise in HTS generators • Builds on past CEM STTR for HTSMBs for flywheels • Exploit SBIRs/STTRs to get started and build technology and “presence” • Government is showing renewed interest in flywheel energy storage systems (Li batteries are showing initial signs of wearing out their welcome) • NASA has major internal flywheel development program, needs CEM composite and HTSMB expertise, and want to team with CEM to go after DARPA money • Favorable circumstance: new DARPA program manager, friend of NASA, and flywheel advocate • Flywheel Technology Status and Roadmap paper may help focus Government funding

23. Near Term Focus • Exploit leading edge telescope motion control system expertise • Follow-on to Giant Magellan Telescope main axis drives system study • Several consortiums have new super large telescopes in various stages of planning and design • Contracts often spread among consortium members and consortium countries • Continue to pursue industry support for active suspension projects • Builds on existing CEM customers and CEM active suspension reputation • New Government interest in Semi-active suspension systems (subset of CEM technology • Expand to new areas • Robotics • U.S. lags in industrial robots but leads in compliant robots that physically interact with humans • Have will continue to team with Professor Deshpande, U.T. Department of Mechanical Engineering

24. Discussion and Questions