T. Baudendistel, PC Krause and Associates, Inc; S. Pekarek, Purdue University; E. A. Walters, PC Krause and Associates, Inc. In the aviation industry, the ever increasing need for more power in addition to the need to reduce weight and size has driven the requirements for higher and higher rotating speeds in aircraft machinery. This in turn has put an increasing burden on the bearings used in these machines. In this presentation, a recently developed fixture was developed to test high-speed bearings in the range of 25,000 rpm. This low-cost test fixture was developed to test bearings to failure by applying an artificial axial load. This low-cost/high-speed bearing tester is instrumented with a low cost torque ripple sensors and temperature probes to aid in the development of a PHM algorithm as well as a suite of temperature probes to monitor bearing temperatures. As the bearings fail the torque ripple and temperature signatures created are recorded for future analysis. Due to the low-cost nature of the fixture, it will also include an accelerometer dedicated to determining the speed of the rotating drive motor. Contact information:...
Read MoreTommy Baudendistel
[gravatar email=”baudendistel@pcka.com” class=”alignleft” size=”96″ default=”https://pcka.com/wp-content/uploads/2010/08/gravatar.jpg”]T. Baudendistel received the BSME, MSME, and PhD from the University of Dayton in 1989, 1993, and 2005, respectively. The MSME was focused on manufacturing while his PhD was in the field of mechatronics with special emphasis on sensors. His interests include the modeling and simulating of mechanical systems. Previously employed at Delphi for 10 years, he received over 14 patents and is in Delphiâs Inventorsâ Hall of Fame. He is the sole inventor of a harmonic motor which is now being researched at the University of Akron under Ohio Aircraft Institute funding. He is currently a Senior Engineer and PCKAâs Manager of the Modeling Simulation and Analysis Team (MSAT) at the Air Force Research Laboratory (AFRL) in Dayton OH. Selected Publications C. Barnes, G. Diehl, T. Baudendistel, J. Potter, L. Burich, âWater-Cooled Load Bank for Aircraft Power Systems Analysis,â 2008 SAE Power Systems Conference, November 11-13, 2008, Bellevue, WA. T. Baudendistel, S. Pekarek, E. A. Walters, âLow-Cost/High-Speed Bearing Tester Using Torque Ripple Sensors,â 2008 DESS Conference, October 2008. M. Boyd, M. Wolff, T. Baudendistel, M. Corbett, P. Lamm, âEvaluating Real-Time Platforms for Aircraft Prognostic Health Management Using Hardware-in-the-Loop,â GDIT Integrated Systems Health Management (ISHM) Conference, August 2008. J. McNichols, C. Barnes, M. Wolff, T. Baudendistel, M. Corbett, P. Lamm. âHardware-in-the-Loop Power Extraction Using Different Real-Time Platforms,â 6th International Energy Conversion Engineering Conference, July 2008. T. Baudendistel, S. Pekarek, E. A. Walters, S. Peecher, S. Field, N. Kumbar, âNoninvasive Approach to Health Management of Aircraft Power Systems Using Torque Ripple,â 2008 MFPT Conference, May 2008. Michael W. Corbett, Peter T. Lamm, T. Baudendistel, J. Mitch Wolff, E. A. Walters, âUsing Hardware-in-the-Loop for Aircraft Prognostic Health Management,â 2007 ISHM Conference, August 2007. T. Baudendistel, S. Pekarek, M. Rotea, E. A. Walters, S. Peecher, S. Field, N. Kumbar, âTools for Prognostics and Health-Monitoring of Aircraft Power Systems,â 2007 ISHM Conference, August 2007. T. Baudendistel, M. Corbett, E. A. Walters, K. Miller, J. Williams, J. Wells, S. Pekarek, M. Rotea, S. Field, S. Peecher, N. Kumbar, M. Wolff, J. Dalton, and P. Lamm, âAdvanced Tools for Aircraft Power and Propulsion Simulation and Analysis,â IAPG Mechanical Workgroup, May 2007, Alexandria, VA. T. Baudendistel, Steve Pekarek, Mario Rotea, E. A. Walters, Steve Peecher, Hao Huang, Sean A. Field, Nathan E. Kumbar, H. Huang, âTools for Health Management of Aircraft Power Systems,â 2nd Annual Propulsion-Safety and Affordable Readiness Conference, March 2007, San Diego, CA. K. Rosenbaum, S. Pekarek, T. Baudendistel, âA Low-Cost Force Sensor for Electromagnetic Actuation Systems,â IEEE Vehicle Power and Propulsion Conference, September 2007, Arlington, TX T. Baudendistel, M. Turner, âA Novel Inverse-Magnetostrictive Force Sensor,â IEEE Sensors Journal, vol. 7, issue 2, February 2007, pp. 245-250. F. Sevil, R. Veillette, I. Husain, N. Ida, H. Klode, T. Baudendistel, âAnalysis of a Flexible Cylindrical Structure for the Design of a Harmonic Motor Drive,â IEEE Industry Applications Conference, Proceedings 42nd IAS...
Read MoreHardware-in-the-Loop Power Extraction Using Different Real-Time Platforms
John McNichols, Caleb Barnes, Mitch Wolff, T. Baudendistel, PC Krause and Associates, Inc; Michael Corbett, Peter Lamb, U.S. Air Force Research Laboratory Aircraft power demands continue to increase with the increase in electrical subsystems. These subsystems directly affect the behavior of the power and propulsion systems and can no longer be neglected or assumed linear in system analyses. The complex models designed to integrate new capabilities have a high computational cost. Hardware-in-the-loop (HIL) is being used to investigate aircraft power systems by using a combination of hardware and simulations. This paper considers two different real-time simulators in the same HIL configuration. A representative electrical power system is removed from a turbine engine simulation and is replaced with the appropriate hardware attached to a 350 horsepower drive stand. Variables are passed between the hardware and the simulation in real-time to update model parameters and to synchronize the hardware with the model. Real-time simulation platforms from dSPACE and National Instruments (NI) are utilized for this investigation. Similar results are obtained when using HIL and a simulated load. Initially, noticeable differences are seen when comparing the results from each real-time operating system. However, discrepancies in test results obtained from the NI system can be resolved. This paper briefly details the underlying problem and its solution before discussing test results which show that both dSPACE and NI can be configured to match the baseline Simulink data. American Institute of Aeronautics and Astronautics 6th International Energy Conversion Engineering Conference, July 2008. Contact information:...
Read MoreWater-Cooled Load Bank for Aircraft Power Systems Analysis
C. Barnes, G. Diehl, T. Baudendistel, PC Krause and Associates, Inc; J. Potter, L. Burich, U.S. Air Force Research Laboratory Using an air-cooled load bank in the high speed drive stand room at AFRL Building 18b Room 15 has presented several problems.   It required significant floor space. It was designed only for 270VDC.  It raised the temperature of the room to a high level due to its 82.5KW resistive load. Lastly, it applies a load in large 2.7kW steps.   This presentation will cover a new 150KW load bank developed to address these issues. The new load bank that was developed is water cooled to transport heat out of the drive stand room by using 30 5KW heater elements configured in three banks of 10. Each element is switched on or off by a controller built into the load bank to meet the loading requirements. Three of the elements are controlled by a Pulse Width Modulation (PWM) circuit to provide 20W steps in loading. The load bank is equipped with rectifiers and adaptor plates to accommodate various generator configurations including single phase AC, 3-phase AC, and DC voltages. In order to minimize floor space used, the load bank is wall mounted above the drive stand. 2008 SAE Power Systems Conference, November 11-13, 2008, Bellevue,...
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