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This paper studies the effects of shaft rub on a rotating system's vibration response with emphasis on heat generation at the contact point. A 3D heat transfer code, coupled to a 3D vibration code, was developed to predict the dynamic response of a rotor in the time domain. The shaft bow is represented by an equivalent bending moment and the contact forces by rotating external forces. The seal ring is modeled as a linear spring, which exerts a normal force to the rotor. The tangential force is then calculated as the product of the normal force with the friction coefficient. Stable or unstable spiraling and oscillating modes were seen to occur in well defined shaft speed zones. In the main, for the configurations studied, the shaft vibration was found to be unstable for speeds below the first critical speed and stable for speeds above the first critical speed. Limit cycle behavior was observed when the phase angle between the unbalance force and the response was around 90 deg. The vibration behavior with rub during startup and shutdown was studied by considering the effects of acceleration/deceleration rate, friction coefficient, and mass unbalance. It was found that friction coefficient and increasing mass unbalance amplified the rub effects while acceleration/deceleration rate reduced it. [DOI: 10.1115/1.4000904] Keywords: Shaft/seal rub, coupled analysis for heat transfer and vibration, thermal bending moment, rub at startup and shutdown

In this study, a modeling approach has been developed to take multiphysical effects into account in the prediction of the rotordynamic behavior of high speed minirotating machinery with a moderate flow confinement. The temperature increase in the confinement and the flow induced forces resulting from the surrounding fluid have been studied and these models are combined with the structural finite element models for determining the rotordynamic behavior. The structure has been analyzed via finite elements based on Timoshenko beam theory. Flow induced forces are implemented to the structure as added mass-stiffness-damping at each node representing the structure in the fluid confinement. A thermal model based on thermal networks in steady-state has been developed. This model is used to calculate the heat dissipation resulting from air friction and temperature increase in the air gap as a function of rotation speed. At each rotation speed, the temperature in the air gap between the rotor and stationary casing is calculated and air properties, which are used for the calculation of flow induced forces are updated. In this way, thermal and fluid effects in medium gap confinements are coupled with the rotordynamic model and their effects on stability, critical speeds, and vibration response are investigated. The experimental results are reported and compared with the theoretical results in an accompanying paper (Part II). [DOI: 10.1115/1.4000787]

This paper presents a new permanent-magnet (PM) brushless machine for wind power generation. This machine adopts an outer-rotor topology, aiming at capturing wind power directly. In order to achieve high power density, a high-speed PM brushless generator is artfully integrated with a coaxial magnetic gear. The design details, with emphasis on the special constraints of wind power generation, are elaborated. By using the time-stepping finite element method, the static characteristics as well as no-load and on-load operations are simulated. A prototype is also built for experimentation. Both simulation and experimental results are given to verify the validity of the proposed machine. Finally, a quantitative comparison is made to justify that the proposed machine is of smaller size, lighter weight, and lower cost than its counterparts. Index Terms--Finite-element method (FEM), magnetic gear, outer rotor, permanent-magnet (PM) machine, wind power generation.

Thermal models used in overload protection relays often fail to predict the rotor temperature for motors with impaired cooling conditions. In this case, the temperature estimated from the rotor resistance can be used as an indicator of the motor's cooling capability. However, this estimated rotor temperature is often corrupted by estimation error due to the asymmetry in the power supply. A detailed analysis of the trajectories of the complex current and voltage space vectors in a synchronous reference frame is presented in this paper, and the negative sequence fundamental frequency components are identified as the major cause of the estimation error. Based on this analysis, a fast and efficient algorithm is proposed to calculate the rotor temperature for line-connected induction machines. By applying the Goertzel algorithm to the complex current and voltage space vectors, constructed directly from the motor terminal measurements, the positive sequence fundamental frequency components are extracted, and the rotor temperature is then estimated with significantly reduced estimation error. Compared to the conventional scheme based on the fast Fourier transform, the proposed algorithm is faster and more efficient, and is therefore more suitable for implementation on a low-cost hardware platform. Index Terms--Complex space vector, condition monitoring, Goertzel algorithm, impaired cooling, induction machine, rotor temperature estimation, unbalanced supply.

This paper presents an experimental investigation of a novel approach for controlling the rotor tip leakage and secondary flow by injecting cooling air from the stationary casing onto the rotor tip. It contains a detailed analysis of the unsteady flow interaction between the injected air and the flow in the rotor tip region and its impact on the rotor secondary flow structures. The experimental investigation has been conducted on a one-and-1/2-stage, unshrouded turbine, which has been especially designed and built for the current investigation. The turbine test case models a highly loaded, high pressure gas turbine stage. Measurements conducted with a two-sensor fast-response aerodynamic probe have provided data describing the time-resolved behavior of flow angles and pressures, as well as turbulence intensity in the exit plane of the rotor. Cooling air has been injected in the circumferential direction at a 30 deg angle from the casing tangent, opposing the rotor turning direction through a circumferential array of ten equidistant holes per rotor pitch. Different cooling air injection configurations have been tested. Injection parameters such as mass flow, axial position, and size of the holes have been varied to see the effect on the rotor tip secondary flows. The results of the current investigation show that with the injection, the size and the turbulence intensity of the rotor tip leakage vortex and the rotor tip passage vortex reduce. Both vortices move toward the tip suction side corner of the rotor passage. With an appropriate combination of injection mass flow rate and axial injection position, the isentropic efficiency of the stage was improved by 0.55 percentage points.

The efficiency of different cooling systems, such as a cold insert, circulation of a cool gas and boiling of a cool liquid, to cool the rotor of a superconducting rotor in a synchronous machine is examined. The findings reveal that the cooling efficiency depends on the cooling system itself and on the gas used.

The rotor winding shape of HTS (High Temperature Superconducting) motor is designed to maximum flux-linkage of stator winging with a given amount of superconductor volume. With the help of three step design procedure of shape design and sizing design, the final optimal rotor winding for easy industrial manufacturing was obtained.

Rotor eddy-current loss is usually significant in high-speed permanent magnet brushless dc (PM BLDC) motors. On the other hand, the rotor is usually protected with a nonmagnetic retaining sleeve. The influence of the conductivity of the retaining sleeve on the rotor eddy-current loss is analyzed in this paper. Furthermore, utility of a conductive copper shield between the sleeve and magnets is demonstrated. Although eddy current is induced in the copper shield, causing additional loss, its magnetic field can smooth the varying field in the rotor and reduce the overall eddy-current loss dramatically. The relationship between the thickness of copper shield and the rotor eddy-current loss is also examined. Index Terms--Conductive shield, high-speed motor, permanent magnet brushless dc (PM BLDC) motor, retaining sleeve, rotor eddycurrent loss, temperature rise.

The sealing of the stator-rotor gap and rotor-platform cooling are vital to the safe operation of the high-pressure turbine. Contrary to the experience in subsonic turbines, this paper demonstrates the potential to improve the efficiency in transonic turbines at certain rim seal rates. Two types of cooling techniques were investigated: purge gas ejected out of the cavity between the stator rim and the rotor disk, and cooling at the rotor-platform. The tests were carried out in a full annular stage fed by a compression tube at [M.sub.2is] =1.1, Re =1.1 x [10.sup.6], and at temperature ratios reproducing engine conditions. The stator outlet was instrumented to allow the aerothermal characterization of the purge flow. The rotor blade was heavily instrumented with fast-response pressure sensors and double-layer thin film gauges. The tests are coupled with numerical calculations performed using the ONERA's code ELSA. The results indicate that the stator-rotor interaction is significantly affected by the stator-rim seal, both in terms of heat transfer and pressure fluctuations. The flow exchange between the rotor disk cavity and the mainstream passage is mainly governed by the vane trailing edge shock patterns. The purge flow leads to the appearance of a large coherent vortex structure on the suction side of the blade, which enhances the overall heat transfer coefficient due to the blockage effect created. The impact of the platform cooling is observed to be restricted to the platform, with negligible effects on the blade suction side. The platform cooling results in a clear attenuation of pressure pulsations at some specific locations. The experimental and computational fluid dynamics results show an increase in the turbine performance compared with the no rim seal case. A detailed loss breakdown analysis helped to identify the shock loss as the major loss source. The presented results should help designers improve the protection of the rotor platform while minimizing the amount of coolant used. [DOI: 10.1115/1.3142859]