Abstract: A brushless electrical machine for converting between electrical and mechanical energy includes a rotor supported on bearings for rotation about an axis of rotation, and a stator that is stationary and magnetically acts upon the rotor. The rotor includes two ferromagnetic rotor portions separated by a magnetic insulator, forming an axial armature air gap between the ferromagnetic rotor portions. At least one of the two ferromagnetic rotor portions has multiple axial extending protrusions facing the axial armature air gap around a circumference. An air core armature having multiple phase windings is located in the axial armature air gap. A ferromagnetic yoke and homopolar flux generator are mounted to the stator. The homopolar flux generator generates homopolar flux in the protrusions of the rotor and the ferromagnetic yoke forms two rotor-to-stator air gaps with the rotor.

Abstract: An acoustic pyrometer measures the average gas temperature across a wide space of known distance, especially turbulent, high temperature gas loaded with caustic particulates. It includes an acoustic signal generator that generates a high amplitude acoustic signal with a short rise time and a detector positioned adjacent the signal generator that detects the onset of the acoustic signal in the signal generator and generates a first electrical signal corresponding in time to the onset of the acoustic signal in the signal generator. A receiver, positioned across the space from the signal generator, receives acoustic signals from the space and generates electrical signals corresponding to amplitude and frequency of the acoustic signals received in the receiver.

Abstract: A flywheel energy storage system includes an energy storage flywheel supported for rotation about a substantially vertical axis on a combination bearing system comprised of a mechanical and a magnetic bearing. A motor and generator accelerates and decelerates the flywheel for storing and retrieving energy. The mechanical bearing is located at one axial end of the flywheel and provides axial downward force to the flywheel and is connected to the mechanical rolling element bearing using a low radial stiffness connecting element. The magnetic bearing is located at the axial end of the flywheel opposite the end with the mechanical bearing and provides axial upward force to support the weight of the flywheel, and also provides passive magnetic radial centering force to the flywheel.

Abstract: A device for preventing power interruptions to a DC bus includes a flywheel supported on bearings for rotation inside a chamber having a drag reducing atmosphere within a container. During charging, the flywheel is driven by an integral brushless permanent magnet excited motor/generator for storing energy, and during retrieval of the stored energy, the flywheel drives and is decelerated by the same motor generator. A closed loop operated synchronous inverter delivers synchronous electrical power to the armature coils of the motor/generator for accelerating the motor/generator. A rectifier connects the armature coils of the motor/generator to the DC bus. Upon an interruption of primary utility power, the motor/generator supplies unregulated voltage power to the DC bus through the rectifier, and the voltage of the unregulated voltage power to the DC bus falls as the flywheel slows during discharge of useable energy from the flywheel through the motor/generator to the DC bus.

Abstract: A method and apparatus for holding a part on a fixture in a precisely known predetermined position includes pressing a surface of the part against a vacuum head and sealing an annular elastomeric sealing ring against the part surface. A valve button of a valve is engaged by the part surface to open the valve and establish communication between a vacuum source. The part is pulled by the vacuum against a hard stop in the vacuum head having a fixed precisely known relationship to said vacuum head reference surface. The hard-stop can be mounted in the base of the vacuum head for pivoting about at least one axis to self-align the hard-stop face with the part face.

Abstract: A liquid jet nozzle for forming a high velocity liquid jet from a pressurized liquid, includes a monolithic Nitinol body having an input side and an output side. A tapering lead-in channel opening in the input side and tapers to a central web, through which extends a small diameter orifice, communicating through the web from the lead-in channel to an egress opening in the output side of the body. The orifice interacts with the high pressure liquid to shape the pressurized liquid into a narrow, high velocity liquid jet which exits the body through the egress opening. A surface layer of nickel titanium oxide on the Nitinol in the orifice provides enhanced resistance to erosion by the high pressure liquid.

Abstract: A flywheel energy storage system that allows high-speed operation with use of mechanical rolling element bearings for radial support of a vertical axis flywheel while they allow it to be mechanically free or unrestrained in the axial direction. Magnetic bearings are used to carry the flywheel weight axially. The axial unconstraint by the mechanical bearings allows the flywheel to freely grow or shrink in axial length from Poisson Effect contraction that occurs when rotating to very high speeds and stress levels as well as from thermal expansions from motor/generator heating or other sources, and also insures that the magnetic bearing carries all of the flywheel weight, thus greatly extending the life of the mechanical bearings. Radially compliant elements mechanically in series with the mechanical bearings provide for a lower radial stiffness, which allows the flywheel to traverse its rigid body resonance at a low speed.

Abstract: A flywheel energy storage system includes an energy storage flywheel supported on a bearing system for rotation about a substantially vertical axis inside in an evacuated chamber enclosed within a sealed container. A motor and a generator accelerates and decelerates the flywheel for storing and retrieving energy. A tilt sensor detects if the orientation of the axis of rotation is outside of tolerance limits from vertical and triggers a signal to signal appropriate system functions to protect the system from damage.

Abstract: An active magnetic thrust bearing, acting on only a single axial side of a rotor, while also having an efficient permanent magnet bias for linearized and highly amplified control, uses two concentric ring poles that axially face a ferromagnetic axial surface of the rotor, creating two annular axial air gaps. A permanent magnet in the stator drives a bias flux through a first path including two radially spaced concentric ring poles and their air gaps, and an annular region of the rotor axially aligned between the two ring poles. The permanent magnet also drives flux through a second high-reluctance flux path in the stator, by-passing the rotor. An electromagnetic coil in the stator drives a control flux in a circuit including the second path, both ring poles and axial air gaps, and the shunt. The bias and control fluxes are therefore superposed in the axial air gaps for amplified response.

Abstract: A flywheel energy storage system having magnetic bearings that are preferably homopolar, that is, the magnetic fields do not alternate polarity around a given circumferential location. This significantly increases efficiency, reduces heating in the evacuated flywheel environment and reduces power requirements of the electronics. The magnetic bearings are also preferably permanent magnet biased. Permanent magnets provide bias flux in the magnetic bearings which produces several benefits. The bias flux linearizes and amplifies the response of the magnetic bearings for much easier and simpler control. Compared with designs using electromagnetic bias, permanent magnet bias results in lower power consumption and increased linearity in force to displacement response due to the large reluctance offered by the permanent magnets. Permanent magnet bias also allows use of only one amplifier per axes instead of two. This greatly reduces the costs and increases reliability.

Abstract: Accordingly, the invention provides a speed control for a flywheel energy storage system that provides accurate and reliable speed control for long-term operation. The speed control uses a current limiting means that safely limits the acceleration current to the motor for accelerating flywheel, and a rate controller that digitally switches the acceleration current on and off to maintain the desired steady state speed. The rate controller turns the acceleration current off when the flywheel speed is above the desired steady state speed and then turns the acceleration current back on when the flywheel speed falls below the desired steady state speeds. The digital type speed control can be made both more accurate and reliable by using straightforward on/off control about the desired steady state operating speed.

Abstract: A combination mechanical and magnetic support system for a flywheel power supply for storing and retrieving energy in which said power supply includes a flywheel that spins about an axis of rotation inside an evacuated chamber, and an attached motor/generator for accelerating and decelerating the flywheel for storing and retrieving the energy. One or more rolling element bearings and at least one magnetic bearing are mounted in bearing housings attached to the chamber for providing radial and axial support for the flywheel in the chamber. A wire metal mesh spring damper between portions of the rolling element bearings and the bearing housings provide both radial damping and radial centering stiffness to the wheel. The support system has a radial stiffness that allows a cylindrical rigid body resonance of said flywheel to occur at a speed less 30% of the normal operating speed.

Abstract: A method and apparatus for manufacturing large, semi-flexible metal components includes a fixture that holds the component blank in a desired position for manufacturing operations by accurate numerically controlled machine tools using original numerical part definition records, utilizing spatial relationships between key features of detail parts or subassemblies as represented by coordination features machined into the parts and subassemblies, thereby making the parts and subassemblies intrinsically determinant of the dimensions and contour of the part.

Abstract: A flywheel power source having a flywheel supported by a bearing system for rotation inside an evacuated container. A brushless motor and generator is coupled to the flywheel for accelerating and decelerating the flywheel for storing and retrieving energy. The generator has a rotor coupled to the flywheel, and a stationary stator wound using multiple-strand individually insulated conductor wire coils. A heat energy transfer system passively cools the stator by heat transfer from the stator to an unpumped liquid coolant surrounding the coils and in intimate contact with the conductors in the coils. The stator is mounted in a stator coolant vessel that is partially filled with the coolant. The liquid coolant limits the maximum temperature of the coils during discharging of the flywheel power source.

Abstract: A gun barrel for a gun has an elongated tube with an axial bore extending completely through the tube from the breech end to the muzzle end. The tube and the contact surface in the axial bore, which contains propellant gasses behind the projectile and engages the projectile while guiding it toward the target, are made of Nitinol having a transition temperature lower than the lowest ambient temperature at which a gun with the barrel is designed to be operated, or of a Nitinol formulation consisting essentially of 60% nickel and 40% titanium. A first sleeve may be mechanically coupled to the barrel tube by shape memory contraction thereon to prestress the barrel tube in compression.

Abstract: An in-situ curing filament winding process for making high quality flywheel rims at low cost, and the rims made by the process, and also an apparatus for performing the process, continuously cures resin during the filament winding process. A lower winding process temperature is used along with a lower cure temperature and inherently higher toughness epoxy resin system allows for the rim to be wound continuously, using a conservative radial deposition rate of approximately ¼-½ inch per hour. Multiple types of fibers can be used in a rim where they best serve the strength and stiffness requirements of the structure. The winding temperature can be kept at approximately 55° C.-80° C., providing low thermal residual stresses. Aliphatic amine or ether amine curing agents with epoxy resin generally work well to reduce the winding temperature and allow low viscosity, but other resin systems that provide similar characteristics can be used.

Abstract: A universal mounting mechanism for holding objects, such as electrical, medical, optical or audio/visual components needing secure physical connection to another surface in such a way that the mounted object can be easily and quickly installed and removed. It locks the object by providing surfaces on three planes that firmly engage the object so it does not move during transportation or when mounted on a fixed surface. It is low in profile so it does not obstruct the use of the items being held. The mount has no loose parts that can be lost during installation or removal of the mounted objects. Furthermore, the mount has the added feature of locking into either the open or closed position. Because the range of motion is limited, the top of the mount will not move into a position where it could be damaged or obstruct the use of adjacently mounted items.

Abstract: A vacuum management and regeneration apparatus and method for operating an energy storage flywheel system having a flywheel supported by a bearing system inside an evacuated chamber enclosed within a container. A motor/generator stores and retrieves energy by accelerating and decelerating the flywheel. A vacuum is maintained in the container with a vacuum level sufficient to reduce the aerodynamic drag on the flywheel, typically between 10−1 Torr to 10−3 Torr depending on the flywheel construction and its operating tip speed. The vacuum management system, including a vacuum pump and a timer, maintains the vacuum level in the container. The timer periodically enables operation of the vacuum pump, such as a mechanical vacuum pump or a getter pump, to reduce the pressure in the container.

Abstract: A projectile for being propelled toward a target includes a cylindrical body of Type 55 Nitinol that has a soft martensitic state that is readily deformed by rifling in the bore of a gun barrel to form grooves which ride on the rifling to spin the projectile. The Nitinol has a low coefficient of friction with the steel barrel and is sufficiently strong to prevent shedding particles or depositing projectile material in the bore. On impact with the target, the Nitinol undergoes a strain-induced shift to an ultra-high strength state in which the projectile is capable of remaining intact and concentrating its full energy on the small area of contact for maximal penetration and damage to the target instead of mushrooming widely and spreading its energy over a wide area as conventional projectiles do. Projectiles in the form of bullets, shotgun slugs, penetrating warheads, caseless ammunition and artillery shells are described.

Abstract: A flywheel system for storing and delivering on demand electrical energy includes a flywheel supported for high speed rotation on bearings in a vacuum enclosure, and a motor-generator for spinning the flywheel up to speed and then for converting the rotational inertia in the flywheel back to electrical power. The flywheel includes a solid steel hub and a rim having only two rings press-fit on the hub with an interference fit. The rings are filament wound construction made primarily from standard modulus carbon fiber/epoxy. The steel hub stores between 40% and 60% of the energy in the flywheel. The press-fitting of the rings on the hub creates radial interference pressure between the hub and each of the composite rings that is greater than 5 ksi when at rest. The outer carbon fiber/epoxy ring is radially thinner than the inner ring, and both the hub outer diameter and the inner diameter of the assembled composite rim are tapered with the same angle.