Linear Motion Energy Conversion

The

UMBRA Reciprocating Linear Alternator

INTRODUCTION:
The conversion of motion to electricity from reciprocating power sources is typically associated with the integration of multiple systems. For each system, risks of failure increase and losses in efficiency (generally in the form of heat) can be expected. The Umbra Reciprocating Linear Alternator (URLA) utilizes specialized materials to ensure durability and minimizes the losses by closely integrating highly-efficient, power-conversion componentry to achieve direct power conversion with an efficiency as high as 85% from a single electromechanical device.

In thermodynamics, the conversion of energy can be expressed as

=
=1

Examples of efficiency losses include, but are not limited to: Pressure line losses (pressure drop) in hydraulic systems Heat losses due to friction in gear-boxes and power trains Electrical line losses due to heat liberation The fewer the number of systems to integrate, the fewer the number of opportunities for efficiency losses. Consequently, for motion to electricity pursuits, fewer systems will yield more electrical energy generation from the same external power source.

(Efficiency Losses)

According to the basic principles of electromagnetic inductance, voltage is directly proportional to the available inductance and the time rate of change of the current. Consequently, a method of improving the power output of an electromagnetic device is to maximize that time rate of change. The URLA maximizes the time rate of change through a mechanical, linear to rotational velocityamplification mechanism. For a low linear speed, the corresponding linear translation of the shaft results in a comparatively higher velocity at the outermost diameter Figure 1 Velocity of the nut. Amplicatio

The URLA simplifies and tightly integrates componentry to mitigate efficiency losses AND employs mechanical velocity amplification to the benefit of electromagnetic inductance to maximize the amount of electrical power generation from a single electromechanical device.

ARCHITECTURE:
The URLA utilizes the principle of electromagnetic induction to produce electricity. Linear motion is converted into rotary motion through a helical interface between the rotor of the permanent magnet generator and the shaft which is similar to a ball screw.

Figure 2 - Architecture

A linear translation of the helical shaft, which is constrained to resist rotation about its axis, results in the rolling of the loaded-balls between the shaft and the nut. The rolling of the balls induces a rotation of the nut (which is constrained to resist linear translation) about the axis of the shaft. The speed of rotation for the nut is a function of the linear input speed of the shaft and the pitch of the helical shaft. Permanent magnets are oriented in rows of alternating poles and bonded to the outer diameter of the nut consequently, the nut becomes the rotor of the electrical alternator. As the nut spins inside a specially designed stator coil, electrons are induced to flow through the coil (using the principle of electromagnetic induction) to yield an electric current.

MATERIALS:
The material selection for the ball screw is based on the environmental conditions, the ability of the material to have maximum wear resistance and superior rolling contact fatigue properties. Umbra has experience in a wide variety of materials either stainless steel and carbon steel. In case of an high corrosion resistance is required, Umbra suggests an induction hardenable stainless steel such as Cronidur 30. Corrosion resistance testing per ASTM B 117 demonstrated that Cronidur 30 with a surface hardness of 58 (Rockwell C) far exceeds that of comparable induction hardened materials such as AISI 440C.

AISI 440C - 58 HRC

Cronidur 30 - 58 HRC

Figure 3 Corrosion Resistance

The URLA utilizes a proprietary combination of materials to achieve superior life properties and corrosion resistance

DESIGN FOR LIFE METHODOLOGY

Motion transfer and bearing surfaces which are subject to rolling fatigue are sized to ensure that the contact pressure is below the stress-strain fatigue limit for the material as indicated by empirical field data, lab tests, and Hertzian theory. Furthermore the rigidity of critical components is optimized with Finite Element Analysis to ensure proper load distribution at different locations.

Contact Pressure

5000

10000

15000

20000

25000

30000 Hours

Figure 4 Life Hours

Electrical components are either selected or designed to withstand the thermal gradients that exist throughout the full spectrum of the mission cycle thereby supporting product life expectations.

TESTING:
Testing was performed on an URLA unit on October 2012 at the University of LAquila, Italy. The test unit, a derivative of the Umbra Electromechanical Actuator (UEMA), was subjected to a range of controlled external forces and speeds. Input and output power were measured to determine the actual URLA power conversion efficiency. The set-up is shown below in Figure 5:

Figure 5 Test Set-up

The URLA selected for the test has the following characteristics:
Feature Operating Speed Maximum stroke Operating Axial load Nominal Power Cooling system Dimension (OD) Dimension (Length) Typical size 200 mm/s 1000 mm/s 100 KN 15 KW Natural Air Convection 360 mm 500 mm

Positioning sensor

Incremental Encoder

Output voltage and current are correlated to specific combination of load and speed. The system allows a wide range of input parameters. Consequently, a wide range of performance results are expected.

RESULTS:
OUTPUT POWER YIELD A compilation of the test results that reveal the power output at relative speeds is shown in Figure 5 Power Output vs Input Speed.

350

3,5 KW

8 KW

12 KW

16,5 KW

300 200 mm/s 250 150 mm/s Vrms_f [V] 200 150 100 mm/s 100 50 0 0 5 10 15 20 Irms_f [A] 25 30 35 40

50 mm/s

Figure 5 RLA Characteristics Curves

From this chart, it can be shown that, for the device tested, in order to achieve 16.5 KW of power output, the input speed must be no less than 200 mm/s. Conversely, an input speed of 50 mm/s can yield no more than 3.5 KW of electricity.

EFFICIENCY It should be noted that unlike traditional generators, the efficiency is constant over a wider range of input speeds and is a function of input power the lower the input power, the lower the efficiency.

Figure 6 RLA Efficiency

Each URLA is characterized by a constant back-driving load given by the internal friction and the permanent magnet generators. The lower the input load, the greater the influence of the backdriving-load on the generated output power and consequently, the lower the conversion efficiency.

CONCLUSION:
The conversion of motion to electricity from reciprocating power sources can be accomplished with efficiencies as high as 85% using the Umbra Reciprocating Linear Alternator (URLA) the URLA mitigates efficiency losses by having fewer system components and fewer opportunities for energy losses through the tight integration of electromechanical components and the smart use of commercially available materials which have the added benefit of corrosion resistance.

Umbra Cuscinetti Inc. 2916 100th Street SW Everett, WA 98204 USA attn.: Antonio Gonzalez +1-937-609-9026 agonzalez@umbrausa.com

Umbra Cuscinetti, S.p.A. Zona Industriale, Loc. Paciana 06034 Foligno (PG) - Italy attn.: Lucio Panzolini +49 170 4564 759 lpanzolini@umbragroup.it