Summary:

Active motion control technology has been exploited for many electromechanical controlled motion applications in manufacturing, vehicles, and medicine. Some specific applications include flywheel energy storage systems, power steering motors for cars, vibration absorbers, and noise cancellation. SatCon Technology Corp. developed this technology with the help of three BMDO SBIR Phase II contracts to increase the precision of pointing and tracking systems using vibration control technology and to develop magnetic bearings for space-based power generators.

Technology Description:

With magnetic bearings, moving parts “float” in a magnetic field without contact, nearly eliminating friction and wear, and completely eliminating the need for lubrication. SatCon Technology Corporation (Cambridge, MA) researched how to actively control the bearings' magnetic force fields to stabilize the rotating machine parts. The result is reduction in machinery vibration and higher power densities (power output per mass) than conventional ball or roller mechanical bearings. This technology has been exploited for many electromechanical controlled motion applications.

MDA Origins:

In three BMDO SBIR Phase II contracts, SatCon developed vibration control systems to increase the precision of BMD pointing and tracking systems and magnetic bearings for space-based rotating machinery for space power generation. The technology for SatCon's flywheels came from two research sources: BMDO-funded research in frictionless magnetic bearings and active magnetic vibration isolation, and NASA research in spinning masses.

SatCon also used their magnetic bearing research work in a BMDO SBIR Phase II contract with Mainstream Engineering Corporation (see Insert #134). SatCon combined magnetic bearings with an electrical drive system to eliminate contact-type bearings in machines that handle fluids or gases, like refrigerator compressors.

While BMDO-funded magnetic bearing technology enabled SatCon to develop a component of permanent magnet variable speed drives, the Navy supported the major part of the company's development.

BMDO has funded SatCon for at least another seven SBIR Phase I contracts that have added to its active motion control work. Many other organizations have also funded them. BMDO also funded SatCon in linear actuators that are finding their way into helicopter vibration reduction.

Spinoff Applications:

SatCon has leveraged research with many government agencies to develop different components of active motion control technology. In active motion control, sensors provide feedback on output and results, a computer analyzes these results and produces electrical signals that direct the system how to respond, and actuators convert these electrical signals into a force. Active motion control technology has a broad range of applications in manufacturing, automotive, medical, and any other areas where mechanical component positions must be controlled. Specific applications include:

Magnetic bearings: Magnetic bearings reduce friction, noise, and vibration by allowing lubrication-free, low-friction operation of rotating parts in compressors, turbines, flywheels, and other extreme-speed, high-temperature applications. This improves performance and increases machine life. This technology applies to flywheels for storing and retrieving energy.

Other applications for magnetic bearings are jet turbine engines and refrigeration compressors. Magnetic bearings eliminate the need for oil, lubricants, and hydraulics in jet engines allowing them to run hotter and weigh less. Bearings that require no lubrication make possible the use of other refrigerants besides Freon, which mixes with oil. By eliminating friction, magnetic bearings also increase compressor lifetime and efficiency and reduce system mass.

Other applications include industrial manufacturing, and machine tools.

Flywheels: Flywheels have been used to store and release mechanical energy since the industrial revolution. But with new light composite materials, frictionless magnetic bearings, and active vibration control, flywheels can be used as electromechanical batteries that are competitive with the more familiar electrochemical varieties. Fabricated from high-strength, lightweight composite materials, the flywheels rotate at high speeds and store large amounts of energy. When an electric system served by the flywheel is fully powered, an electric drive accelerates the flywheel, causing it to store energy. When the external power is interrupted the flywheel is transformed into a generator. Energy stored as momentum in the spinning mass generates electricity as the flywheel spins down. When the power comes back on, the flywheel can be powered back up to speed until needed again.

SatCon is using compact, high-energy flywheel energy storage systems for uninterruptible power supplies, should the electricity go out for telephone and cable company lines. Flywheel energy storage systems can also be used for load leveling and maintaining power quality for utilities. Flywheels can store and supply power in the drive train for automobiles. Flywheels on satellites can serve a dual purpose: as a power supply and also as momentum wheels to control attitude.

Flywheel energy storage systems would also be useful for critical systems in factories or hospitals so managers could power up a generator, shut down systems without crashing, or just ride through the most common, seconds-long power outages. Flywheels have an advantage over batteries in that they are more reliable, have a longer life, and are environmentally friendly.

Electric motors: Active motion control technology is being applied to alternators and electric power-steering motors for cars. With advanced electronic computation and power technology, automotive drive trains of the future would be less expensive, lighter, more energy efficient, and environmentally friendly. Researchers are searching for ways to generate more electricity—even when the cars are at idle—for cars that increasingly have more electronic gadgetry.

Vibration absorbers: Absorbers use a vibrating mass to cancel noise and vibration. Potential commercial applications include reducing aircraft vibration and quieting home appliances, machinery, and military equipment. Also, SatCon's absorbers could enhance the performance of standard shock absorbing systems currently used in automobiles.

Micro-Sensors: Ranging in size from 10 microns to a few millimeters, micro-sensors are made of silicon and installed on silicon chips to measure rotation, vibration, and magnetic field. The devices can be used to measure noise and vibration in military and commercial aircraft, automobiles, and other systems.

Commercialization:

SatCon's electromechanical products have commercialization potential in automotive, telecommunications, utility, industrial manufacturing, aerospace, and satellite applications. Flywheels are a major area of commercialization for SatCon, although their only production-quantity order so far is in industrial manufacturing. In addition, SatCon is moving into “smart” electric motors. They are developing magnetics and motor technology, software, and power electronics.

Automotive: Another major area of effort is automotive. SatCon has applied its technology to flywheel energy storage systems to replace batteries in hybrid-electric cars, electric motors, and improved alternators.

In 1992, under an initiative from the Technology Applications program, presentations of BMDO-funded technologies were made to the Big Three automakers. All three requested further information on SatCon's magnetic bearing technology. In further meetings between David Eisenhaure and Tom Kizer of Chrysler's innovative Liberty group, the companies agreed to pursue several joint developments. In July 1993, SatCon signed an agreement with Chrysler Corporation to develop power electronics for innovative automotive drive train components. In addition, SatCon worked in a joint development program with Chrysler Corporation to develop the entire drive train—including the flywheel energy storage system, electric motor, and turbo alternator—for the Patriot race car. At the International Auto Show in January 1994, Chrysler unveiled the Patriot prototype, which demonstrated a 98-percent efficiency with its power electronics for turbine engine alternators, the most dense power electronics ever built. SatCon and Chrysler received Discover magazine’s 1995 Technology and Innovation Award for the development of flywheel energy storage systems on the Patriot program.

In another joint development program near the beginning of 1994, SatCon worked with the Electricore Consortium to combine power electronics and flywheels in a drive train to convert turbine power to electrical power efficiently. They were able to demonstrate increased overall turbine-alternator system efficiency with better gas mileage, making turbine-alternators a leading contender for future hybrid electric vehicle (HEV) applications. SatCon’s power electronics could be used with any alternative fuel vehicle including pure electric vehicles, which may be a significant market in the future.

Chrysler chose to stop funding the Patriot race car with its own money and successfully bid the technology for $84 million to the Department of Energy’s (DOE) Partnership for a New Generation of Vehicles. As a team member, SatCon worked to transition the Patriot power electronics products for HEV and electric vehicles. Turbine alternators are a key component for electric vehicles and are being investigated by all major car companies. SatCon has seen no revenues from the project yet, however, so they have, in the meantime, started working with General Motors and Williams International on an HEV.

In addition, SatCon has an independent $100,000 contract with the Department of Energy to design a high-speed alternator for a flywheel energy storage system for HEVs. Also, in March 1997 DOE awarded SatCon $500,000 to develop, in conjunction with MIT, a high-speed motor alternator for HEVs. The alternator will have a peak power of 30 kW and a speed of 30,000 rpm.

An extension to its Patriot program research, SatCon subcontracted to Lockheed Martin in September 1996 to provide component analysis, design, and sizing for an HEV version of the Army’s next Scout Vehicle. Lockheed Martin is the prime contractor for a Phase I project funded by the Defense Advanced Research Projects Agency (DARPA).

In March 1997, SatCon received $200,000 from the Wright Patterson Air Force Base and BMDO for two projects. The first is to develop a flight-weight high temperature magnetic bearing actuator for high performance turbine engines. The second is for a microfabricated inertial guidance sensor that is simple in design, resistant to shock, and low in cost. The guidance control could be used for automobile navigation systems and suspension control and robotics.

Industrial manufacturing: SatCon is commercializing products in industrial manufacturing. The company entered into a long-term manufacturing agreement with Applied Materials to provide a “smart” drive component for the process chamber of semiconductor manufacturing equipment Applied Material produces. This is SatCon's first production quantity order. It is also working towards a component for positioning photolithography machinery.

Telecommunications: Flywheel Energy Storage Systems are used as an uninterruptible power supply to maintain service for cable television and telephone companies during power outages. SatCon already has over $10 million in commercial orders and letters of intent for prototype flywheel energy storage systems. On January 31, 1997, SatCon announced that San Diego Gas & Electric Company purchased SatCon's 20C1000 Cable Television Flywheel System to be installed with a local cable television system provider for evaluation. The system is to be evaluated for delivering high quality power to customers with sensitive power loads such as cable and telecommunications providers.
SatCon is hoping cable companies, with their need to solve the problem of uninterruptible power, will be an early adopter of the technology. For fiber-optic cable, flywheels would be built into the local distribution system as decentralized power devices. At about 100 houses per unit, the market for such devices would be large.

Satellites: Flywheels for energy storage have advantages over battery power supplies for satellites because of the large number of charge and discharge cycles as satellites move through the light and dark portions of their orbits. Magnetic bearing flywheels are also more compact and lightweight and do not require lubrication. Flywheel energy storage systems are attracting interest for constellations of low-Earth-orbit (LEO) satellites. The systems could provide power easily during the 90 minutes LEO satellites orbit in darkness, when the solar panels cannot provide power. The systems also can be drawn down to very low energy levels regularly without damaging the system, unlike batteries. SatCon announced January 11, 1997, that one of its flywheels will be tested by NASA in a satellite application in March 1998. It will be used primarily as a battery, but also may provide attitude control power. In February 1997, Phillips Laboratory, on behalf of BMDO, awarded SatCon $2 million to develop flywheels made of lightweight glass filaments or carbon fiber to extend the life of satellites.

Company Profile:

In January 1993, SatCon completed an $8.8 million initial public offering. SatCon reorganized in 1995, creating the Energy Systems Division to concentrate on product development for SatCon’s Flywheel Energy Storage Systems and one other division for research. In 1997 they also created a division to produce and market precision products.

SatCon holds nine U.S. patents: one for a magnetic bearing and suspension system, one for a magnetic translator bearing, and others for actuators, motors, and flywheel technology. The company also has 12 patent applications pending and others in progress in magnetics, motors, flywheels, and power electronics.

In March/April 1997, SatCon acquired manufacturing capability through acquiring two companies. K&D Magmotor (Worcester, MA) provides a 6,000-sq.-ft. facility (with an additional 6,000 sq. ft. being added) for the manufacture of motors. Film Micro-electronics Inc. provides a 15,000-sq.-ft. facility for manufacturing power electronics.

Contact Information:

Dr. David Eisenhaure (company president)
Mr. Michael C. Turmelle (vice president and treasurer)
William O’Donnell (director of corporate communications)
SatCon Technology Corp.
161 First Street
Cambridge MA 02142-1221
Tel:617-661-0540
Fax:617-661-3373