Emcon Systems Technical Experience
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Dr. Robert H. Badgley
Career Experience and Accomplishments
August 2008
Analysis and Troubleshooting
- Resolved pressure fluctuations on large natural gas pipeline valve for Washington Gas in Rockville, MD
- Corrected excessive vibration and resulting structural failures in large HVAC fans operating in Smithsonian Air & Space Museum, Udvar-Hazy Center, Dulles Airport
- Identified motor & fan noise & vibration problem sources in 13-SEER and Packaged Terminal Air Conditioners manufactured in Haier, Inc. factory in Tsingtao, China
- Conducted stress and loads assessment in large reinforced concrete foundation, including driven pilings, for new wind tunnel drive motors at Arnold Air Development Center, Tullahoma, Tennessee
- Resolved fan shaft failures in commercial office building air handling units by low-cost V-belt change
- Corrected rotor instability due to loose rotor bars in induction motors
- Assisted in resolving industrial gas turbine engine vibration problems at combined cycle power station in UK
- Resolved failures in GE LM2500 US Navy ship main propulsion engines
- Reduced gear noise in US Army helicopter rotor drive gearboxes
- Provided expert witness technical support in reciprocating compressor failures
- Resolved failures of vertical water pumps with water lubricated bearings
- Resolved failures in GE T64 gas turbine engines in Canadian Forces CC-115 aircraft
- Resolved lift fan drive shaft failures in US Navy air cushion landing craft (LCAC)
- Resolved Allison TF-40B gas turbine engine failures in Navy air cushion landing craft
- Resolved bearing failures in Allison 501K17 gas turbine engines in US Navy ships
- Resolved failures in V-16 diesel engines and electric generators in Navy FFG-7 ships
- Resolved failures in gas turbine starting air compressors in US Navy FFG-7 ships
- Resolved failures in induced draft fans.
- Resolved synchronous motor startup problems in municipal water pumping station.
- Resolved high vibration in 8,000 HP fluid pump drive motors in municipal disposal plant, by bearing sump redesign.
Component Development
- Current design and development of 1000-5000 HP back-to-back motor dynamometers for electric drives manufacturer
- Designed and developed in-place replaceable bearing mounts in chiller drive motors
- Designed, developed and tested 15,000 HP solid-pole 4-pole synchronous machines
- Managed design of 41,000 HP permanent magnet ship propulsion motors
- Designed and developed low-noise, low-profile air cabinets for induction motors
- Designed and developed ruggedized multiple-start rotors for coker jet pump motors
- Developed elastomer stiffness and damping application technology
- Developed elastomer dampers for ball and roller bearing supports
- Developed air-lubricated foil bearing technology
- Developed uranium enrichment centrifuge technology, including bearings, balancing, and instability analysis and solutions
- Developed uranium enrichment centrifuge technology development facility
- Developed technology facility for high speed drive shaft system testing
- Designed and developed industrial chiller drive motors featuring single frame size
- Developed and supported manufacturing of motors for high speed compressor drives
- Developed new motor design for reduced-size vertical pump-drive motors
- Developed new designs for motor-generator sets
Procedures and Software
- Prepared installation plan, including heavy lifts, for large (20,000 HP) motor-generator set
- Selected and acquired MAGSOFT software for electric motor and generator analysis
- Selected & acquired FLUENT CFD software for motor air flow cooling analysis
- Managed 3D solid modeling software development and implementation
- Evaluated, selected, & acquired DYROBES rotordynamic software for motor mfr.
- Managed integration of rotordynamic software into induction motor design system
- Prepared SOP and QA procedures for large industrial rotor balancing vacuum bunker
- Managed rotating machinery rotordynamic and FEA modeling and analyses
- Created and applied vibration diagnosis expert system
- Created, tested, and applied multiplane-multispeed rotor balance software & systems
- Managed data acquisition and control software development for heavy industrial multiplane-multispeed rotor balance machines
Program Management
- Led motor manufacturer’s engineering department during ISO9001 certification
- Set up and managed US Navy aircraft engine battle damage program
- As a US Army officer, set up and fielded various nuclear weapons test projects
Production Tooling
- Designed and manufactured large high-speed rotor balance machines for factory use
- Designed and supported manufacturing of multiplane high-speed production balancing machines
- Prepared industrial compressor rotor balancing system for European manufacturer
- Prepared laser metal removal system for at-speed automated rotor balancing for Japanese manufacturer of uranium enrichment centrifuges