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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 181 records · Page 10

Simplified fatigue life analysis for traction drive contacts

A simplified fatigue life analysis for traction drive contacts of arbitrary geometry is presented. The analysis is based on the Lundberg-Palmgren theory used for rolling-element bearings. The effects of torque, element size, speed, contact ellipse ratio, and the influence of traction coefficient are shown. The analysis shows that within the limits of the available traction coefficient, traction contacts exhibit longest life at high speeds. Multiple, load-sharing roller arrangements have an advantageous effect on system life, torque capacity, power-to-weight ratio and size.

Rohn, D. A.↗

Dynamic analysis of astronaut motions in microgravity: Applications for Extravehicular Activity (EVA)

Simulations of astronaut motions during extravehicular activity (EVA) tasks were performed using computational multibody dynamics methods. The application of computational dynamic simulation to EVA was prompted by the realization that physical microgravity simulators have inherent limitations: viscosity in neutral buoyancy tanks; friction in air bearing floors; short duration for parabolic aircraft; and inertia and friction in suspension mechanisms. These limitations can mask critical dynamic effects that later cause problems during actual EVA's performed in space. Methods of formulating dynamic equations of motion for multibody systems are discussed with emphasis on Kane's method, which forms the basis of the simulations presented herein. Formulation of the equations of motion for a two degree of freedom arm is presented as an explicit example. The four basic steps in creating the computational simulations were: system description, in which the geometry, mass properties, and interconnection of system bodies are input to the computer; equation formulation based on the system description; inverse kinematics, in which the angles, velocities, and accelerations of joints are calculated for prescribed motion of the endpoint (hand) of the arm; and inverse dynamics, in which joint torques are calculated for a prescribed motion. A graphical animation and data plotting program, EVADS (EVA Dynamics Simulation), was developed and used to analyze the results of the simulations that were performed on a Silicon Graphics Indigo2 computer. EVA tasks involving manipulation of the Spartan 204 free flying astronomy payload, as performed during Space Shuttle mission STS-63 (February 1995), served as the subject for two dynamic simulations. An EVA crewmember was modeled as a seven segment system with an eighth segment representing the massive payload attached to the hand. For both simulations, the initial configuration of the lower body (trunk, upper leg, and lower leg) was a neutral microgravity posture. In the first simulation, the payload was manipulated around a circular trajectory of 0.15 m radius in 10 seconds. It was found that the wrist joint theoretically exceeded its ulnal deviation limit by as much as 49. 8 deg and was required to exert torques as high as 26 N-m to accomplish the task, well in excess of the wrist physiological limit of 12 N-m. The largest torque in the first simulation, 52 N-m, occurred in the ankle joint. To avoid these problems, the second simulation placed the arm in a more comfortable initial position and the radius and speed of the circular trajectory were reduced by half. As a result, the joint angles and torques were reduced to values well within their physiological limits. In particular, the maximum wrist torque for the second simulation was only 3 N-m and the maximum ankle torque was only 6 N-m.

Newman, Dava J.↗

Rotational joint assembly for the prosthetic leg

A rotational joint assembly for a prosthetic leg has been devised, which enables an artificial foot to rotate slightly when a person is walking, running or turning. The prosthetic leg includes upper and lower tubular members with the rotational joint assembly interposed between them. The assembly includes a restrainer mechanism which consists of a pivotably mounted paddle element. This device applies limiting force to control the rotation of the foot and also restores torque to return the foot back to its initial position.

Owens, L. J.↗

Subminiature hydraulic actuator

Subminiature, single-vane rotary actuator for wind-tunnel test-model control-surface actuation systems presents severe torque and system band-pass requirements with stringent space and weight limitations. Actuator has very low leakage of fluid from one side to other, permitting use in precision position servo-systems.

Sevart, F. D.↗

COBE attitude as seen from the FDF

The goal of the Flight Dynamics Facility (FDF) attitude support is twofold: to determine spacecraft attitude and to explain deviations from nominal attitude behavior. Attitude determination often requires resolving contradictions in the sensor observations. This may be accomplished by applying calibration corrections or by revising the observation models. After accounting for all known sources of error, solution accuracy should be limited only by observation and propagation noise. The second half of the goal is to explain why the attitude may not be as originally intended. Reasons for such deviations include sensor or actuator misalignments and control system performance. In these cases, the ability to explain the behavior should, in principle, be limited only by knowledge of the sensor and actuator data and external torques. Documented here are some results obtained to date in support of the Cosmic Background Explorer (COBE). Advantages and shortcomings of the integrated attitude determination/sensor calibration software are discussed. Some preliminary attitude solutions using data from the Diffuse Infrared Background Experiment (DIRBE) instrument are presented and compared to solutions using Sun and Earth sensors. A dynamical model is constructed to illustrate the relative importance of the various sensor imprefections. This model also shows the connection between the high- and low-frequency attitude oscillations.

Sedlak, J.↗

Disk tides and accretion runaway

It is suggested that tidal interaction of an accreting planetary embryo with the gaseous preplanetary disk may provide a mechanism to breach the so-called runaway limit during the formation of the giant planet cores. The disk tidal torque converts a would-be shepherding object into a 'predator,' which can continue to cannibalize the planetesimal disk. This is more likely to occur in the giant planet region than in the terrestrial zone, providing a natural cause for Jupiter to predate the inner planets and form within the O(10(exp 7) yr) lifetime of the nebula.

Ward, William R.↗

Testing and Maturing a Mass Translating Mechanism for a Deep Space CubeSat

Near Earth Asteroid (NEA) Scout is a deep space satellite set to launch aboard NASA’s Exploration Mission 1. The spacecraft fits within a CubeSat standard 6U (about 300 x 200 x 100 mm) and is designed to travel 1 AU over a 2.5 year mission to observe NEA VG 1991. The spacecraft will use an 86 square meter solar sail to maneuver from lunar orbit to the NEA. One of the critical mechanisms aboard NEA Scout, the Active Mass Translator (AMT), has gone through rigorous design and test cycles since its conception in July of 2015. The AMT is a two-axis translation table required to balance the spacecraft’s center of mass (CM) and solar sail center of pressure (CP) while also trimming disturbance torque created by off-nominal sail conditions. The AMT has very limited mass and volume requirements, but is still required to deliver a large translation range—about 160 x 68 mm—at sub mm accuracy and precision. The system must accommodate and protect a shielded wire harness and coax cables during translation. Lastly, the system has been constrained to operate in complete exposure to space with limited power and data budgets for mechanical and thermal needs. The NEA Scout team has developed and carried out a rigorous test suite for the prototype and engineering development unit (EDU). These tests uncovered numerous design failures and led to many failure investigations and iteration cycles. This paper will site each discovery and discuss at length the most surprising and difficult failures to date as the NEA Scout AMT moved through functional, random vibration, thermal vacuum, harnessing, and design life verification testing. A paper was previously presented at the 43rd Aerospace Mechanisms Symposia entitled, “Development of a High Performance, Low Profile Translation Table with Wire Feedthrough for a Deep Space CubeSat”. This paper will make note of specific lessons learned from the test activities: testing ideologies for high-risk missions, thermal mitigation design for small mechanisms, non-flight qualified stepper motor accommodation, harnessing volume allocation/design, and ground testing of mechanisms developed for zero-g environments.

Few, Alex↗

Testing and Maturing a Mass Translating Mechanism for a Deep Space CubeSat

Near Earth Asteroid (NEA) Scout is a deep space satellite set to launch aboard NASA's Exploration Mission 1. The spacecraft fits within a CubeSat standard 6U (about 300 x 200 x 100 mm) and is designed to travel 1 AU over a 2.5 year mission to observe NEA VG 1991. The spacecraft will use an 86 sq.m solar sail to maneuver from lunar orbit to the NEA. One of the critical mechanisms aboard NEA Scout, the Active Mass Translator (AMT), has gone through rigorous design and test cycles since its conception in July of 2015. The AMT is a two-axis translation table required to balance the spacecraft's center of mass (CM) and solar sail center of pressure (CP) while also trimming disturbance torque created by off-nominal sail conditions. The AMT has very limited mass and volume requirements, but is still required to deliver a large translation range-about 160 x 68 mm-at sub mm accuracy and precision. The system is constrained to operate in complete exposure to space with limited power and data budgets for mechanical and thermal needs. The NEA Scout team developed and carried out a rigorous test suite for the prototype and engineering development unit (EDU). These tests uncovered numerous design failures and led to many failure investigations and iteration cycles. A paper was previously presented at the 43rd Aerospace Mechanisms Symposia entitled, "Development of a High Performance, Low Profile Translation Table with Wire Feedthrough for a Deep Space CubeSat". This paper will make note of specific lessons learned: manufacturing philosophy, testing ideologies for high-risk missions, thermal mitigation design for small, motor-driven mechanisms.

Few, Alex↗

Exchange Bias Between van der Waals Materials: Tilted Magnetic States and Field-Free Spin–Orbit-Torque Switching

Magnetic van der Waals heterostructures provide a unique platform to study magnetism and spintronics device concepts in the 2D limit. Here, studies of exchange bias from the van der Waals antiferromagnet CrSBr acting on the van der Waals ferromagnet Fe3GeTe2 (FGT) are reported. Additionally, the orientation of the exchange bias is along the in-plane easy axis of CrSBr, perpendicular to the out-of-plane anisotropy of the FGT, inducing a strongly tilted magnetic configuration in the FGT. Furthermore, the in-plane exchange bias provides sufficient symmetry breaking to allow deterministic spin–orbit torque switching of the FGT in CrSBr/FGT/Pt samples at zero applied magnetic field. A minimum thickness of the CrSBr of >10 nm is needed to provide a non-zero exchange bias at 30 K.

36 MATERIALS SCIENCE↗

A Study of Spur Gears Lubricated With Grease-Observations From Seven Experiments

To improve understanding of gears operating with a perfluoro type space-qualified grease, seven spur gear experiments were performed. Test conditions were selected to study the influences of torque, lubricant type, and atmosphere. Two testing torques provided nominal pitch-line Hertz stresses greater and lesser than the contact stress limit as recommended by the grease manufacturer. As was expected, all tests resulted in some gear tooth wear. Discoloration of the perfluoro type grease occurred for all tests. Tests in dry nitrogen produced some dark-grey colored perfluoro type grease. Testing in either ambient or dry air produced red debris after short test duration, and for tests of longer duration large amounts of red debris, red grease, and wear were evident. Tests using higher torques produced more debris. The first indications of discoloration occurred more quickly with higher test torques. Total amounts of wear were quite significant, up to four times the profile tolerance for AGMA Class 10 gears.

Krantz, Timothy L.↗

Predicted Performance of On-Off Systems for Precise Satellite Attitude Control

An investigation has been made of the use of on-off reaction jets for precision attitude control of a satellite. Since a symmetrical vehicle is assumed, only single-axis control needs to be considered. The responses to initial disturbances and also limit-cycle characteristics for several systems have been evaluated. Calculated results indicate that realistic values of settling time and fuel consumption for the example considered can be obtained. The performance of a given system depends on the characteristics of the error detector used. In cases where the detector output was saturated for a relatively low error input, the settling time deteriorated when a lead network was used to provide damping. This deterioration could be eliminated if a separate rate signal to produce vehicle rate limiting were available. As an alternate approach, two systems were investigated which used a timed sequence of torques and could operate with a detector output of very small linear range. Although the performance of these systems was poorer than that of the lead network system without detector saturation, the performance was better than that of the lead network system with low values of detector saturation. The effects on limit-cycle characteristics of hysteresis, lead network constants, dead zone, and thrust time delays were also investigated.

Brown, Stuart C.↗

Multiple injection for improving knock, gaseous and particulate matter emissions in direct injection SI engines

Advances in fuel injector technology have enabled research and development on a large variety of direct injection spark ignition (DISI) engine fueling strategies targeted to improve engine performance and reduce engine-out emissions. This study explores the effect of multiple injections on knock, engine efficiency and stability, and particulate number and gaseous emissions on a single-cylinder DISI research engine. Work to date on multiple injections in the literature is reviewed, and then two aspects of multiple injection strategies are experimentally investigated: the number of injections (up to five times in a cycle); and the timing of the injections (classified relative to the timing of intake valve opening and closing). A boosted, single-cylinder research engine equipped with a state-of-the-art piezoelectric hollow cone spray direct injector and research-grade E10 gasoline was used for the study. The results show multiple injections maintain torque and combustion stability compared with single injection and slightly increase the knock limits and indicated thermal efficiencies (maximum 0.7% absolute, 2.8% relative compared with single-injection baseline) due to improved heat release phasing, especially with an additional late injection during the intake valve closed (compression stroke) period. The gaseous pollutant emissions including nitrogen oxides and unburned hydrocarbons were reduced by 25% with multiple injections, particularly with injection during the compression stroke. In contrast, carbon monoxide emissions increased with multiple injections for all conditions. Increasing the number of injection events significantly reduced particulate number emissions (half with each additional injection), and the decrease in particulate number was not sensitive to the injection timing.

42 ENGINEERING↗

Theoretical modeling of a bottom-raised oscillating surge wave energy converter structural loadings and power performances

Here, this study presents theoretical formulations to evaluate the fundamental parameters and performance characteristics of a bottom-raised oscillating surge wave energy converter (OSWEC) device. Employing a flat plate assumption and potential flow formulation in elliptical coordinates, closed-form equations for the added mass, radiation damping, and excitation forces/torques in the relevant pitch-pitch and surge-pitch directions of motion are developed and used to calculate the system's response amplitude operator and the forces and moments acting on the foundation. The model is benchmarked against numerical simulations using WAMIT and WEC-Sim, showcasing excellent agreement. The sensitivity of plate thickness on the analytical hydrodynamic solutions is investigated over several thickness-to-width ratios ranging from 1:80 to 1:10. The results show that as the thickness of the benchmark OSWEC increases, the deviation of the analytical hydrodynamic coefficients from the numerical solutions grows from 3% to 25%. Differences in the excitation forces and torques, however, are contained within 12%. While the flat plate assumption is a limitation of the proposed analytical model, the error is within a reasonable margin for use in the design space exploration phase before a higher-fidelity (and thus more computationally expensive) model is employed. A parametric study demonstrates the ability of the analytical model to quickly sweep over a domain of OSWEC dimensions, illustrating the analytical model's utility in the early phases of design.

13 HYDRO ENERGY↗

Comparison of electro-thermal performance of advanced cooling techniques for electric vehicle motors

Permanent magnet synchronous motors are commonly used in the powertrain of electric vehicles because of their high power and torque densities. Attempts to increase power and torque densities beyond the state-of-the-art often suffer from thermal limitations of the adopted winding-wire insulation class. In this paper, overall effectiveness of four different cooling technologies, namely conventional stator jacket cooling, embedded circular and rectangular cooling channels within stator core, and direct winding heat exchangers have been studied numerically. Here, by realizing temperature dependent magnetic and material properties, winding and core losses, a two-way coupling algorithm has been utilized to study the detailed electro-magnetic and thermal performance of BMW i3 motor with aforementioned cooling techniques. The numerical results illustrated that the direct winding heat exchangers approach provides better electro-thermal performance in comparison to the other cooling techniques analyzed. On the contrary, embedded rectangular and circular channel in stator core adversely affect the electro-magnetic performance and overall efficiency of the motor, despite their superior thermal performance compared to the jacket cooling

42 ENGINEERING↗

Process Intensification for Nanocomposite Aluminum Extrusions: CRADA 411 (Final Report)

The project evaluated the feasibility of using Shear Assisted Processing and Extrusion (ShAPE) for the fabrication of extrusions with a diameter of 0.5” and higher from an Al-alloy powder feedstock that contains nanoscale second phases for achieving enhanced elevated temperature strength. PNNL has previously extruded 0.2” diameter rods with high strength aluminum alloy powder Al-12.4TM. This project aimed to scale the process up to a diameter of 1.0” at a length of >24” while retaining the excellent mechanical properties achieved for the 0.2” diameter rods. As part of the project, extrusion dies were fabricated with various design features. As an example, scroll features on the tool die face was introduced to enhance powder mixing, and reduce extrusion load. Varying extrusion ratios were used to obtain better microstructural homogeneity. Use of tool design features together with the optimization of process parameters helped in the fabrication of extrusions that were up to 48” long with a diameter of 0.5” using Al-12.4 TM powder feedstock in a two-step process involving cold compaction followed by extrusion. Extrusions with a diameter of 1.0” could also be fabricated, but limitations on the extent of consolidation were experienced as a result of the torque and ram force capacity of the current ShAPE machine.

36 MATERIALS SCIENCE↗

Pyrotechnic shock measurement and data analysis requirements

A study of laboratory measurement and analysis of pyrotechnic shock prompted by a discrepancy in preliminary Mariner Jupiter/Saturn shock test data is reported. It is shown that before generating shock response plots from any recorded pyrotechnic event, a complete review of each instrumentation and analysis system must be made. In addition, the frequency response capability of the tape recorder used should be as high as possible; the discrepancies in the above data were due to inadequate frequency response in the FM tape recorders. The slew rate of all conditioning amplifiers and input converters must be high enough to prevent signal distortion at maximum input voltage; amplifier ranges should be selected so that the input pulse is approximately 50% of full scale; the Bessel response type should be chosen for digital shock analysis if antialiasing filters are employed; and transducer selection must consider maximum acceleration limit, mounted resonance frequency, flat clean mounting surfaces, base bending sensitivity, and proper torque.

Albers, L.↗

Optimal tooth numbers for compact standard spur gear sets

The design of a standard gear mesh is treated with the objective of minimizing the gear size for a given ratio, pinion torque, and allowable tooth strength. Scoring, pitting fatigue, bending fatigue, and the kinematic limits of contact ratio and interference are considered. A design space is defined in terms of the number of teeth on the pinion and the diametral pitch. This space is then combined with the objective function of minimum center distance to obtain an optimal design region. This region defines the number of pinion teeth for the most compact design. The number is a function of the gear ratio only. A design example illustrating this procedure is also given.

Savage, M.↗

Optimal tooth numbers for compact standard spur gear sets

The design of a standard gear mesh is treated with the objective of minimizing the gear size for a given ratio, pinion torque, and allowable tooth strength. Scoring, pitting fatigue, bending fatigue, and the kinematic limits of contact ratio and interference are considered. A design space is defined in terms of the number of teeth on the pinion and the diametral pitch. This space is then combined with the objective function of minimum center distance to obtain an optimal design region. This region defines the number of pinion teeth for the most compact design. The number is a function of the gear ratio only. A design example illustrating this procedure is also given.

Savage, M.↗