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At least 199 records · Page 11

A Survey of Current Rotorcraft Propulsion Health Monitoring Technologies

A brief review is presented on the state-of-the-art in rotorcraft engine health monitoring technologies including summaries on current practices in the area of sensors, data acquisition, monitoring and analysis. Also, presented are guidelines for verification and validation of Health Usage Monitoring System (HUMS) and specifically for maintenance credits to extend part life. Finally, a number of new efforts in HUMS are summarized as well as lessons learned and future challenges. In particular, gaps are identified to supporting maintenance credits to extend rotorcraft engine part life. A number of data sources were consulted and include results from a survey from the HUMS community, Society of Automotive Engineers (SAE) documents, American Helicopter Society (AHS) papers, as well as references from Defence Science & Technology Organization (DSTO), Civil Aviation Authority (CAA), and Federal Aviation Administration (FAA).

Delgado, Irebert R.↗

Advanced orbit transfer vehicle propulsion system study

A reuseable orbit transfer vehicle concept was defined and subsequent recommendations for the design criteria of an advanced LO2/LH2 engine were presented. The major characteristics of the vehicle preliminary design include a low lift to drag aerocapture capability, main propulsion system failure criteria of fail operational/fail safe, and either two main engines with an attitude control system for backup or three main engines to meet the failure criteria. A maintenance and servicing approach was also established for the advanced vehicle and engine concepts. Design tradeoff study conclusions were based on the consideration of reliability, performance, life cycle costs, and mission flexibility.

Cathcart, J. A.↗

Space civil engineering - A new discipline

Space Civil Engineering is an emerging engineering discipline that focuses on extending and expanding the Civil Engineering know-how and practice to the development and maintenance of infrastructure on celestial bodies. Space Civil Engineering is presently being developed as a new discipline within the Department of Civil Engineering at Colorado State University under a recently established NASA Space Grant College Program. Academic programs geared toward creating Space Civil Engineering Options at both undergraduate and graduate levels are being formulated. Basic ideas and concepts of the curriculum in the Space Civil Engineering Option at both undergraduate and graduate levels are presented. The role of Space Civil Engineering in the Space Program is discussed.

Sadeh, Willy Z.↗

In-Flight Operation of the Dawn Ion Propulsion System: Status at One Year from the Vesta Rendezvous

The Dawn mission, part of NASA's Discovery Program, has as its goal the scientific exploration of the two most massive main-belt asteroids, Vesta and Ceres. The Dawn spacecraft was launched from Cape Canaveral Air Force Station on September 27, 2007 on a Delta-II 7925H-9.5 (Delta-II Heavy) rocket that placed the 1218 kg spacecraft into an Earth-escape trajectory. On-board the spacecraft is an ion propulsion system (IPS) developed at the Jet Propulsion Laboratory which will provide most of the delta V needed for heliocentric transfer to Vesta, orbit capture at Vesta, transfer among Vesta science orbits, departure and escape from Vesta, heliocentric transfer to Ceres, orbit capture at Ceres, and transfer among Ceres science orbits. The Dawn ion thruster [I thought we only called it a thruster. Both terms are used in the paper, but I think a replacement of every occurrence of "engine" with "thruster" would be clearer.] design is based on the design validated on NASA's Deep Space 1 (DS1) mission. However, because of the very substantial (11 km/s) delta V requirements for this mission Dawn requires two engines to complete its mission objectives. The power processor units (PPU), digital control and interface units (DCIU) slice boards and the xenon control assembly (XCA) are derivatives of the components used on DS1. The DCIUs and thrust gimbal assemblies (TGA) were developed at the Jet Propulsion Laboratory. The spacecraft was provided by Orbital Sciences Corporation, Sterling, Virginia, and the mission is managed by and operated from the Jet Propulsion Laboratory. Dawn partnered with Germany, Italy and Los Alamos National Laboratory for the science instruments. The mission is led by the principal investigator, Dr. Christopher Russell, from the University of California, Los Angeles. The first 80 days after launch were dedicated to the initial checkout of the spacecraft followed by cruise to Mars. Cruise thrusting leading to a Mars gravity assist began on December 17, 2007 and was successfully concluded as planned on October 31, 2008. During this time period the Dawn IPS was operated mostly at full power for approximately 6500 hours, consumed 71.7 kg of xenon and delivered approximately 1.8 km/s of delta V to the spacecraft. The thrusting to Mars was followed by a coasting period of approximately 3.5 months that included a Mars flyby in February of 2009. The Mars flyby provided a gravity assist (MGA) for a plane change and approximately 1 km/s of heliocentric energy increase and is the only part of the mission following launch in which a needed velocity change is not accomplished by the IPS. During the coast period IPS was operated for a trajectory correction maneuver and for engineering tests but was not operated for primary propulsion. Closest approach to Mars occurred as planned on February 17, 2009 and was followed by another coasting period of just under 4 months in duration. During this last coasting phase IPS was operated only for routine maintenance activities and for system engineering tests. Deterministic thrusting for heliocentric transfer to Vesta resumed on June 8, 2009. Since resumption of cruise to Vesta IPS has been operated at throttled power levels, most of the time at full power, and with a duty cycle of approximately 93%, leading to an arrival at Vesta in July of 2011 and arrival at Ceres in February 2015. This paper provides an overview of Dawn's mission objectives and the results of Dawn IPS mission operations through one year from the spacecraft's rendezvous with Vesta.

Garner, Charles E.↗

In-Flight Operation of the Dawn Ion Propulsion System Through Start of the Vesta Cruise Phase

The Dawn mission, part of NASA's Discovery Program, has as its goal the scientific exploration of the two most massive main-belt asteroids, Vesta and Ceres. The Dawn spacecraft was launched from Cape Canaveral Air Force Station on September 27, 2007 on a Delta-II 7925H-9.5 (Delta-II Heavy) rocket that placed the 1218 kg spacecraft into an Earth-escape trajectory. On-board the spacecraft is an ion propulsion system (IPS) which will provide most of the delta V needed for heliocentric transfer to Vesta, orbit capture at Vesta, transfer to Vesta science orbits, departure and escape from Vesta, heliocentric transfer to Ceres, orbit capture at Ceres, and transfer to Ceres science orbits. The Dawn ion design is based on the design validated on NASA's Deep Space 1 (DS1) mission. However, because of the very substantial (11 km/s) delta V requirements for this mission Dawn requires two engines to complete its mission objectives. The power processor units (PPU), digital control and interface units (DCIU) slice boards and the xenon control assembly (XCA) are derivatives of the components used on DS1. The DCIUs and thrust gimbal assemblies (TGA) were developed at the Jet Propulsion Laboratory. The spacecraft was provided by Orbital Sciences Corporation, Sterling, Virginia, and the mission is managed by and operated from the Jet Propulsion Laboratory. Dawn partnered with Germany, Italy and Los Alamos National Laboratory for the science instruments. The mission is led by the principal investigator, Dr. Christopher Russell, from the University of California, Los Angeles. The first 80 days after launch were dedicated to the initial checkout of the spacecraft followed by cruise to Mars. Cruise thrusting leading to a Mars gravity assist began on December 17, 2007 and was successfully concluded as planned on October 31, 2008. During this time period the Dawn IPS was operated mostly at full power for approximately 6500 hours, consumed 71.7 kg of xenon and delivered approximately 1.8 km/s of delta V to the spacecraft. The thrusting to Mars was followed by a coasting period of approximately 3.5 months that included a Mars flyby in February of 2009. The Mars flyby provided a gravity assist (MGA) for a plane change and approximately 1 km/s of heliocentric energy increase and is the only part of the mission following launch in which a needed velocity change is not accomplished by the IPS. During the coast period IPS was operated for a trajectory correction maneuver and for engineering tests but was not operated for primary propulsion. Closest approach to Mars occurred as planned on February 17, 2009 and was followed by another coasting period of just under 4 months in duration. During this last coasting phase IPS was operated only for routine maintenance activities and for system engineering tests. Deterministic thrusting for heliocentric transfer to Vesta resumed on June 8, 2009. IPS will be operated for over two years at throttled power levels leading to arrival at Vesta in September of 2011 and arrival at Ceres in February 2015. This paper provides an overview of Dawn's mission objectives and the results of Dawn IPS mission operations through the start of deterministic thrusting to Vesta.

Garner, Charles E.↗

Maintainability of the Space Shuttle Orbiter main engine.

Review of the long-life and minimum-turnaround-maintenance features in the design of the Space Shuttle Orbiter main engine aimed at reducing the latter's field operating costs. These features include the regeneratively cooled hot-gas system selected, the provision of additional fatigue margins in the design of rotating machinery elements, and employment of a proven approach to engine condition monitoring for fault detection and identification.

Goe, R. T.↗

Turbine Engine Clearance Control Systems: Current Practices and Future Directions

Improved blade tip sealing in the high pressure compressor (HPC) and high pressure turbine (HPT) can provide dramatic reductions in specific fuel consumption (SFC), time-on-wing, compressor stall margin, and engine efficiency as well as increased payload and mission range capabilities. Maintenance costs to overhaul large commercial gas turbine engines can easily exceed $1M. Engine removal from service is primarily due to spent exhaust gas temperature (EGT) margin caused mainly by the deterioration of HPT components. Increased blade tip clearance is a major factor in hot section component degradation. As engine designs continue to push the performance envelope with fewer parts and the market drives manufacturers to increase service life, the need for advanced sealing continues to grow. A review of aero gas turbine engine HPT performance degradation and the mechanisms that promote these losses are discussed. Benefits to the HPT due to improved clearance management are identified. Past and present sealing technologies are presented along with specifications for next generation engine clearance control systems.

Lattime, Scott B.↗

An accumulation method for early fault warning and its application to wind turbine systems

Unexpected failures in engineering systems lead to expensive maintenance actions and should be avoided if at all possible. This is particularly true for wind turbine systems for which unexpected failures not only demand costly repairs but also cause long downtime. Motivated by this need, we present an accumulation method for fault early warning and failure anticipation. Here, our research shows that one critical element allowing the ability of early warning is to accumulate the small-magnitude symptoms resulting from gradual changes in an engineering system like wind turbines. Our idea is inspired by the classical cumulative sum method, or CUSUM, but we have to redesign the accumulation mechanism for tackling unique challenges in wind turbine data. The new accumulation method is applied to two real wind turbine datasets, one with gearbox failures and the other with generator failures, and demonstrates superior performance as compared with CUSUM.

17 WIND ENERGY↗

Piezoelectric Vibration Damping Study for Rotating Composite Fan Blades

Resonant vibrations of aircraft engine blades cause blade fatigue problems in engines, which can lead to thicker and aerodynamically lower performing blade designs, increasing engine weight, fuel burn, and maintenance costs. In order to mitigate undesirable blade vibration levels, active piezoelectric vibration control has been investigated, potentially enabling thinner blade designs for higher performing blades and minimizing blade fatigue problems. While the piezoelectric damping idea has been investigated by other researchers over the years, very little study has been done including rotational effects. The present study attempts to fill this void. The particular objectives of this study were: (a) to develop and analyze a multiphysics piezoelectric finite element composite blade model for harmonic forced vibration response analysis coupled with a tuned RLC circuit for rotating engine blade conditions, (b) to validate a numerical model with experimental test data, and (c) to achieve a cost-effective numerical modeling capability which enables simulation of rotating blades within the NASA Glenn Research Center (GRC) Dynamic Spin Rig Facility. A numerical and experimental study for rotating piezoelectric composite subscale fan blades was performed. It was also proved that the proposed numerical method is feasible and effective when applied to the rotating blade base excitation model. The experimental test and multiphysics finite element modeling technique described in this paper show that piezoelectric vibration damping can significantly reduce vibrations of aircraft engine composite fan blades.

Min, James B.↗

Demonstration, Testing and Qualification of a High Temperature, High Speed Magnetic Thrust Bearing

The gas turbine industry has a continued interest in improving engine performance and reducing net operating and maintenance costs. These goals are being realized because of advancements in aeroelasticity, materials, and computational tools such as CFD and engine simulations. These advancements aid in increasing engine thrust-to-weight ratios, specific fuel consumption, pressure ratios, and overall reliability through higher speed, higher temperature, and more efficient engine operation. Currently, rolling element bearing and squeeze film dampers are used to support rotors in gas turbine engines. Present ball bearing configurations are limited in speed (<2 million DN) and temperature (<5OO F) and require both cooling air and an elaborate lubrication system. Also, ball bearings require extensive preventative maintenance in order to assure their safe operation. Since these bearings are at their operational limits, new technologies must be found in order to take advantage of other advances. Magnetic bearings are well suited to operate at extreme temperatures and higher rotational speeds and are a promising solution to the problems that conventional rolling element bearings present. Magnetic bearing technology is being developed worldwide and is considered an enabling technology for new engine designs. Using magnetic bearings, turbine and compressor spools can be radically redesigned to be significantly larger and stiffer with better damping and higher rotational speeds. These advances, a direct result of magnetic bearing technology, will allow significant increases in engine power and efficiency. Also, magnetic bearings allow for real-time, in-situ health monitoring of the system, lower maintenance costs and down time.

DeWitt, Kenneth↗

From Data to Knowledge: A Graph-Based Reliability Approach to Assess System Health

With the goal of maximizing plant reliability and availability, complex systems such as nuclear power plants continuously monitor and record the performance and the health status of many components, assets, and systems. Such data may take the form of online monitoring data, condition reports, and maintenance reports and it carries the potential to provide system engineers with insights into anomalous behaviors or degradation trends as well as the possible causes behind them and to predict their direct consequences. The analysis of such data poses however few challenges. While some of these challenges are technical in nature (i.e., data are often distributed over several physical servers or databases), others are conceptual in nature (i.e., data elements come in different formats, numeric or textual), and measured values have different scales (e.g., vibration spectra and oil temperature). This paper directly tackles these challenges, and it focuses on the integration of all these data elements in order to assist plant system engineers in analyzing component, assets, and systems performances and optimize maintenance activities. This is performed by 1) extracting knowledge from textual data via technical language processing methods, and 2) quantifying system, asset, and component health from numeric condition-based data. We rely on model-based system engineering (MBSE) models of systems and assets to identify their architecture and functional (i.e., cause and effect) relations. Numeric and textual data elements are then associated with an MBSE graph element, based on their nature. This bonding of MBSE models and data elements constitutes a first-of-its-kind knowledge graph of a nuclear power plants system, with data elements being organized in a structured manner that enables system engineers to identify cause-effect trends in data elements and carry out appropriate actions in response.

97 MATHEMATICS AND COMPUTING↗

Erosion Coatings Developed to Increase the Life and Durability of Composites

Both the NASA Glenn Research Center and the Allison Advanced Development Company (AADC) have worked to develop and demonstrate erosion-resistant coatings that would increase the life and durability of composite materials used in commercial aircraft engines. These composite materials reduce component weight by 20 to 30 percent and result in less fuel burn and emissions and more fuel savings. Previously, however, their use was limited because of poor erosion resistance, which causes concerns about safety and leads to high maintenance costs. The coatings were tested by the University of Cincinnati, and the composites were manufactured by Texas Composites and coated by Engelhard and NASA Glenn. Rolls-Royce Corporation uses composite materials, which are stronger and less dense than steel or titanium, to make bypass vanes for their AE3007 engines. These engines are widely used in regional jet aircraft (Embraer) and unmanned air vehicles such as the Northrop Grumman Global Hawk. Coatings developed by NASA/Rolls-Royce can reduce erosion from abrasive materials and from impurities in the air that pass over these vanes, allowing Rolls-Royce to take advantage of the benefits of composite materials over titanium without the added costs of increased maintenance and/or engine failure. The Higher Operating Temperature Propulsion Components (HOTPC) Project developed cost-effective, durable coatings as part of NASA's goal to increase aviation system capacity growth. These erosion coatings will reduce the number of special inspections or instances of discontinued service due to erosion, allowing aircraft capacity to be maintained without inconveniencing the traveling public. A specific example of extending component life showed that these coatings increased the life of graphite fiber and polymer composite bypass vanes up to 8 times over that of the uncoated vanes. This increased durability allows components to operate to full design life without the fear of wear or failure. Recently, Rolls-Royce completed over 2000 hr of engine testing with the coated fan exit bypass vanes. There was no loss of coating after nearly 5000 typical engine cycles. Midway through the engine tests, the coated vanes were removed from the engine during a scheduled maintenance and inspection period. The vanes were shipped back to Glenn, where they underwent further stress testing in the Structural Dynamics Lab, mimicking more extreme conditions than those typical of the AE3007 engine cycle. These vanes were then replaced in the AE3007 and subjected to another 1000 hr of engine tests. Once again, there was no loss of coating and only a minimal appearance of cracking.

Sutter, James K.↗

Firmware Tampering Detection in Heavy-Duty Vehicles through J1939 CAN Analysis

Modern heavy-duty vehicles rely on complex networks of Electronic Control Units (ECUs) that communicate using the J1939 protocol. While this system makes it easier to update and configure vehicle components, it also opens the door to serious cybersecurity risks if not properly secured. This work investigates the potential for firmware tampering through the J1939 communication protocol, which enables ECU configuration and reprogramming over the Controller Area Network (CAN) bus. By monitoring CAN traffic during legitimate maintenance operations and reverse-engineering OEM diagnostic software, we identified common and proprietary J1939 message identifiers, authentication patterns, and vulnerabilities within Unified Diagnostic Services (UDS). These findings demonstrate that inadequate authentication mechanisms can allow malicious actors to alter ECU firmware or disable safety functions, posing severe operational and safety risks. Our analysis contributes to the development of vehicle intrusion detection systems capable of recognizing abnormal reprogramming activity and future firmware fingerprinting methods to verify software integrity across ECUs. This work highlights the importance of standardizing secure firmware authentication across manufacturers to strengthen cyber resilience in heavy-duty vehicle systems.

33 ADVANCED PROPULSION SYSTEMS↗

Research requirements for development of improved helicopter rotor efficiency

The research requirements for developing an improved-efficiency rotor for a civil helicopter are documented. The various design parameters affecting the hover and cruise efficiency of a rotor are surveyed, and the parameters capable of producing the greatest potential improvement are identified. Research and development programs to achieve these improvements are defined, and estimated costs and schedules are presented. Interaction of the improved efficiency rotor with other technological goals for an advanced civil helicopter is noted, including its impact on engine noise, hover and cruise performance, one-engine-inoperative hover capability, and maintenance and reliability.

Davis, S. J.↗

Impact of future fuel properties on aircraft engines and fuel systems

The effect of modifications in hydrocarbon jet fuels specifications on engine performance, component durability and maintenance, and aircraft fuel system performance is discussed. Specific topics covered include: specific fuel consumption; ignition at relight limits; exhaust emissions; combustor liner temperatures; carbon deposition; gum formation in fuel nozzles, erosion and corrosion of turbine blades and vanes; deposits in fuel system heat exchangers; and pumpability and flowability of the fuel. Data that evaluate the ability of current technology aircraft to accept fuel specification changes are presented, and selected technological advances that can reduce the severity of the problems are described and discussed.

Rudey, R. A.↗

Effect of broadened-specification fuels on aircraft engines and fuel systems

A wide variety of studies on the potential effects of broadened-specification fuels on future aircraft engines and fuel systems are summarized. The compositions and characteristics of aircraft fuels that may be derived from current and future crude-oil sources are described, and the most critical properties that may effect aircraft engines and fuel systems are identified and discussed. The problems that are most likely to be encountered because of changes in selected fuel properties are explored; and the related effects on engine performance, component durability and maintenance, and aircraft fuel-system performance are examined. The ability of current technology to accept possible future fuel specification changes is assessed and selected technological advances that can reduce the severity of the potential problems are illustrated.

Rudey, R. A.↗

Effect of broadened-specification fuels on aircraft engines and fuel systems

A wide variety of studies on the potential effects of broadened-specification fuels on future aircraft engines and fuel systems are summarized. The compositions and characteristics of aircraft fuels that may be derived from current and future crude-oil sources are described, and the most critical properties that may affect aircraft engines and fuel systems are identified and discussed. The problems that are most likely to be encountered because of changes in selected fuel properties are described; and the related effects on engine performance, component durability and maintenance, and aircraft fuel-system performance are discussed. The ability of current technology to accept possible future fuel-specification changes is discussed, and selected technological advances that can reduce the severity of the potential problems are illustrated.

Rudey, R. A.↗

Research and technology, 1984 report

Research and technology projects in the following areas are described: cryogenic engineering, hypergolic engineering, hazardous warning instrumentation, structures and mechanics, sensors and controls, computer sciences, communications, material analysis, biomedicine, meteorology, engineering management, logistics, training and maintenance aids, and technology applications.

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