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Bonded and weldable strain gages for aircraft flight loads measurements at high temperatures, discussing installation, calibration and performance tests
Electronic ergometer calibration equipment and errors at high work loads
The design and performance of a 19-GHz one-horn maser radiometer is discussed. The antenna is a lensed, conical horn with 3-deg angular resolution. The radiometer is stabilized by chopping against an internal cold load. A novel chopping scheme allows continual calibration of maser gain fluatuations with only a modest penalty in noise. The method of calibrating this instrument is described. The instrument has been used to map the sky with an equivalent blackbody temperature sensitivity of 1 mK per 3 x 3 deg resolution element.
An instrumented task board, used for measuring forces applied by the Protoflight Manipulator Arm (PFMA) to the task board, was fabricated and delivered to Marshall Space Flight Center. SRS Technologies phased out the existing IBM compatible data acquisition system, used with a instrumented task board, and integrated the force measuring electronic hardware in with the Macintosh II data acquisition system. The purpose of this change was to acquire all data with the same time tag, allowing easier and more accurate data reduction in addition to real-time graphics. A three-dimensional optical position sensing system for determining the location of the PFMA's end effect or in reference to the center of the instrumented task board was also designed and delivered under. An improved task board was fabricated which included an improved instrumented beam design. The modified design of the task board improved the force/torque measurement system by increasing the sensitivity, reliability, load range and ease of maintenance. A calibration panel for the optical position system was also designed and fabricated. The calibration method developed for the position sensors enhanced the performance of the sensors as well as simplified the installation and calibration procedures required. The modifications made under this effort expanded the capabilities of the task board system. The system developed determines the arm's position relative to the task board and measures the signals to the joints resulting from the operator's control signals in addition to the task board forces. The software and hardware required to calculate and record the position of the PFMA during the performance of tasks with the instrumented task board were defined, designed and delivered to MSFC. PFMA joint input signals can be measured from a breakout box to evaluate the sensitivity or response of the arm operation to control commands. The data processing system provides the capability for post processing of time-history graphics and plots of the PFMA positions, the operator's actions, and the PFMA servo reactions in addition to realtime force and position sensor data presentation.
The Wide Field Camera 3 (WFC3) instrument for the Hubble Space Telescope (HST) will replace the current Wide Field and Planetary Camera 2 (WFPC2). By providing higher throughput and sensitivity than WFPC2, and operating from the near-IR to the near-UV, WFC3 will once again bring the performance of HST above that from ground-based observatories. Crucial to the integration of the WFC3 optical bench is a pair of 2-axis cathetometers used to view targets which cannot be seen by other means when the bench is loaded into its enclosure. The setup and calibration of these cathetometers is described, along with results from a comparison of the cathetometer system with other metrology techniques.
The Wide Field Camera 3 (WFC3) instrument for the Hubble Space Telescope (HST) will replace the current Wide Field and Planetary Camera 2 (WFPC2). By providing higher throughput and sensitivity than WFPC2, and operating from the near-IR to the near-UV, WFC3 will once again bring the pefiormance of HST above that from ground-based observatories. Crucial to the integration of the WFC3 optical bench is a pair of 2-axis cathetometers used to view targets which cannot be seen by other means when the bench is loaded into its enclosure. The setup and calibration of these cathetometers is described, along with results from a comparison of the cathetometer system with other metrology techniques. Finally, the use of the cathetometers on the flight optical bench and measurement results are given.
In this study, the capability of finite element model (FEM) analysis to assess aircraft structural response and occupant injury risk during aircraft water ditching conditions was evaluated. A FEM of the Fokker F28 aircraft, previously validated against full-scale crash test data, was simulated in a realistic water impact environment utilizing recorded conditions from the ditching of US Airways Flight 1549 into the Hudson River. The FEM of the F28 aircraft, was developed from a NASTRAN loads model provided by the vehicle manufacturer, calibrated using component fuselage drop-tests, and validated through test-analysis comparisons from a full-scale crash test of the F28 onto soil. Simulation results are presented in several categories: vehicle kinematics, structural accelerations, damage, occupant responses, and injury risk predictions. Results were consistent with the general outcomes of Flight 1549, indicating that the developed vehicle FEM, validated against land impact test data, may provide an effective tool for evaluating water ditching events.
Wind tunnel force balance calibration is preformed utilizing a variety of different methods and does not have a direct traceable standard such as standards used for most calibration practices (weights, and voltmeters). These different calibration methods and practices include, but are not limited to, the loading schedule, the load application hardware, manual and automatic systems, re-leveling and non-re-leveling. A study of the balance calibration techniques used by NASA was undertaken to develop metrics for reviewing and comparing results using sample calibrations. The study also includes balances of different designs, single and multi-piece. The calibration systems include, the manual, and the automatic that are provided by NASA and its vendors. The results to date will be presented along with the techniques for comparing the results. In addition, future planned calibrations and investigations based on the results will be provided.
A shake test of the Large Rotor Test Apparatus (LRTA) was performed in an effort to enhance NASAscapability to measure dynamic hub loads for full-scale rotor tests. This paper documents the results of theshake test as well as efforts to calibrate the LRTA balance system to measure dynamic loads.Dynamic rotor loads are the primary source of vibration in helicopters and other rotorcraft, leading topassenger discomfort and damage due to fatigue of aircraft components. There are novel methods beingdeveloped to reduce rotor vibrations, but measuring the actual vibration reductions on full-scale rotorsremains a challenge. In order to measure rotor forces on the LRTA, a balance system in the non-rotatingframe is used. The forces at the balance can then be translated to the hub reference frame to measure therotor loads. Because the LRTA has its own dynamic response, the balance system must be calibrated toinclude the natural frequencies of the test rig.
Radiant heating experiments were performed in the laboratory on an instrumented multispar wing structure to investigate: (1) how accurately the structural temperatures of a Mach 3 cruise-flight profile could be simulated, (2) what the effects of the heating and heating inaccuracies would be on the responses of strain-gage bridges installed on the structure, and (3) how these responses would affect flight loads measurements. Test temperatures throughout the structure agreed well with temperatures calculated for a Mach 3 profile. In addition, temperatures produced by two identical tests were repeatable to less than + or -6 K deg. Thermally induced strain-gage-bridge responses were large enough to be detrimental to a high-speed flight loads program with a goal of establishing aerodynamic loads (exclusive of thermal loads). It was shown that heating simulation can be used effectively for thermal calibration (that is, to provide corrections for a high-temperature environment), and that thermal calibration may not be needed if the simulation data are used to carefully select bridges and load equations.
The X-57 flight project will provide an opportunity to assess the benefits of distributed electric propulsion. The plan is to use a TECNAM P2006T twin-engine light aircraft (Aeronautiche TECNAM S.p.A., Capua, Italy) as the baseline aircraft, but design and fabricate a new wing to test the technology. The wing when fully integrated onto the X-57 TECNAM P2006T fuselage will incorporate two wingtip cruise electric motors and 12 high-lift electric motors along the wing span. The testing described in this paper confirmed the strength of the X-57 wing for flight and provided an opportunity to calibrate the wing flight strain gages for monitoring loads in flight. The X-57 wing was qualification tested in the National Aeronautics and Space Administration Armstrong Flight Research Center Flight Loads Laboratory. This paper documents the airworthiness approach, test setup, instrumentation, and preliminary results. The X-57 ground load testing lessons learned are also discussed.
Our objective was to elucidate how varying gravitational fields affect blood perfusion in the sole of the foot. Human subjects underwent whole-body tilting at four angles: upright (1 G(sub z), 22 deg (.38 G(sub z)), 10 deg (.17 G(sub z)), and supine (0 G(sub z)), simulating the gravitational fields of Earth, Mars, Moon, and microgravity, respectively. Cutaneous capillary blood flow was monitored on the plantar surface of the heel by laser Doppler flowmetry while weight bearing load was measured beneath the same foot with a calibrated scale. Foot mean arterial pressures (MAP) were calculated by adding estimated hydrostatic pressures to continuously recorded heart-level blood pressures for each subject. At each tilt angle, subjects increased weight bearing on one foot in graded load increments of one kilogram beginning with zero. The weight bearing at which null flow first occurred was determined as the closing load (CL). Subsequently, the weight bearing was reduced in reverse steps until blood flow returned (opening load, OL). CL and OL were normalized to each subject's body weight and expressed as percent of body weight. Mean CLs (SD in parentheses) for simulated Earth, Mars, Moon, and micro-gravities were 14 (5), 8 (2), 6 (2), and 5 (2) percent of body weight, respectively. OLs were 12 (3), 6 (1), 5 (2), and 4 (1), respectively. Calculated foot MAPs for each simulated gravitational field were 192 (19), 127 (12), 106 (10), and 87 (9) mm Hg, respectively. CL and OL were significantly correlated with foot MAP (r = 0.70, 0.72, respectively). Overall, CL and OL were significantly different (p is less than 0.001). The data suggest that decreased local arterial pressure in the foot lowers tolerance to external compression. Consequently, the human foot sole may be more prone to cutaneous ischernia during loading in microgravity than on Earth.
Computed results from UMARC and DART analyses are compared with the blade bending moments and vibratory hub loads data obtained from a full-scale wind tunnel test of the McDonnell Douglas five-bladed advanced bearingless rotor. The 5 per-rev vibratory hub loads data are corrected using results from a dynamic calibration of the rotor balance. The comparison between UMARC computed blade bending moments at different flight conditions are poor to fair, while DART results are fair to good. Using the free wake module, UMARC adequately computes the 5P vibratory hub loads for this rotor, capturing both magnitude and variations with forward speed. DART employs a uniform inflow wake model and does not adequately compute the 5P vibratory hub loads for this rotor.
The Rotor Systems Research Aircraft helicopter technology demonstration test bed incorporates an active isolator system which reduces the rotor vibrations that are transmitted to the airframe and allows the simultaneous measurement of all six forces and moments generated by the rotor. The first full system calibration was performed in 1983 to verify the system's static load measurement capabilities; the analysis of the data encompassed multiple linear regressions to determine calibration matrices for different data sets, and a hysteresis removal algorithm for the estimation of in-flight measurement errors. The results obtained indicate that the active isolator system meets most performance predictions.
A multiple component load cell for measuring load is described, and its capability and reliability are evaluated by utilizing it to measure the reaction forces between the Centaur and Centaur Support Structure. The system employs 11 six-component balances in a single test rig to react a combination of loads. The vehicle and balance loads, procedures for fabricating each balance, and the assembly of the balances are discussed. The calibration and testing of the balances are examined. It is noted that the multiple component load cell system is a cost-effective method for obtaining an accurate measurement of friction effects and primary loads.
An advanced Microwave Precipitation Radiometer (AMPR) has been developed and flown in the NASA ER-2-high-altitude aircraft for imaging various atmospheric and surface processes, primarily the internal structure of rain clouds. The AMPR is a scanning four-frequency total power microwave radiometer that is externally calibrated with high-emissivity warm and cold loads. Separate antenna systems allow the sampling of the 10.7- and 19.35-GHz channels at the same spatial resolution, while the 37.1- and 85.5-GHz channels utilize the same multifrequency feedhorn as the 19.35-GHz channel. Spatial resolutions from an aircraft altitude of 20-km range from 0.6 km at 85.5 GHz to 2.8 km at 19.35 and 10.7 GHz. All channels are sampled every 0.6 km in both along-track and cross-track directions, leading to a contiguous sampling pattern of the 85.5-GHz 3-dB beamwidth footprints, 2.3X oversampling of the 37.1-GHz data, and 4.4X oversampling of the 19.35- and 10.7-GHz data. Radiometer temperature sensitivities range from 0.2 to 0.5 C. Details of the system are described, including two different calibration systems and their effect on the data collected. Examples of oceanic rain systems are presented from Florida and the tropical west Pacific that illustrate the wide variety of cloud water, rainwater, and precipitation-size ice combinations that are observable from aircraft altitudes.
The Langley Research Center (LaRC) Single Vector Balance Calibration System (SVS) was first introduced in 2000 by Peter Parker. The SVS combines the Design of Experiments (DOE) methodology with a novel load application system. Since that time three systems have been designed and developed with different load range capabilities (ranging from 2 pounds to 3,000 pounds). Approximately fifteen balances have been calibrated and their data compared to conventional techniques. This paper will present results of these comparisons, based on the mathematical models and accuracies, and discuss differences that were observed. In addition, changes in the implementation of the initial load schedules developed using DOE will be highlighted. One of the principles behind DOE is randomization. The initial loading schedules used to date have been randomized in the traditional DOE sense but not for repeat calibrations or experiments. Implementation of this randomization within blocks and its impact on data quality will be reviewed. Areas of potential future development will be presented which include changes in the centers to include loads with the force position system in the pure error estimates.
A new concept for the NASA Jet Propulsion Laboratory (JPL) All-Terrain Hex-Limbed Extra-Terrestrial Explorer (ATHLETE) robotic constructor / mobility system employs tendon-driven actuation of individual limbs, similar to high-capacity cranes in terrestrial work environments, that can offload cargo from tall landers. While maintaining mechanical joints that allow each limb to function as a highly dexterous multi-Degree-Of-Freedom (DOF) robotic arm, tendon-driven truss sections increase the capacity of moment loads for extended configurations of the limb. The tendon-driven crane-like limb will be capable of offloading cargo from tall landers such as the SpaceX Starship. This paper describes the structural analysis, operations, calibration, and actuation of limbs designed to address specific target load cases that might be required for human exploration missions on planetary surfaces.