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NASA NTRS2016

Wind Tunnel Balance Calibration: Are 1,000,000 Data Points Enough?

Measurement systems are typically calibrated based on standard practices established by a metrology standards laboratory, for example the National Institute for Standards and Technology (NIST), or dictated by an organization's metrology manual. Therefore, the calibration is designed and executed according to an established procedure. However, for many aerodynamic research measurement systems a universally accepted standard, traceable approach does not exist. Therefore, a strategy for how to develop a calibration protocol is left to the developer or user to define based on experience and recommended practice in their respective industry. Wind tunnel balances are one such measurement system. Many different calibration systems, load schedules and procedures have been developed for balances with little consensus on a recommended approach. Especially lacking is guidance the number of calibration data points needed. Regrettably, the number of data points tends to be correlated with the perceived quality of the calibration. Often, the number of data points is associated with ones ability to generate the data rather than by a defined need in support of measurement objectives. Hence the title of the paper was conceived to challenge recent observations in the wind tunnel balance community that shows an ever increasing desire for more data points per calibration absent of guidance to determine when there are enough. This paper presents fundamental concepts and theory to aid in the development of calibration procedures for wind tunnel balances and provides a framework that is generally applicable to the characterization and calibration of other measurement systems. Questions that need to be answered are for example: What constitutes an adequate calibration? How much data are needed in the calibration? How good is the calibration? This paper will assist a practitioner in answering these questions by presenting an underlying theory on how to evaluate a calibration based on objective measures. This will enable the developer and user to design calibrations with quantified performance in terms of their capability to meet the user's objectives and a basis for comparing existing calibrations that may have been developed in an ad-hoc manner.

Rhew, Ray D.↗
NASA NTRS2016

Rotary Balance Wind Tunnel Testing for the FASER Flight Research Aircraft

Flight dynamics research was conducted to collect and analyze rotary balance wind tunnel test data in order to improve the aerodynamic simulation and modeling of a low-cost small unmanned aircraft called FASER (Free-flying Aircraft for Sub-scale Experimental Research). The impetus for using FASER was to provide risk and cost reduction for flight testing of more expensive aircraft and assist in the improvement of wind tunnel and flight test techniques, and control laws. The FASER research aircraft has the benefit of allowing wind tunnel and flight tests to be conducted on the same model, improving correlation between wind tunnel, flight, and simulation data. Prior wind tunnel tests include a static force and moment test, including power effects, and a roll and yaw damping forced oscillation test. Rotary balance testing allows for the calculation of aircraft rotary derivatives and the prediction of steady-state spins. The rotary balance wind tunnel test was conducted in the NASA Langley Research Center (LaRC) 20-Foot Vertical Spin Tunnel (VST). Rotary balance testing includes runs for a set of given angular rotation rates at a range of angles of attack and sideslip angles in order to fully characterize the aircraft rotary dynamics. Tests were performed at angles of attack from 0 to 50 degrees, sideslip angles of -5 to 10 degrees, and non-dimensional spin rates from -0.5 to 0.5. The effects of pro-spin elevator and rudder deflection and pro- and anti-spin elevator, rudder, and aileron deflection were examined. The data are presented to illustrate the functional dependence of the forces and moments on angle of attack, sideslip angle, and angular rate for the rotary contributions to the forces and moments. Further investigation is necessary to fully characterize the control effectors. The data were also used with a steady state spin prediction tool that did not predict an equilibrium spin mode.

Denham, Casey↗
NASA NTRS2016

Photogrammetric Deflection Measurements for the Tiltrotor Test Rig (TTR) Multi-Component Rotor Balance Calibration

Calibrating the internal, multi-component balance mounted in the Tiltrotor Test Rig (TTR) required photogrammetric measurements to determine the location and orientation of forces applied to the balance. The TTR, with the balance and calibration hardware attached, was mounted in a custom calibration stand. Calibration loads were applied using eleven hydraulic actuators, operating in tension only, that were attached to the forward frame of the calibration stand and the TTR calibration hardware via linkages with in-line load cells. Before the linkages were installed, photogrammetry was used to determine the location of the linkage attachment points on the forward frame and on the TTR calibration hardware. Photogrammetric measurements were used to determine the displacement of the linkage attachment points on the TTR due to deflection of the hardware under applied loads. These measurements represent the first photogrammetric deflection measurements to be made to support 6-component rotor balance calibration. This paper describes the design of the TTR and the calibration hardware, and presents the development, set-up and use of the photogrammetry system, along with some selected measurement results.

Calibration↗
NASA NTRS2018

The Evaluation of Cryogenic Force Balance Calibration Methodologies with Respect to Wind Tunnel Results

Independent tests of the NASA Common Research Model (CRM) at NASA's National Transonic Facility (NTF) and the European Transonic Windtunnel (ETW) revealed discrepancies at low operating temperatures and high Reynolds numbers that warranted further investigation. Since each facility used their own force balance for their tunnel entry, one suggestion for the discrepancy was the temperature compensation methodology developed and applied for each balance. This hypothesis is explored through simulation and experimentally. Independent calibrations of NASA's NTF-118A balance at NASA Langley and ETW reveal discrepancies in the thermal compensation of the normal force and pitching moment primary sensitivities with temperature, while the axial force primary sensitivities are in good agreement. The application of the force balance calibrations performed at NASA and ETW to the prior wind tunnel data suggests that the thermal compensation discrepancies are an order of magnitude less than the discrepancies observed between the wind tunnel aerodynamic coefficients.

Burns, Devin E.↗
NASA NTRS2020

Wind Tunnel Balance Design: A NASA Langley Perspective

This document chronicles and captures force balance design principles accumulated over the last 50 years at NASA Langley Research Center (LaRC). Many design and guidance internal memorandums have been drafted over the years, some as informal as a design engineer€™s notes for a particular balance design. To date, there has been no comprehensive balance design or best practices documentation available on LaRC's extensive design expertise. Therefore, the primary goal of this knowledge capture document is to assemble and organize the presentation of this historical corpus of knowledge for future balance engineers.

Devin E Burns↗
NASA NTRS2011

A Universal Tare Load Prediction Algorithm for Strain-Gage Balance Calibration Data Analysis

An algorithm is discussed that may be used to estimate tare loads of wind tunnel strain-gage balance calibration data. The algorithm was originally developed by R. Galway of IAR/NRC Canada and has been described in the literature for the iterative analysis technique. Basic ideas of Galway's algorithm, however, are universally applicable and work for both the iterative and the non-iterative analysis technique. A recent modification of Galway's algorithm is presented that improves the convergence behavior of the tare load prediction process if it is used in combination with the non-iterative analysis technique. The modified algorithm allows an analyst to use an alternate method for the calculation of intermediate non-linear tare load estimates whenever Galway's original approach does not lead to a convergence of the tare load iterations. It is also shown in detail how Galway's algorithm may be applied to the non-iterative analysis technique. Hand load data from the calibration of a six-component force balance is used to illustrate the application of the original and modified tare load prediction method. During the analysis of the data both the iterative and the non-iterative analysis technique were applied. Overall, predicted tare loads for combinations of the two tare load prediction methods and the two balance data analysis techniques showed excellent agreement as long as the tare load iterations converged. The modified algorithm, however, appears to have an advantage over the original algorithm when absolute voltage measurements of gage outputs are processed using the non-iterative analysis technique. In these situations only the modified algorithm converged because it uses an exact solution of the intermediate non-linear tare load estimate for the tare load iteration.

balance calibration analysis↗
NASA NTRS1942

Aerodynamic Characteristics for Internal-Balance and Frise Type Ailerons on an NACA 6 Series Low-Drag Tip Section of the Wing for the XP-63 Airplane

At the request of the Army Air Forces, Materiel Command, tests were made in the two-Dimensional low-turbulence tunnel of a mode l submitted by Bell Aircraft Corporation as the tip section of the wing of the xp-63 airplane. " The model was a NACA 66, 2x-2l6 a = 0.6 airfoil section of 50-inch chord and made of dural according to standard sheet-metal practice. The model was fitted for an internal-balance aileron with a tab and a Frise type aileron. Several alterations of the skirts and balance on the internal- balance aileron were tested to obtain the various aerodynamic characteristics of the aileron.

AILERONS - DEFLECTION↗
NASA NTRS2014

A Range Correction for Icesat and Its Potential Impact on Ice-sheet Mass Balance Studies

We report on a previously undocumented range error in NASA's Ice, Cloud and land Elevation Satellite (ICESat) that degrades elevation precision and introduces a small but significant elevation trend over the ICESat mission period. This range error (the Gaussian-Centroid or 'G-C'offset) varies on a shot-to-shot basis and exhibits increasing scatter when laser transmit energies fall below 20 mJ. Although the G-C offset is uncorrelated over periods less than1 day, it evolves over the life of each of ICESat's three lasers in a series of ramps and jumps that give rise to spurious elevation trends of −0.92 to −1.90 cm yr(exp −1), depending on the time period considered. Using ICESat data over the Ross and Filchner-Ronne ice shelves we show that (1) the G-C offset introduces significant biases in ice-shelf mass balance estimates, and (2) the mass balance bias can vary between regions because of different temporal samplings of ICESat.We can reproduce the effect of the G-C offset over these two ice shelves by fitting trends to sample-weighted mean G-C offsets for each campaign, suggesting that it may not be necessary to fully repeat earlier ICESat studies to determine the impact of the G-C offset on ice-sheet mass balance estimates.

mass balance↗
NASA NTRS2015

Towards an Understanding of Atmospheric Balance

During a 35 year period I published 30+ pear-reviewed papers and technical reports concerning, in part or whole, the topic of atmospheric balance. Most used normal modes, either implicitly or explicitly, as the appropriate diagnostic tool. This included examination of nonlinear balance in several different global and regional models using a variety of novel metrics as well as development of nonlinear normal mode initialization schemes for particular global and regional models. Recent studies also included the use of adjoint models and OSSEs to answer some questions regarding balance. lwill summarize what I learned through those many works, but also present what l see as remaining issues to be considered or investigated.

Balance↗
NASA NTRSDate not supplied

Additively Manufactured Wind Tunnel Balances for Propulsive Force Measurement

Propulsive forces and moments during powered descent are not understood well enough to design an entry, decent, and landing vehicle with high confidence using solely computational fluid dynamics modelling (CFD). Therefore, wind tunnel testing is required to quantify uncertainties in computational modeling and simulation. Wind tunnel balances are structural, high-precision, multi-axis force transducers that provide direct measurement of these aerodynamic forces and moments, however their complex designs make them costly and time consuming to produce and approaches used to manufacture them have not changed significantly since the 1960s. This work demonstrates that additive manufacturing (AM) can be used to manufacture wind tunnel balances with significantly reduced fabrication time and expense. Moreover, the design flexibility afforded by the additive manufacturing process has the potential to enable new capabilities with respect to measuring propulsion forces during entry, decent, and landing testing. Here we present two novel balance designs enabled by AM. One will provide direct measurement of aerodynamic interference forces and moments on powered descent models (retropropulsion forces) to support CFD validation and further development of Mars human landing vehicle concepts. The second design will be used to characterize a reaction control system during entry descent and landing testing over a wide Mach number range.

Wind tunnel balance↗
NASA NTRSDate not supplied

Additively Manufactured Balances for Propulsive Force Measurement

Propulsive forces and moments during powered descent are not understood well enough to design an entry, decent, and landing vehicle with high confidence using solely computational fluid dynamics modelling (CFD). Therefore, wind tunnel testing is required to quantify uncertainties in computational modeling and simulation. Wind tunnel balances are structural, high-precision, multi-axis force transducers that provide direct measurement of these aerodynamic forces and moments, however their complex designs make them costly and time consuming to produce and approaches used to manufacture them have not changed significantly since the 1960s. This work demonstrates that additive manufacturing (AM) can be used to manufacture wind tunnel balances with significantly reduced fabrication time and expense. Moreover, the design flexibility afforded by the additive manufacturing process has the potential to enable new capabilities with respect to measuring propulsion forces during entry, decent, and landing testing. Here we present two novel balance designs enabled by AM. One will provide direct measurement of aerodynamic interference forces and moments on powered descent models (retropropulsion forces) to support CFD validation and further development of Mars human landing vehicle concepts. The second design will be used to characterize a reaction control system during entry decent and landing testing over a wide Mach number range.

Wind tunnel balance↗
NASA NTRSDate not supplied

Graphical and Numerical Description of Strain-Gage Balance Interactions

A new approach for the graphical and numerical description of balance interactions is presented. The approach uses data from single-component loads as input. This choice has the two advantages. First, the number of applied loads is at the minimum needed for interactions to be observed. In addition, the loads used for the description of interactions can easily be repeated at different sites. Output differences relative to the outputs of the zero load point of a load series are used for the description of interactions. Similarly, load differences relative to the loads of the zero load point of a load series are used for the description of the loads. Interactions are plotted versus the load differences for each load component while omitting the outputs of the primary gage of the chosen load component. The resulting plots have a characteristic star pattern as interactions are zero at zero load. Numerical estimates of the slopes of the interactions can be reverse-engineered from the load prediction equations of a balance if calibration data is examined. The slopes are the off-diagonal coefficients of the inverse of the matrix that has the coefficients of the linear terms of the fitted loads if the Non-Iterative Method is used for the analysis. Similarly, the slopes are the off-diagonal coefficients of the inverse of the matrix that is the non-iterative part of the primary load iteration equation if the Iterative Method is used for the analysis. Data from the calibration of a force balance is processed to illustrate the proposed graphical and numerical description of interactions.

wind tunnel test↗
NASA NTRSDate not supplied

Graphical and Numerical Description of Strain-Gage Balance Interactions

A new approach for the graphical and numerical description of strain-gage balance interactions is presented. The approach uses data from single-component loads as input. This choice has the two advantages. First, the number of applied loads is at the minimum needed for interactions to be observed. In addition, the loads used for the description of interactions can easily be repeated at different sites. Output differences relative to the outputs of the zero load point of a load series are used for the description of interactions. Similarly, load differences relative to the loads of the zero load point of a load series are used for the description of the loads. Interactions are plotted versus the load differences for each load component while omitting outputs of the primary gage of the chosen load component. The resulting plots have a star pattern as all interactions are zero at zero load. Estimates of the slopes of the interactions can be obtained from the load prediction equations of a balance if calibration data is examined. The slopes are the off-diagonal coefficients of the inverse of the matrix that has the coefficients of the linear terms of the fitted loads if the Non-Iterative Method is used for the analysis. Similarly, the slopes are the off-diagonal coefficients of the inverse of the matrix that is the non-iterative part of the primary load iteration equation if the Iterative Method is used for the analysis. Data sets from a manual and a machine calibration of a force balance are processed to illustrate the proposed description of interactions.

strain-gage balance↗
NASA NTRS1972

Recent developments in a wind tunnel magnetic balance.

A functional description of a prototype six component magnetic balance system for wind tunnel application is presented. The relationship of forces and moments on a ferromagnetic body to applied magnetic fields and gradients is shown. The method of producing the required fields in the prototype balance, its magnet arrangement and its performance are discussed. Aerodynamic data obtained with this balance on several model geometries are presented and compared with wind tunnel and ballistic range results.

Stephens, T.↗
NASA NTRS1972

On the balance of stresses in the plasma sheet.

The stress resulting from magnetic tension on the neutral sheet must, in a steady state, be balanced by any one or a combination of (1) a pressure gradient in the direction along the axis of the tail, (2) a similar gradient of plasma flow kinetic energy, and (3) the tension resulting from a pressure anisotropy within the plasma sheet. Stress balance in the first two cases requires that the ratios h/LX and BZ/BX be of the same order of magnitude, where h is the half-thickness of the neutral sheet, LX is the length scale for variations along the axis of the tail, and BZ and BX are the magnetic field components in the plasma sheet just outside the neutral sheet. The second case requires, in addition, that the plasma flow speed within the neutral sheet be of the order of or larger than the Alfven speed outside the neutral sheet. Stress balance in the third case requires that just outside the neutral sheet the plasma pressure obey the marginal firehose stability condition.

Rich, F. J.↗
NASA NTRS1972

Flexible rotor balancing by the influence coefficient method. Part 1: Evaluation of the exact point-speed and least squares procedures

The practical aspects of balancing real, flexible rotors were investigated through inclusion of rotor out-of-roundness data at the measurement probe locations. The computer program was demonstrated to be fully capable of handling out-of-roundness data in the investigation. Testing was performed predominantly with a machine having a 41-inch long, 126-pound rotor. This rotor was operated over a speed range encompassing three rotor-bearing system critical speeds. Both balancing procedures were evaluated for several different conditions of initial rotor unbalance. Safe (and slow) passage through all the critical speeds was obtained after two or three balancing runs in most cases. The Least Squares procedure was found to be generally equivalent in capability to the Exact Point-Speed procedure for the configurations studies. (U)

Tessarzik, J. M.↗
NASA NTRS1973

The radiation balance of the earth-atmosphere system from Nimbus 3 radiation measurements

The radiation balance of the earth-atmosphere system and its components was computed from global measurements of radiation reflected and emitted from the earth to space. These measurements were made from the meteorological satellite Nimbus 3 during the periods from April 16 to August 15, 1969; October 3 to 17, 1969; and January 21 to February 3, 1970. Primarily the method of evaluation, its inherent assumptions, and possible error sources were discussed. Results are presented by various methods: (1) global, hemispherical, and zonal averages obtained from measurements in all semimonthly periods and (2) global maps of the absorbed solar radiation, the albedo, the outgoing longwave radiation, and the radiation balance obtained from measurements during semimonthly periods in each season (May 1 to 15, July 16 to 31, and October 3 to 17, 1969, and January 21 to February 3, 1970). Annual global averages of the albedo and of the outgoing longwave radiation were determined. These values balance to within 1 percent the annual global energy input by solar radiation that was computed for a solar constant.

Raschke, E.↗
NASA NTRS1973

Estimates of fluid and energy balances of Apollo 17

Fluid and caloric balance has been calculated for the Apollo 17 crew. This included measurement of nitrogen, water, and caloric value of the ingested food and the volume and nitrogen content of the excreted urine and feces. Body composition changes were determined from total body water and extracellular fluid volume differences. The body composition measurements made it possible to divide the weight loss into lean body mass and adipose tissue losses. From this division a caloric equivalent was calculated. These tissue losses indicated that the caloric requirements of the mission were considerably greater than the actual caloric intake. The 3.3 kilo mean loss of body weight represented 1 kilo of lean body mass and 2.3 kilos of adipose tissue. Calculated fluid balance was more positive during the mission than during the control period. These changes are unlike the body composition and fluid balance changes reported in bedrested subjects.

Johnson, P. C.↗