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Ring, brush, and insulator materials effect on electrical noise and mechanical wear characteristics in space vehicle guidance systems - miniature slip ring assemblies
Lubricating materials for use in a vacuum environment have been the subject of a series of experimental investigations. Evaporation properties were evaluated for solid polymeric compositions. Friction and wear studies explored the behavior during sliding contact for series of polymeric compositions, binary alloys containing soft film-forming phases, complex alloys with film-forming materials, and a burnished MoS2 film. Friction and wear experiments were conducted at 10(exp-9)mm Hg with a 3/16-inch-radius-hemisphere rider specimen sliding on the flat surface of a rotating 2-1/2-inch-diameter disk specimen with materials that had low rates of evaporation. The influence of fillers in polytetrafluoroethylene (PTFE) on decomposition during vacuum friction studies was determined with a mass spectrometer. A real advantage in reducing decomposition and improving friction wear properties is gained by adding fillers (e.g., copper) that improve thermal conductivity through the composite materials. A polyimide and an epoxy-MoS2 composition material were found to have better friction and wear properties than PTFE compositions. A series of alloys (cast binary as well as more complex alloys) that contained microinclusions of potential film-forming material was studied. These materials replaced the normal surface oxides as they were worn away on sliding contact. Iron sulfide, nickel oxide, and tin are typical film-forming materials employed and were demonstrated to be effective in inhibiting surface welding and reducing friction. A burnished MoS2 film applied to type 440-C stainless steel in argon with a rotating soft wire brush had good endurance properties but somewhat higher friction than commercially available bonded films. An oil film applied to the burnished MoS2 markedly reduced its endurance life.
The results of research programs to develop sliding electrical contact materials, both brushes and slip rings, are discussed. Problems attendant to operating sliding contacts in a vacuum are defined; limitations of commercial materials in solving these problems are described, and special materials and surface finish conditions which have resulted in solutions to these problems are presented. Data from operational tests on the newly developed materials are compared with similar data obtained from materials now used as standards in consumer products. Possible commercial applications of the more efficient sliding contact materials are discussed briefly.
Investigation studied the long term operation of miniature slip ring assembles in high vacuum of space and included the influence of ring, brush, and insulator materials on electrical noise and mechanical wear. Results show that soft metal vapor plating and niobium diselenide miniature slip rings are beneficial.
Liquid crystal solution nondestructively detects voids or poor bond lines in fiber glass laminates. A thin coating of the solution is applied by spray or brush to the test article surface, and when heated indicates the exact location of defects by differences in color.
Material designs for electronic applications - motor brushes, dielectrics for wire coatings, electrical properties of cryogenic fluids, and potting compounds
Aluminum and magnesium composite sheet laminates reinforced with low density, high strength modular filament sheets are produced by diffusion bonding and explosive bonding. Both processes are accomplished in normal atmosphere and require no special tooling or cleaning other than wire brushing the metal surfaces just prior to laminating.
Development, and evaluation of sieve sampler, and rotating wire brush sampler for planetary soil probing
Instrumentation setup measures resistivity values between .000003 and 100,000 ohm-cm and Hall values between 0.2 and 10 billion cc/coulomb, with an absolute error of less than 5 percent. Results of measurement are given for 8 electrical brush specimens and pure silver.
Fabrication of sintered impurity semiconductor brushes for electrical energy transfer
Development of slip ring assembly with inner and outer peripheral surfaces used as electrical contacts for brushes
Lunar dust deposition and brushing effects on spectral solar reflectance of thermal control materials in vacuum
Space mission requirements for the 70's have established a 50,000-hour-lifetime challenge for the mechanisms designer. This challenge may be met by two approaches: (1) development of new materials for wear-prone elements, and (2) design innovation of new electromechanical devices that do not include mechanical wear-prone components. Present state-of-the-art materials require restricted operation regarding load, speed, and power for gears, bearings, and brush-slipring components. These restrictions are discussed, and methods of improvement are suggested. The design-innovations approach is discussed and is illustrated by the design of an experimental magnetically suspended motor.
During entry, the Apollo 14 spacecraft busses should have de-energized when the main bus-tie motor switches were switched to the off position. One motor switch did not transfer and main bus A remained energized until the battery bus-tie circuit breakers were opened after landing. Analysis revealed that residual catalyst caused the terminal pin seals to revert to a gummy state. Resulting reversion products then migrated to the motor commutator and caused brush degradation, increased and erratic commutator resistance, and reduced motor torque. The motor stalled when available motor torque was reduced below that required to drive through the maximum torque point of the switch.
A space-qualified, high reliability, 150 ft-lb rated torque rotary acutator based on the Bendix Dynavector drive concept was developed. This drive is an integrated variable reluctance orbit motor-epicyclic transmission actuator. The performance goals were based on future control moment gyro torquer applications and represent a significant advancement in the torque-to-weight ratio, backlash, inertia and response characteristics of electric rotary drives. The program accomplishments have been in two areas: (1) the development of two high ratio (818:1) actuator configurations (breadboard and flightweight), and (2) the invention of a reliable proximity switch sensor system for self-commutation without use of optical or electrical brush techniques.
A space-qualified, high reliability, 150 ft-lb rated torque rotary actuator is described. This drive is an integrated variable reluctance orbit motor-epicyclic transmission actuator. The performance goals were based on future control moment gyrotorquer applications and represent an advancement in the torque-to-weight ratio, backlash, inertia and response characteristics of electric rotary drives. The program accomplishments have been in two areas (1) the development of two high ratio (818:1) actuator configurations (breadboard and flightweight) and (2) the invention of a reliable proximity switch sensor system for self-commutation without use of optical or electrical brush techniques.
Concept utilizes porous metal or nonmetal matrix containing liquid metal in porous structure and confines liquid metal to contact area between rotor and brush by capillary forces. System may also be used to lubricate bearing systems.
The National Aeronautics and Space Administration (NASA), launched ITOS-D with an improved attitude control system. A Hall generator brushless dc torque motor replaced the brush dc torque motor on Tiros-M and ITOS-A. Two CO2 attitude horizon sensors and one mirror replaced the four wideband horizon sensors and two mirrors on ITOS-1 and NOAA-1. Redundant pitch-control electronic boxes containing additional electronic circuitry for earth-splitting and brushless motor electronics were used. A method of generating a spacecraft earth-facing side reference for comparison to the time occurrence of the earth-splitting pulse was used to automatically correct pitch-attitude error. A single rotating flywheel, supported by a single bearing, provided gyroscopic stability and the required momentum interchange to keep one side of the satellite facing the earth. Magnetic torquing against the earth's magnetic field eliminated the requirement for expendable propellants which would limit satellite life in orbit.