Full-Field Deformation Measurement Techniques for a Rotating Composite Shaft
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Kohlman, Lee W.↗
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Mechanical sequencer
A mechanical sequencer having a rotatable drive shaft is described. The drive shaft has a spline formed thereon. A freely rotatable shaft contains a plurality of rollers positioned thereon, the axis of the freely rotatable shaft having an axis parallel to and offset from the axis of the drive shaft. A drive fitting has an opening therein, the drive fitting being positioned on the drive shaft spline for rotating the fitting with the shaft. A finger is formed integral with the drive fitting for enabling the fitting to move the rollers and the freely rotatable shift. A crank structure is positioned in a plane in a plane perpendicular to the axis of the drive shaft and the freely rotatable shaft. The crank structure has a drive shaft opening through which the shaft passes. The crank structure further contains a slot into which the freely rotatable shaft and one of the rollers extends for driving the crank structure during movement of the freely rotatable shaft.
Appleberry, W. T.↗
Research Capabilities for Oil-Free Turbomachinery Expanded by New Rotordynamic Simulator Facility
A new test rig has been developed for simulating high-speed turbomachinery shafting using Oil-Free foil air bearing technology. Foil air journal bearings are self-acting hydrodynamic bearings with a flexible inner sleeve surface using air as the lubricant. These bearings have been used in turbomachinery, primarily air cycle machines, for the past four decades to eliminate the need for oil lubrication. More recently, interest has been growing in applying foil bearings to aircraft gas turbine engines. They offer potential improvements in efficiency and power density, decreased maintenance costs, and other secondary benefits. The goal of applying foil air bearings to aircraft gas turbine engines prompted the fabrication of this test rig. The facility enables bearing designers to test potential bearing designs with shafts that simulate the rotating components of a target engine without the high cost of building actual flight hardware. The data collected from this rig can be used to make changes to the shaft and bearings in subsequent design iterations. The rest of this article describes the new test rig and demonstrates some of its capabilities with an initial simulated shaft system. The test rig has two support structures, each housing a foil air journal bearing. The structures are designed to accept any size foil journal bearing smaller than 63 mm (2.5 in.) in diameter. The bearing support structures are mounted to a 91- by 152-cm (3- by 5-ft) table and can be separated by as much as 122 cm (4 ft) and as little as 20 cm (8 in.) to accommodate a wide range of shaft sizes. In the initial configuration, a 9.5-cm (3.75-in.) impulse air turbine drives the test shaft. The impulse turbine, as well as virtually any number of "dummy" compressor and turbine disks, can be mounted on the shaft inboard or outboard of the bearings. This flexibility allows researchers to simulate various engine shaft configurations. The bearing support structures include a unique bearing mounting fixture that rotates to accommodate a laserbased alignment system. This can measure the misalignment of the bearing centers in each of 2 translational degrees of freedom and 2 rotational degrees of freedom. In the initial configuration, with roughly a 30.5-cm- (12-in.-) long shaft, two simulated aerocomponent disks, and two 50.8-cm (2-in.) foil journal bearings, the rig can operate at 65,000 rpm at room temperature. The test facility can measure shaft displacements in both the vertical and horizontal directions at each bearing location. Horizontal and vertical structural vibrations are monitored using accelerometers mounted on the bearing support structures. This information is used to determine system rotordynamic response, including critical speeds, mode shapes, orbit size and shape, and potentially the onset of instabilities. Bearing torque can be monitored as well to predict the power loss in the foil bearings. All of this information is fed back and forth between NASA and the foil bearing designers in an iterative fashion to converge on a final bearing and shaft design for a given engine application. In addition to its application development capabilities, the test rig offers several unique capabilities for basic bearing research. Using the laser alignment system mentioned earlier, the facility will be used to map foil air journal bearing performance. A known misalignment of increasing severity will be induced to determine the sensitivity of foil bearings to misalignment. Other future plans include oil-free integral starter generator testing and development, and dynamic load testing of foil journal bearings.
Howard, Samuel A.↗
Dynamic modelling and analysis of a magnetically suspended flexible rotor
A 12-state lumped-element model is presented for a flexible rotor supported by two attractive force electromagnetic journal bearings. The rotor is modeled as a rigid disk with radial mass unbalance mounted on a flexible, massless shaft with internal damping (Jeffcott rotor). The disk is offset axially from the midspan of the shaft. Bearing dynamics in each radial direction are modeled as a parallel combination of a negative (unstable) spring and a linear current-to-force actuator. The model includes translation and rotation of the rigid mass and the first and second bending models of the flexible shaft, and it simultaneously includes internal shaft damping, gyroscopic effects, and the unstable nature of the attractive force magnetic bearings. The model is used to analyze the dependence of the system transmission zeros and open-loop poles on system parameters. The dominant open-loop poles occur in stable/unstable pairs with bandwidth dependent on the ratios of bearing (unstable) stiffnesses to rotor mass and damping dependent on the shaft spin rate. The zeros occur in complex conjugate pairs with bandwidth dependent on the ratios of shaft stiffness to rotor mass and damping dependent on the shaft spin rate. Some of the transmission zeros are non-minimum phase when the spin rate exceeds the shaft critical speed. The transmission zeros and open-loop poles impact the design of magnetic bearing control systems. The minimum loop cross-over frequency of the closed-loop system is the speed of the unstable open-loop poles. For the supercritical shaft spin rates, the presence of non-minimum phase zeros limits the distribution rejection achievable at frequencies near or above the shaft critical speed. Since non-minimum phase transmission zeros can only be changed by changing the system inputs and/or outputs, closed-loop performance is limited for supercritical spin rates unless additional force or torque actuators are added.
Mccallum, Duncan C.↗
Design and testing of a model CELSS chamber robot
A robot system for use in an enclosed environment was designed and tested. The conceptual design will be used to assist in research performed by the Controlled Ecological Life Support System (CELSS) project. Design specifications include maximum load capacity, operation at specified environmental conditions, low maintenance, and safety. The robot system must not be hazardous to the sealed environment, and be capable of stowing and deploying within a minimum area of the CELSS chamber facility. This design consists of a telescoping robot arm that slides vertically on a shaft positioned in the center of the CELSS chamber. The telescoping robot arm consists of a series of links which can be fully extended to a length equal to the radius of the working envelope of the CELSS chamber. The vertical motion of the robot arm is achieved through the use of a combination ball screw/ball spline actuator system. The robot arm rotates cylindrically about the vertical axis through use of a turntable bearing attached to a central mounting structure fitted to the actuator shaft. The shaft is installed in an overhead rail system allowing the entire structure to be stowed and deployed within the CELSS chamber. The overhead rail system is located above the chamber's upper lamps and extends to the center of the CELSS chamber. The mounting interface of the actuator shaft and rail system allows the entire actuator shaft to be detached and removed from the CELSS chamber. When the actuator shaft is deployed, it is held fixed at the bottom of the chamber by placing a square knob on the bottom of the shaft into a recessed square fitting in the bottom of the chamber floor. A support boot ensures the rigidity of the shaft. Three student teams combined into one group designed a model of the CELSS chamber robot that they could build. They investigated materials, availability, and strength in their design. After the model arm and stand were built, the class performed pre-tests on the entire system. A stability pre-test was used to determine whether the model robot arm would tip over on the stand when it was fully extended. Results showed the stand tipped when 50 Newtons were applied horizontally to the top of the vertical shaft while the arm was fully extended. This proved that it was stable. Another pre-test was the actuator slip test used to determine if there is an adequate coefficient of friction between the actuator drive wheels and drive cable to enable the actuator to fully extend and retract the arm. This pre-test revealed that the coefficient of friction was not large enough to prevent slippage. Sandpaper was glued to the drive wheel and this eliminated the slippage problem. The class preformed a fit test in the CELSS chamber to ensure that the completed robot arm is capable of reaching the entire working envelope. The robot was centered in the chamber and the arm was fully extended to the sides of the chamber. The arm was also able to retract to clear the drain pipes separating the upper and lower plant trays.
Davis, Mark↗
Anti-Rotation Device Releasable by Insertion of a Tool
A drive mechanism enables a socket-type wrench to rotate a shaft and prevents accidental rotation of the shaft when the wrench is not coupled to the shaft. In the original intended application, the shaft would be part of an attachment mechanism on a spacecraft, and the purpose to be served by the drive is to prevent back-driving of the shaft by launch vibrations while enabling an astronaut equipped with the appropriate wrench to actuate the shaft while in orbit. The design could also be adapted to terrestrial applications in which it is necessary to prevent rotational back-driving. The mechanism includes a gear near the tip of the shaft, and a drive nut that constitutes the tip of the shaft. The gear and drive nut are positioned in a recess in a housing. The recess is sized to receive the wrench socket that mates with the drive nut. Also contained in the housing are four linkages that include pins that are spring-loaded into engagement with the gear to prevent rotation of the shaft. When the wrench socket is inserted in the recess, it pushes on the linkages in such a manner as to disengage the pins from the gear.
Warden, Harry K.↗
Workpiece positioning vise
A pair of jaw assemblies simultaneously driven in opposed reciprocation by a single shaft has oppositely threaded sections to automatically center delicate or brittle workpieces such as lithium fluoride crystal beneath the blade of a crystal cleaving machine. Both jaw assemblies are suspended above the vise bed by a pair of parallel guide shafts attached to the vise bed. Linear rolling bearings, fitted around the guide shafts and firmly held by opposite ends of the jaw assemblies, provide rolling friction between the guide shafts and the jaw assemblies. A belleville washer at one end of the drive shaft and thrust bearings at both drive shaft ends hold the shaft in compression between the vise bed, thereby preventing wobble of the jaw assemblies due to wear between the shaft and vise bed.
Hallberg, F. C.↗
OTVE turbopump condition monitoring, task E.5
Recent work has been carried out on development of isotope wear analysis and optical and eddy current technologies to provide bearing wear measurements and real time monitoring of shaft speed, shaft axial displacement and shaft orbit of the Orbit Transfer Vehicle hydrostatic bearing tester. Results show shaft axial displacement can be optically measured (at the same time as shaft orbital motion and speed) to within 0.3 mils by two fiberoptic deflectometers. Evaluation of eddy current probes showed that, in addition to measuring shaft orbital motion, they can be used to measure shaft speed without having to machine grooves on the shaft surface as is the usual practice for turbomachinery. The interim results of this condition monitoring effort are presented.
Coleman, Paul T.↗
Preload release mechanism
This invention relates to a preload release mechanism comprising a preload spring assembly adapted to apply a preload to a first connector member which is mounted on a support structure and adapted for connection with a second connector member on an object. The assembly comprises telescoped bushings and a preload spring. A tubular shaft extends through the spring assembly and openings in the first connector member and support structure, on which it is clamped. A plunger rod in the shaft is provided with a tip end and a recess in the rod near the other end thereof. A retainer precludes passage of the rod through the shaft in one direction and an end cap closes the bore of the shaft at the other end and provides a shoulder which extends radially of the shaft. A plunger return spring biases the plunger rod against the plunger retainer with the plunger tip protruding from the shaft and a spring assembly return spring engages at its ends the shoulder of the end cap and one end of the spring assembly. Detents received in lateral openings in the tubular shaft are held captive by the plunger rod and one end of the spring assembly to lock the spring assembly on the tubular shaft and apply a preload to the first connector member. Upon completion of the connection, detents and spring assembly are released by plunger contact with the object to be connected, thereby releasing the preload while the connection is maintained.
Generoli, Robert M.↗
Impact micro-positioning actuator
An impact micro-positioning actuator. In one aspect of the invention, a threaded shaft is threadably received in a nut and the nut is impacted by an impacting device, causing the nut first to rotate relative to the shaft by slipping as a result of shaft inertia and subsequently to stick to the shaft as a result of the frictional force therebetween. The nut is returned to its initial position by a return force provided by a return mechanism after impact. The micro-positioning actuator is further improved by controlling at least one and preferably all of the following: the friction, the impact provided by the impacting device, the return force provided by the return mechanism, and the inertia of the shaft. In another aspect of the invention, a threaded shaft is threadably received in a nut and the shaft is impacted by an impacting device, causing the shaft to rotate relative to the nut.
Cuerden, Brian↗
Using Composite Materials in a Cryogenic Pump
Several modifications have been made to the design and operation of an extended-shaft cryogenic pump to increase the efficiency of pumping. In general, the efficiency of pumping a cryogenic fluid is limited by thermal losses which is itself caused by pump inefficiency and leakage of heat through the pump structure. A typical cryogenic pump includes a drive shaft and two main concentric static components (an outer pressure containment tube and an intermediate static support tube) made from stainless steel. The modifications made include replacement of the stainless-steel drive shaft and the concentric static stainless-steel components with components made of a glass/epoxy composite. The leakage of heat is thus reduced because the thermal conductivity of the composite is an order of magnitude below that of stainless steel. Taking advantage of the margin afforded by the decrease in thermal conductivity, the drive shaft could be shortened to increase its effective stiffness, thereby increasing the rotordynamic critical speeds, thereby further making it possible to operate the pump at a higher speed to increase pumping efficiency. During the modification effort, an analysis revealed that substitution of the shorter glass/epoxy shaft for the longer stainless-steel shaft was not, by itself, sufficient to satisfy the rotordynamic requirements at the desired increased speed. Hence, it became necessary to increase the stiffness of the composite shaft. This stiffening was accomplished by means of a carbon-fiber-composite overwrap along most of the length of the shaft. Concomitantly with the modifications described thus far, it was necessary to provide for joining the composite-material components with metallic components required by different aspects of the pump design. An adhesive material formulated specially to bond the composite and metal components was chosen as a means to satisfy these requirements.
Batton, William D.↗
Low-Noise Operating Mode for Propeller-Driven Electric Airplanes
Mechanical shaft power and shaft speed of reciprocating internal combustion engines are closely coupled. Maximum rated shaft power is typically produced at or near peak shaft speed. If a general aviation airplane equipped with a reciprocating engine and a variable-pitch propeller attempts a low-noise takeoff by reducing propeller tip speed, propeller power and thrust are reduced. Such takeoffs are not tolerated due to punishing performance effects, such as increased field lengths and poor climb rates. Certain electric motors, however, are able to deliver maximum shaft power over a wide range of shaft speed. Electric or hybrid-electric propeller-driven airplanes should be able to exploit this behavior. At low shaft speeds, high shaft power levels and high blade pitch angles could be combined to recover much of the thrust that would otherwise be lost. This could enable a low-noise operating mode for propellers normally designed for performance rather than for noise. The subject of this paper is an analytical investigation into low-noise takeoffs and steady overflights of a notional general aviation airplane equipped with a propeller driven by an electric motor.
Berton, Jeffrey J.↗
Rotary leveling base platform
A leveling apparatus for the precise adjustment of a scientific instrument is reported. A base member is provided having a hollow cylindrical shape. A table for supporting the instrument rests on the base and has a shaft portion extending below the table. The upper portion of the shaft fits tightly into the hollow portion of the base member whereas the lower portion of the shaft is machined to fit loosely. The lower portion of the shaft is provided with a groove. Adjusting screws are threaded through the hollow cylindrical portion and are adapted to enter the groove. By adjusting the screws, the lower portion of the shaft is moved in a vertical plane since the shaft is loosely fitted into the cylinder. The upper portion of the shaft which is tightly fitted into the upper end of the cylinder causes the cylinder to deform slightly providing a fulcrum point which allows the table to be leveled in response to the adjustment of the adjusting screws.
Delaplaine, R. W.↗
J-hook latching device
Described here is a latching device for latching two items together that has a housing and a shaft mounted to one item such that rotation of the shaft by a sprocket causes the shaft to move longitudinally up and down. The shaft has one end extending beyond the housing with an alignment cone attached to this end for engaging a receptor on the other item. A latch mounted to a shaft by a traveling nut provides a pivot point for the latch so that rotation of the shaft causes the pivot point of the latch to translate along the longitudinal axis of the shaft. Camming surfaces and a camming spring are used for rotating the latch so that the latch will engage and disengage a receptor on the other item.
Milam, Malcolm B.↗
Dynamic tester for rotor seals and bearings
A dynamic tester for testing vibration damping seals and bearings is constructed having a hollow shaft extending through the seal or bearing, with the shaft internally supported at each end by fluid bearings on hollow bosses connected to an interior of an enclosure, with no rolling members connected to the shaft is described. A high pressure working fluid is forced through the hollow bosses to operate the bearings. Additionally, the shaft is provided with a reaction turbine that angularly vents a portion of the high pressure working fluid in order to rotate the shaft at high speed, up to 40,000 rpm. The seal or bearing is mounted in a bushing, in turn supported by rods to a shaking device that vibrates the seal or bearing as the shaft is rotated. A plurality of proximity sensors are mounted from outside the enclosure to sense shaft and seal bushing vibrations, and a plurality of pressure ports are disposed in the enclosure to allow sensing of dynamic and static pressures of the testing apparatus.
Vonpragenau, George L.↗
Preliminary Tuft Testing of Metallic Bristles Versus PS212, PS300, and HVOF300
Turbine engine brush seals are designed with sacrificial brushes and hard shaft coatings to minimize shaft wear and reduce the cost of engine overhauls. Replacing a worm seal is more cost and time effective than refinishing an engine shaft. However, this tribological design causes excessive brush wear and reduces long term seal efficiency. An alternative approach is to coat the shaft with a solid lubricant and allow the bristles to wear into the shaft coating similar to traditional abradable labyrinth seals. This approach can result in reduced seal leakage by forcing the leakage to flow through the seal bristle pack or through a more tortuous shaft wear track. Key to this approach is limiting the shaft wear to an acceptable level were surface refinishing would not be required during every engine overhaul. Included in this paper are brush seal tuft test results for four metallic bristles (nickel-chrome or cobalt-chrome based superalloys) tested against three solid lubricant coatings (NASA's PS212, PS300, and HVOF300). These test results are also compared to previous baseline tests conducted with plasma sprayed chrome carbide. Compared to the baseline results, no tribological benefit was achieved with the metallic bristle/solid lubricant tribopairs tested. To improve the performance of the solid lubricant coatings, issues regarding lubricant phase sizes (homogeneity), and composition need to be addressed.
Fellenstein, James A.↗
Blade tip clearance control apparatus using bellcrank mechanism
A clearance control apparatus has a positioning mechanism for controlling clearance between rotor blade tips and a shroud segment of a gas turbine engine casing. The positioning mechanism is supported by the casing, coupled to the shroud segment, and actuatable for moving the shroud segment toward and away from the rotor blade tips to reach a position at which a desired clearance is established. The mechanism includes a shaft and a bellcrank actuating assembly. The shaft is mounted through a passage defined by a mounting structure on the casing for radial movement along a longitudinal axis of the shaft toward and away from the rotor axis and is coupled at its inner end to the shroud segment. The bellcrank actuating assembly is coupled to an outer end of the shaft and mounted to the casing adjacent the shaft for pivotal movement about an axis spaced from and extending transverse to the longitudinal axis of the shaft. The pivotal movement of the bellcrank actuating assembly produces radial movement of the shaft and shroud segment therewith toward and away from the rotor blade tips.
Corsmeier, Robert J.↗
Multimodal Friction Ignition Tester
The multimodal friction ignition tester (MFIT) is a testbed for experiments on the thermal and mechanical effects of friction on material specimens in pressurized, oxygen-rich atmospheres. In simplest terms, a test involves recording sensory data while rubbing two specimens against each other at a controlled normal force, with either a random stroke or a sinusoidal stroke having controlled amplitude and frequency. The term multimodal in the full name of the apparatus refers to a capability for imposing any combination of widely ranging values of the atmospheric pressure, atmospheric oxygen content, stroke length, stroke frequency, and normal force. The MFIT was designed especially for studying the tendency toward heating and combustion of nonmetallic composite materials and the fretting of metals subjected to dynamic (vibrational) friction forces in the presence of liquid oxygen or pressurized gaseous oxygen test conditions approximating conditions expected to be encountered in proposed composite material oxygen tanks aboard aircraft and spacecraft in flight. The MFIT includes a stainless-steel pressure vessel capable of retaining the required test atmosphere. Mounted atop the vessel is a pneumatic cylinder containing a piston for exerting the specified normal force between the two specimens. Through a shaft seal, the piston shaft extends downward into the vessel. One of the specimens is mounted on a block, denoted the pressure block, at the lower end of the piston shaft. This specimen is pressed down against the other specimen, which is mounted in a recess in another block, denoted the slip block, that can be moved horizontally but not vertically. The slip block is driven in reciprocating horizontal motion by an electrodynamic vibration exciter outside the pressure vessel. The armature of the electrodynamic exciter is connected to the slip block via a horizontal shaft that extends into the pressure vessel via a second shaft seal. The reciprocating horizontal motion can be chosen to be random with a flat spectrum over the frequency range of 10 Hz to 1 kHz, or to be sinusoidal at any peak-to-peak amplitude up to 0.8 in. (.2 cm) and fixed or varying frequency up to 1 kHz. The temperatures of the specimen and of the vessel are measured by thermocouples. A digital video camera mounted outside the pressure vessel is aimed into the vessel through a sapphire window, with its focus fixed on the interface between the two specimens. A position transducer monitors the displacement of the pneumatic-cylinder shaft. The pressure in the vessel is also monitored. During a test, the output of the video camera, the temperatures, and the pneumatic-shaft displacement are monitored and recorded. The test is continued for a predetermined amount of time (typically, 10 minutes) or until either (1) the output of the position transducer shows a sudden change indicative of degradation of either or both specimens, (2) ignition or another significant reaction is observed, or (3) pressure in the vessel increases beyond a pre-set level that triggers an automatic shutdown.
Davis, Eddie↗