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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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NASA NTRS1985

Data presentation techniques for rotating machinery malfunction diagnosis

Baseline steady state data is excellent for documentation of vibration signals at normal operating conditions. Assuming that a set of initial data was acquired with the machinery in a good state of repair, any future changes or deterioration in mechanical condition can be easily compared to the baseline information. Often this type of comparison will yield sufficient information for evaluation of the problem. However, many malfunctions require the analysis of transient data in order to identify the malfunction. Steady-state data formats consist of: Time Base Waveform, Orbit, Spectrum. Transient data formats consist of: Polar, Bode, Cascade. Our objective is to demonstrate the use of the above formats to diagnose a machine malfunction. A turbine-driven compressor train is chosen as an example. The machine train outline drawing is shown.

Spettel, T.↗

NASA NTRS1993

Transient performance of fan engine with water ingestion

In a continuing investigation on developing and applying codes for prediction of performance of a turbine jet engine and its components with water ingestion during flight operation, including power settings, and flight altitudes and speed changes, an attempt was made to establish the effects of water ingestion through simulation of a generic high bypass ratio engine with a generic control. In view of the large effects arising in the air compression system and the prediffuser-combustor unit during water ingestion, attention was focused on those effects and the resulting changes in engine performance. Under all conditions of operation, whether ingestion is steady or not, it became evident that water ingestion causes a fan-compressor unit to operate in a time-dependent fashion with periodic features, particularly with respect to the state of water in the span and the film in the casing clearance space, at the exit of the machine. On the other hand, the aerodynamic performance of the unit may be considered as quasi-steady once the distribution of water has attained an equilibrium state with respect to its distribution and motion. For purposes of engine simulation, the performance maps for the generic fan-compressor unit were generated based on the attainment of a quasi-steady state (meaning steady except for long-period variations in performance) during ingestion and operation over a wide enough range of rotational speeds.

Murthy, S. N. B.↗

NASA NTRS2012

Simulated Single Tooth Bending of High Temperature Alloys

Future unmanned space missions will require mechanisms to operate at extreme conditions in order to be successful. In some of these mechanisms, very high gear reductions will be needed to permit very small motors to drive other components at low rotational speed with high output torque. Therefore gearing components are required that can meet the mission requirements. In mechanisms such as this, bending fatigue strength capacity of the gears is very important. The bending fatigue capacity of a high temperature, nickel-based alloy, typically used for turbine disks in gas turbine engines and two tool steel materials with high vanadium content, were compared to that of a typical aerospace alloy-AISI 9310. Test specimens were fabricated by electro-discharge machining without post machining processing. Tests were run at 24 and at 490 C. As test temperature increased from 24 to 490 C the bending fatigue strength was reduced by a factor of five.

Handschuh, Robert, F.↗

NASA NTRS2002

Optical Testing of Diamond Machined, Aspheric Mirrors for Groundbased, Near-IR Astronomy

The Infrared Multi-Object Spectrometer (IRMOS) is a facility-class instrument for the Kitt Peak National Observatory 4 and 2.1 meter telescopes. IRMOS is a near-IR (0.8-2.5 micron) spectrometer and operates at approximately 80 K. The 6061-T651 aluminum bench and mirrors constitute an athermal design. The instrument produces simultaneous spectra at low- to mid-resolving power (R=lambda/delta lambda= 300-3000) of approximately 100 objects in its 2.8 x 2.0 arcmin field. We describe ambient and cryogenic optical testing of the IRMOS mirrors across a broad range in spatial frequency (figure error, mid-frequency error, and microroughness). The mirrors include three rotationally symmetric, off-axis conic sections, one off-axis biconic, and several flat fold mirrors. The symmetric mirrors include convex and concave prolate and oblate ellipsoids. They range in aperture from 94x86 mm to 286x269 mm and in f-number from 0.9 to 2.4. The biconic mirror is concave and has a 94x76 mm aperture, R(sub x)=377 mm, k(sub x)=0.0778, R(sub y)=407 mm, and k(sub y)=0.1265 and is decentered by -2 mm in X and 227 mm in Y. All of the mirrors have an aspect ratio of approximately 6:1. The surface error fabrication tolerances are less than 10 nm RMS microroughness, 'best effort' for mid-frequency error, and less than 63.3 nm RMS figure error. Ambient temperature (approximately 293 K) testing is performed for each of the three surface error regimes, and figure testing is also performed at approximately 80 K. Operation of the ADE Phaseshift MicroXAM white light interferometer (micro-roughness) and the Bauer Model 200 profilometer (mid-frequency error) is described. Both the sag and conic values of the aspheric mirrors make these tests challenging. Figure testing is performed using a Zygo GPI interferometer, custom computer generated holograms (CGH), and optomechanical alignment fiducials. Cryogenic CGH null testing is discussed in detail. We discuss complications such as the change in prescription with temperature and thermal gradients. Correction for the effect of the dewar window is also covered. We discuss the error budget for the optical test and alignment procedure. Data reduction is accomplished using commercial optical design and data analysis software packages. Results from CGH testing at cryogenic temperatures are encouraging thus far.

Chambers, V. John↗

NASA NTRS1988

Three legged walking mobile platform: Kinematic and dynamic analysis and simulation

The three legged walker is proposed as a mobile work platform for numerous tasks associated with lunar base site preparation and construction. It is seen as one of several forms of surface transportation, each of which will be best suited for its respective tasks. Utilizing the principle of dynamic stability and taking advantage of the Moon's gravity, it appears to be capable of walking in any radial direction and rotating about a point. Typical curved path walking could involve some combination of the radial and rotational movements. Comprised mainly of a body, six actuators, and six moving parts, it is mechanically quite simple. Each leg connects to the body at a hip joint and has a femur, a knee joint, and a tibia that terminates at a foot. Also capable of enabling or enhancing the dexterity of a series of implements, the walker concept provides a mechanically simple and weight efficient means of drilling, digging, mining, and transporting cargo, and performing other like tasks. A proof of principle machine demonstrated the feasibility of the walking concept.

Mcmurray, Gary V.↗

NASA NTRS2009

Windage Power Loss in Gas Foil Bearings and the Rotor-Stator Clearance of High Speed Generators Operating in High Pressure Environments

Closed Brayton Cycle (CBC) and Closed Supercritical Cycle (CSC) engines are prime candidates to convert heat from a reactor into electric power for robotic space exploration and habitation. These engine concepts incorporate a permanent magnet starter/generator mounted on the engine shaft along with the requisite turbomachinery. Successful completion of the long-duration missions currently anticipated for these engines will require designs that adequately address all losses within the machine. The preliminary thermal management concept for these engine types is to use the cycle working fluid to provide the required cooling. In addition to providing cooling, the working fluid will also serve as the bearing lubricant. Additional requirements, due to the unique application of these microturbines, are zero contamination of the working fluid and entirely maintenance-free operation for many years. Losses in the gas foil bearings and within the rotor-stator gap of the generator become increasingly important as both rotational speed and mean operating pressure are increased. This paper presents the results of an experimental study, which obtained direct torque measurements on gas foil bearings and generator rotor-stator gaps. Test conditions for these measurements included rotational speeds up to 42,000 revolutions per minute, pressures up to 45 atmospheres, and test gases of nitrogen, helium, and carbon dioxide. These conditions provided a maximum test Taylor number of nearly one million. The results show an exponential rise in power loss as mean operating density is increased for both the gas foil bearing and generator windage. These typical "secondary" losses can become larger than the total system output power if conventional design paradigms are followed. A nondimensional analysis is presented to extend the experimental results into the CSC range for the generator windage.

Bruckner, Robert J.↗

NASA NTRS1994

Spline-Screw Payload-Fastening System

Payload handed off securely between robot and vehicle or structure. Spline-screw payload-fastening system includes mating female and male connector mechanisms. Clockwise (or counter-clockwise) rotation of splined male driver on robotic end effector causes connection between robot and payload to tighten (or loosen) and simultaneously causes connection between payload and structure to loosen (or tighten). Includes mechanisms like those described in "Tool-Changing Mechanism for Robot" (GSC-13435) and "Self-Aligning Mechanical and Electrical Coupling" (GSC-13430). Designed for use in outer space, also useful on Earth in applications needed for secure handling and secure mounting of equipment modules during storage, transport, and/or operation. Particularly useful in machine or robotic applications.

Vranish, John M.↗

NASA NTRS1980

Method and tool for machining a transverse slot about a bore

A method and apparatus for cutting a transverse slot about a bore of smaller diameter than that of the slot are disclosed. The invention consists of introducing a cutting head facing transversely to the bore, through the bore opening its distance from the mill shaft being progressively extended by the addition of spacers between the head and the shaft until the desired slot depth is obtained. The spacers are held in position by a cable passing from the cutting head through the series of spacers and out along the mill shaft. The mill shaft carrying the cutting head is moved transversely into the object wherein the slot is being cut as the object is being rotated thereabout by the mill table to which it is affixed.

David-Malig, M. A.↗

NASA NTRS2002

STS-112 Flight Day 4 Highlights

On the fourth day of STS-112, its crew (Jeffrey Ashby, Commander; Pamela Melroy, Pilot; David Wolf, Mission Specialist; Piers Sellers, Mission Specialist; Sandra Magnus, Mission Specialist; Fyodor Yurchikhin, Mission Specialist) onboard Atlantis and the Expedition 5 crew (Valery Korzun, Commander; Peggy Whitson, Flight Engineer; Sergei Treschev, Flight Engineer) onboard the International Space Station (ISS) are seen preparing for the installation of the S1 truss structure. Inside the Destiny Laboratory Module, Korzun and other crewmembers are seen as they busily prepare for the work of the day. Sellers dons an oxygen mask and uses an exercise machine in order to purge the nitrogen from his bloodstream, in preparation for an extravehicular activity (EVA). Whitson uses the ISS's Canadarm 2 robotic arm to grapple the S1 truss and remove it from Atlantis' payload bay, with the assistance of Magnus. Using the robotic arm, Whitson slowly maneuvers the 15 ton truss structure into alignment with its attachment point on the starboard side of the S0 truss structure, where the carefully orchestrated mating procedures take place. There is video footage of the entire truss being rotated and positioned by the arm, and ammonia tank assembly on the structure is visible, with Earth in the background. Following the completion of the second stage capture, the robotic arm is ungrappled from truss. Sellers and Wolf are shown exiting the the Quest airlock hatch to begin their EVA. They are shown performing a variety of tasks on the now attached S1 truss structure, including work on the Crew Equipment Translation Cart (CETA), the S-band Antenna Assembly, and umbilical cables that provide power and remote operation capability to cameras. During their EVA, they are shown using a foot platform on the robotic arm. Significant portions of their activities are shown from the vantage of helmet mounted video cameras. The video closes with a final shot of the ISS and its new S1 truss.

Source record↗

NASA NTRS1985

Mod-2 wind turbine field operations experiment

The three-machine, 7.5 MW Goodnoe Hills located near Goldendale, Washington and is now in a research/experimental operations phase that offers a unique opportunity to study the effects of single and multiple wind turbines interacting with each other, the power grid; and the environment. Following a brief description of the turbine and project history, this paper addresses major problem areas and research and development test results. Field operations, both routine and nonroutine, are discussed. Routine operation to date has produced over 13,379,000 KWh of electrical energy during 11,064 hr of rotation. Nonroutine operation includes suspended activities caused by a crack in the low speed shaft that necessitated a redesign and reinstallation of this assembly on all three turbines. With the world's largest cluster back in full operation, two of the turbines will be operated over the next years to determine their value as energy producer. The third unit will be used primarily for conducting research tests requiring configuration changes to better understand the wind turbine technology. Technical areas summarized pertain to system performance and enhancements. Specific research tests relating to acoustics, TV interference, and wake effects conclude the paper.

Gordon, L. H.↗

NASA NTRS2010

Dynamic Visual Acuity: a Functionally Relevant Research Tool

Coordinated movements between the eyes and head are required to maintain a stable retinal image during head and body motion. The vestibulo-ocular reflex (VOR) plays a significant role in this gaze control system that functions well for most daily activities. However, certain environmental conditions or interruptions in normal VOR function can lead to inadequate ocular compensation, resulting in oscillopsia, or blurred vision. It is therefore possible to use acuity to determine when the environmental conditions, VOR function, or the combination of the two is not conductive for maintaining clear vision. Over several years we have designed and tested several tests of dynamic visual acuity (DVA). Early tests used the difference between standing and walking acuity to assess decrements in the gaze stabilization system after spaceflight. Supporting ground-based studies measured the responses from patients with bilateral vestibular dysfunction and explored the effects of visual target viewing distance and gait cycle events on walking acuity. Results from these studies show that DVA is affected by spaceflight, is degraded in patients with vestibular dysfunction, changes with target distance, and is not consistent across the gait cycle. We have recently expanded our research to include studies in which seated subjects are translated or rotated passively. Preliminary results from this work indicate that gaze stabilization ability may differ between similar active and passive conditions, may change with age, and can be affected by the location of the visual target with respect to the axis of motion. Use of DVA as a diagnostic tool is becoming more popular but the functional nature of the acuity outcome measure also makes it ideal for identifying conditions that could lead to degraded vision. By doing so, steps can be taken to alter the problematic environments to improve the man-machine interface and optimize performance.

Peters, Brian T.↗

NASA NTRS1962

VISUAL CONTROL OF RENDEZVOUS

Space rendezvous involving human occupants will be required in many phases of space flight. In order that rendezvous capability be concurrent with other phases of manned space flight to insure that such tasks as the rotation and addition of crews for manned space station, supply of stations and launching complexes for deep-space probes, and the emergency rescue of personnel may be carried out, it is desirable to determine the ability of a human pilot to control the rendezvous maneuver. The National Aeronautics and Space Administration has conducted a study program to determine vehicle requirements and control techniques for a number of proposed methods for performing piloted space rendezvous. The final step in each phase of the rendezvous study program has been a simulation of the man-machine combination to test its feasibility. Initially, an analytical study was conducted to determine a range of conditions that would exist at the beginning of the terminal phase of rendezvous (ref. 1). Piloted systems were investigated for rendezvous control using these initial conditions. One such study of piloted rendezvous in which all the required control information was displayed to the simulator pilot on instruments is presented in reference 2. While the control of the rendezvous maneuver by use of the instrument display was shown to be feasible, the sufficiently accurate measurement of the necessary information to operate the instrument was realized to be a difficult problem. Consideration was therefore given to the possibility of maneuvering range and range rate required for the control of the rendezvous from visual sightings made during the initial control application. To provide this capability, an analytical study was made. This analytical study, presented in reference 3, derived three techniques for obtaining range and range rate visually and conducted a simplified preliminary situation to test the three analytical techniques. The study reported herein is a continuation of the simulation work begun in reference 3, and is aimed at determining the ability of a pilot to use visual information to reduce or eliminate the need for some or all of the data that would normally be displayed on instruments.

Rendezvous↗

NASA NTRS1992

Three-dimensional turbopump flowfield analysis

A program was conducted to develop a flow prediction method applicable to rocket turbopumps. The complex nature of a flowfield in turbopumps is described and examples of flowfields are discussed to illustrate that physics based models and analytical calculation procedures based on computational fluid dynamics (CFD) are needed to develop reliable design procedures for turbopumps. A CFD code developed at NASA ARC was used as the base code. The turbulence model and boundary conditions in the base code were modified, respectively, to: (1) compute transitional flows and account for extra rates of strain, e.g., rotation; and (2) compute surface heat transfer coefficients and allow computation through multistage turbomachines. Benchmark quality data from two and three-dimensional cascades were used to verify the code. The predictive capabilities of the present CFD code were demonstrated by computing the flow through a radial impeller and a multistage axial flow turbine. Results of the program indicate that the present code operated in a two-dimensional mode is a cost effective alternative to full three-dimensional calculations, and that it permits realistic predictions of unsteady loadings and losses for multistage machines.

Sharma, O. P.↗

NASA NTRS1985

Remarks on rotor stability (A contribution to discussion during symposium on instability in rotating machinery)

Influence of nonlinear factors in fluid lubricated bearings on rotor vibrations is discussed as are computation of threshold of stability for systems with multiple degrees of freedom. The reason for this investigation was to learn more about the influence of tilting pad bearings on vertical rotors. The eigenvalues, the stability threshold, the response on the Heaviside-function and the unbalance response were calculated for a rigid rotor, a Jeffcott rotor and for the finite element model of a real rotor. The comparison of the linear and nonlinear calculations shows the limit of the linear calculations. The computation is supposed to show, that the model of the Jeffcott rotor is not sufficient in most practical cases to determine the stability threshold. This was known for some years, when computed results were compared with the behavior of real machines. That's why a program was developed, which is roughly described.

Kraemer, E.↗

NASA NTRS1992

Automatic detection of anomalies in Space Shuttle Main Engine turbopumps

A prototype expert system (developed on both PC and Symbolics 3670 lisp machine) for detecting anomalies in turbopump vibration data has been tested with data from ground tests 902-473, 902-501, 902-519, and 904-097 of the Space Shuttle Main Engine (SSME). The expert system has been utilized to analyze vibration data from each of the following SSME components: high-pressure oxidizer turbopump, high-pressure fuel turbopump, low-pressure fuel turbopump, and preburner boost pump. The expert system locates and classifies peaks in the power spectral density of each 0.4-sec window of steady-state data. Peaks representing the fundamental and harmonic frequencies of both shaft rotation and bearing cage rotation are identified by the expert system. Anomalies are then detected on the basis of sequential criteria and two threshold criteria set individually for the amplitude of each of these peaks: a prior threshold used during the first few windows of data in a test, and a posterior threshold used thereafter. In most cases the anomalies detected by the expert system agree with those reported by NASA. The two cases where there is significant disagreement will be further studied and the system design refined accordingly.

Lo, Ching F.↗

NASA NTRS2007

Design of Oil-Lubricated Machine for Life and Reliability

In the post-World War II era, the major technology drivers for improving the life, reliability, and performance of rolling-element bearings and gears have been the jet engine and the helicopter. By the late 1950s, most of the materials used for bearings and gears in the aerospace industry had been introduced into use. By the early 1960s, the life of most steels was increased over that experienced in the early 1940s, primarily by the introduction of vacuum degassing and vacuum melting processes in the late 1950s. The development of elastohydrodynamic (EHD) theory showed that most rolling bearings and gears have a thin film separating the contacting bodies during motion and it is that film which affects their lives. Computer programs modeling bearing and gear dynamics that incorporate probabilistic life prediction methods and EHD theory enable optimization of rotating machinery based on life and reliability. With improved manufacturing and processing, the potential improvement in bearing and gear life can be as much as 80 times that attainable in the early 1950s. The work presented summarizes the use of laboratory fatigue data for bearings and gears coupled with probabilistic life prediction and EHD theories to predict the life and reliability of a commercial turboprop gearbox. The resulting predictions are compared with field data.

Zaretsky, Erwin V.↗

NASA NTRS1990

Hybrid vision activities at NASA Johnson Space Center

NASA's Johnson Space Center in Houston, Texas, is active in several aspects of hybrid image processing. (The term hybrid image processing refers to a system that combines digital and photonic processing). The major thrusts are autonomous space operations such as planetary landing, servicing, and rendezvous and docking. By processing images in non-Cartesian geometries to achieve shift invariance to canonical distortions, researchers use certain aspects of the human visual system for machine vision. That technology flow is bidirectional; researchers are investigating the possible utility of video-rate coordinate transformations for human low-vision patients. Man-in-the-loop teleoperations are also supported by the use of video-rate image-coordinate transformations, as researchers plan to use bandwidth compression tailored to the varying spatial acuity of the human operator. Technological elements being developed in the program include upgraded spatial light modulators, real-time coordinate transformations in video imagery, synthetic filters that robustly allow estimation of object pose parameters, convolutionally blurred filters that have continuously selectable invariance to such image changes as magnification and rotation, and optimization of optical correlation done with spatial light modulators that have limited range and couple both phase and amplitude in their response.

Juday, Richard D.↗

NASA NTRS1986

The LATDYN user's manual

The LATDYN User's Manual presents the capabilities and instructions for the LATDYN (Large Angle Transient DYNamics) computer program. The LATDYN program is a tool for analyzing the controlled or uncontrolled dynamic transient behavior of interconnected deformable multi-body systems which can undergo large angular motions of each body relative other bodies. The program accommodates large structural deformation as well as large rigid body rotations and is applicable, but not limited to, the following areas: (1) development of large flexible space structures; (2) slewing of large space structure components; (3) mechanisms with rigid or elastic components; and (4) robotic manipulations of beam members. Presently the program is limited to two dimensional problems, but in many cases, three dimensional problems can be exactly or approximately reduced to two dimensions. The program uses convected finite elements to affect the large angular motions involved in the analysis. General geometry is permitted. Detailed user input and output specifications are provided and discussed with example runstreams. To date, LATDYN has been configured for CDC/NOS and DEC VAX/VMS machines. All coding is in ANSII-77 FORTRAN. Detailed instructions regarding interfaces with particular computer operating systems and file structures are provided.

Housner, J. M.↗