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At least 325 records · Page 18

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NASA NTRS1997

A New 1000 F Magnetic Bearing Test Rig

NASA and the Army are currently exploring the possibility of using magnetic bearings in gas turbine engines. The use of magnetic bearings in gas turbine engines could increase the reliability by eliminating the lubrication system. The use of magnetic bearings could also increase the speed and the size of the shafts in the engine, thus reducing vibrations and possibly eliminating third bearings. Magnetic bearings can apply forces to the shafts and move them so that blade tips and seals do not rub. This could be part of an active vibration cancellation system. Also, whirling (displacing the shaft center line) may delay rotating stall and increase the stall margin of the engine. Magnetic bearings coupled with an integral starter generator could result in a more efficient 'more electric' engine. The IHPTET program, a joint DOD-industry program, has identified a need for a high temperature, (as high as 1200 F), magnetic bearing that could be demonstrated in a phase m engine. A magnetic bearing is similar to an electric motor. The magnetic bearing has a laminated rotor and stator made out of cobalt steel. The stator has a series of coils of wire wound around it. These coils f u. a series of electromagnets around the circumference. These magnets exert a force on the rotor to keep the rotor in the center of the cavity. The centering force is commanded by a controller based on shaft position, (measured by displacement probes). The magnetic bearing can only pull and is basically unstable before active control is applied The engine shafts, bearings, and case form a flexible structure which contain a large number of modes. A controller is necessary to stabilize these modes. A power amplifier is also necessary to provide the current prescribed by the controller to the magnetic bearings. In case of very high loads, a conventional back up bearing will engage and stop the rotor and stator from rubbing.

Kascak, Albert F.↗

NASA NTRS2006

Stabilizing Gyroscopic Modes in Magnetic-Bearing-Supported Flywheels by Using Cross-Axis Proportional Gains

For magnetic-bearing-supported high-speed rotating machines with significant gyroscopic effects, it is necessary to stabilize forward and backward tilt whirling modes. Instability or low damping of these modes can prevent the attainment of desired shaft speed. We show analytically that both modes can be stabilized by using cross-axis proportional gains and high- and low-pass filters in the magnetic bearing controller. Furthermore, at high shaft speeds, where system phase lags degrade the stability of the forward-whirl mode, a phasor advance of the control signal can partially counteract the phase lag. In some range of high shaft speed, the derivative gain for the tilt modes (essential for stability for slowly rotating shafts) can be removed entirely. We show analytically how the tilt eigenvalues depend on shaft speed and on various controller feedback parameters.

Brown, Gerald V.↗

NASA NTRS2006

Space Shuttle Body Flap Actuator Bearing Testing for NASA Return to Flight

The Space Shuttle body flap (BF) is located beneath the main engine nozzles and is required for proper aerodynamic control during orbital descent. The body flap is controlled by four actuators connected by a common shaft and driven by the hydraulic power drive unit. Inspection of the actuators during refurbishment revealed three shaft bearings with unexpected damage. One was coated with black oxide on the balls and race wear surfaces, a second contained a relatively deep wear scar, and the third with scratches and an aluminum particle in the wear track. A shaft bearing life test program was initiated to measure the wear life and explain the 5.08-micrometer wear scar. A tribological analysis was conducted to demonstrate that the black oxide coated wear surfaces did not damage the bearing, interfere with the lubrication, or cause severe bearing wear. Pre-damaged (equivalent of 30 missions), commercial equivalent bearings and previously flown shaft bearings were tested at axial loads, speeds, and temperatures seen during flight operations. These bearing were successfully life tested at 60 C for 24 hours or 90 flights. With a safety factor of 4X, the bearings were qualified for 22 flights when only a maximum of 12 flights are expected. Additional testing at 23 C was performed to determine the lubricant life and to further understand the mechanism that caused the blackened balls. Test results indicating bearing life was shortened at a lower temperature surprised the investigators. Start\Stop bearing testing that closely simulates mission profile was conducted at 23 C. Results of this testing showed lubricant life of 12 flights including a safety factor of four. Additional testing with bearings that have the equivalent of 30 missions of damage is being tested at 23 C. These tests are being performed over the Shuttle load profile to demonstrate the residual bearing life in the actuators exceeds 12 missions. Testing showed that the end of the shaft bearing life was characterized by bearing temperature rise, preload drop, and the onset of a severe wear bearing failure mechanism. The severe wear failure mechanism is characterized by rough wear scars, extensive bearing wear and steel transfer between the balls and the races.

Jet, Timothy R.↗

NASA NTRS2006

Motor Controller System For Large Dynamic Range of Motor Operation

A motor controller system uses a rotary sensor with a plurality of signal conditioning units, coupled to the rotary sensor. Each of these units, which is associated with a particular range of motor output shaft rotation rates, generate a feedback signal indicative of the position of the motor s output shaft. A controller (i) converts a selected motor output shaft rotation rate to a corresponding incremental amount of rotational movement for a selected fixed time period, (ii) selects, at periodic completions of the selected fixed time period, the feedback signal from one of the signal conditioning units for which the particular range of motor output shaft rotation rates associated therewith encompasses the selected motor output shaft rotation rate, and (iii) generates a motor drive signal based on a difference between the incremental amount of rotational movement and the feedback signal from the selected one of the signal conditioning Units.

Howard, David E.↗

NASA NTRS1990

Magnetic translator bearings

A magnetic bearing system for enabling translational motion includes a carriage and a shaft for movably supporting the carriage; a first magnetic bearing fixed to one of the carriage and shaft and slidably received in a first channel of the other of the carriage and shaft. The first channel is generally U shaped with two side walls and a back wall. The magnetic bearing includes a pair of spaced magnetic pole pieces, each pole piece having a pair of electromagnetic coils mounted on poles on opposite ends of the pole piece proximate the side walls, and a third electromagnetic coil mounted on a pole of the pole piece proximate the backwall; a motion sensor for sensing translational motion along two axes and rotationally about three axes of the carriage and shaft relative to each other; and a correction circuit responsive to the sensor for generating a correction signal to drive the coils to compensate for any misalignment sensed between the carriage and the shaft.

Hockney, Richard L.↗

NASA NTRS1989

Digital to synchro converter

A digital-to-synchro converter is provided where a binary input code specifies a desired shaft angle and where an resolver type position transducer is employed with additional circuitry to generate a shaft position error signal indicative of the angular difference between the desired shaft angle and the actual shaft angle. The additional circuitry corrects for known and calculated errors in the shaft position detection process and equipment.

Predina, Joseph P.↗

NASA NTRS1989

Cylindrical surface profile and diameter measuring tool and method

A tool is shown having a cross beam assembly (15) made of beams (18, 19, 20, 21) joined by a center box structure (23). The assembly (15) is adapted to be mounted by brackets (16) to the outer end of a cylindrical case (11). The center box structure (23) has a vertical shaft (25) rotatably mounted therein and extending beneath the assembly (15). Secured to the vertical shaft (25) is a radius arm (28) which is adapted to rotate with shaft (25). On the longer end of the radius arm (28) is a measuring tip (30) which contacts the cylindrical surface to be measured and which provides an electric signal representing the radius of the cylindrical surface from the center of rotation of the radius arm (28). An electric servomotor (49) rotates the vertical shaft (25) and an electronic resolver (61) provides an electric signal representing the angle of rotation of the shaft (25). The electric signals are provided to a computer station (73) which has software for its computer to calculate and print out the continuous circumference profile of the cylindrical surface, and give its true diameter and the deviations from the ideal circle.

Currie, James R.↗

NASA NTRS2008

Torque Sensor Based on Tunnel-Diode Oscillator

A proposed torque sensor would be capable of operating over the temperature range from 1 to 400 K, whereas a typical commercially available torque sensor is limited to the narrower temperature range of 244 to 338 K. The design of this sensor would exploit the wide temperature range and other desirable attributes of differential transducers based on tunnel-diode oscillators as described in "Multiplexing Transducers Based on Tunnel-Diode Oscillators". The proposed torque sensor would include three flexural springs that would couple torque between a hollow outer drive shaft and a solid inner drive shaft. The torque would be deduced from the torsional relative deflection of the two shafts, which would be sensed via changes in capacitances of two capacitors defined by two electrodes attached to the inner shaft and a common middle electrode attached to the outer shaft.

Chui, Talso↗

NASA NTRS2008

Gimballed Shoulders for Friction Stir Welding

In a proposed improvement of tooling for friction stir welding, gimballed shoulders would supplant shoulders that, heretofore, have been fixedly aligned with pins. The proposal is especially relevant to self-reacting friction stir welding. Some definitions of terms, recapitulated from related prior NASA Tech Briefs articles, are prerequisite to a meaningful description of the proposed improvement. In friction stir welding, one uses a tool that includes (1) a rotating shoulder on top (or front) of the workpiece and (2) a pin that rotates with the shoulder and protrudes from the shoulder into the depth of the workpiece. In conventional friction stir welding, the main axial force exerted by the tool on the workpiece is reacted through a ridged backing anvil under (behind) the workpiece. When conventional friction stir welding is augmented with an auto-adjustable pin-tool (APT) capability, the depth of penetration of the pin into the workpiece is varied in real time by a position- or forcecontrol system that extends or retracts the pin as needed to obtain the desired effect. In self-reacting (also known as self-reacted) friction stir welding as practiced heretofore, there are two shoulders: one on top (or front) and one on the bottom (or back) of the workpiece. In this case, a threaded shaft protrudes from the tip of the pin to beyond the back surface of the workpiece. The back shoulder is held axially in place against tension by a nut on the threaded shaft. Both shoulders rotate with the pin and remain aligned coaxially with the pin. The main axial force exerted on the workpiece by the tool and front shoulder is reacted through the back shoulder and the threaded shaft into the friction-stir-welding machine head, so that a backing anvil is no longer needed. A key transmits torque between the bottom shoulder and the threaded shaft, so that the bottom shoulder rotates with the shaft. This concludes the prerequisite definitions of terms.

Carter, Robert↗

NASA NTRS2007

Tachometers Derived From a Brushless DC Motor

The upper part of the figure illustrates the major functional blocks of a direction-sensitive analog tachometer circuit based on the use of an unexcited two-phase brushless dc motor as a rotation transducer. The primary advantages of this circuit over many older tachometer circuits include the following: Its output inherently varies linearly with the rate of rotation of the shaft. Unlike some tachometer circuits that rely on differentiation of voltages with respect to time, this circuit relies on integration, which results in signals that are less noisy. There is no need for an additional shaft-angle sensor, nor is there any need to supply electrical excitation to a shaft-angle sensor. There is no need for mechanical brushes (which tend to act as sources of electrical noise). The underlying concept and electrical design are relatively simple. This circuit processes the back-electromagnetic force (back-emf) outputs of the two motor phases into a voltage directly proportional to the instantaneous rate (sign magnitude) of rotation of the shaft. The processing in this circuit effects a straightforward combination of mathematical operations leading to a final operation based on the well-known trigonometric identity (sin x)2 + (cos x)2 = 1 for any value of x. The principle of operation of this circuit is closely related to that of the tachometer circuit described in Tachometer Derived From Brushless Shaft-Angle Resolver (MFS-28845), NASA Tech Briefs, Vol. 19, No. 3 (March 1995), page 39. However, the present circuit is simpler in some respects because there is no need for sinusoidal excitation of shaftangle- resolver windings.

Howard, David E.↗

NASA NTRS2011

Miniature high speed compressor having embedded permanent magnet motor

A high speed centrifugal compressor for compressing fluids includes a permanent magnet synchronous motor (PMSM) having a hollow shaft, the being supported on its ends by ball bearing supports. A permanent magnet core is embedded inside the shaft. A stator with a winding is located radially outward of the shaft. The PMSM includes a rotor including at least one impeller secured to the shaft or integrated with the shaft as a single piece. The rotor is a high rigidity rotor providing a bending mode speed of at least 100,000 RPM which advantageously permits implementation of relatively low-cost ball bearing supports.

Zhou, Lei↗

NASA NTRS2006

Tool for Two Types of Friction Stir Welding

A tool that would be useable in both conventional and self-reacting friction stir welding (FSW) has been proposed. The tool would embody both a prior tooling concept for self-reacting FSW and an auto-adjustable pin-tool (APT) capability developed previously as an augmentation for conventional FSW. Some definitions of terms are prerequisite to a meaningful description of the proposed tool. In conventional FSW, depicted in Figure 1, one uses a tool that includes (1) a rotating shoulder on top (or front) of the workpiece and (2) a rotating pin that protrudes from the shoulder into the depth of the workpiece. The main axial force exerted by the tool on the workpiece is reacted through a ridged backing anvil under (behind) the workpiece. When conventional FSW is augmented with an APT capability, the depth of penetration of the pin into the workpiece is varied in real time by a position- or force-control system that extends or retracts the pin as needed to obtain the desired effect. In self-reacting (also known as self-reacted) friction stir welding (SR-FSW), there are two rotating shoulders: one on top (or front) and one on the bottom (or back) of the workpiece. In this case, a threaded shaft protrudes from the tip of the pin to beyond the back surface of the workpiece. The back shoulder is held axially in place against tension by a nut on the threaded shaft. The main axial force exerted on the workpiece by the tool and front shoulder is reacted through the back shoulder and the threaded shaft, back into the FSW machine head, so that a backing anvil is no longer needed. A key transmits torque between the bottom shoulder and the threaded shaft, so that the bottom shoulder rotates with the shaft. A tool for SRFSW embodying this concept was reported in "Mechanism for Self-Reacted Friction Stir Welding" (MFS-31914), NASA Tech Briefs, Vol. 28, No. 10 (October 2004), page 53. In its outward appearance, the proposed tool (see Figure 2) would fit the above description of an SR-FSW tool. In this case, the FSW machine would have an APT capability and the pin would be modified to accept a bottom shoulder. The APT capability could be used to vary the distance between the front and back shoulders in real time to accommodate process and workpiece-thickness variations. The tool could readily be converted to a conventional FSW tool, with or without APT capability, by simply replacing the modified pin with a conventional FSW pin.

Carter, Robert↗

NASA NTRS2014

Engine Power Turbine and Propulsion Pod Arrangement Study

A study has been conducted for NASA Glenn Research Center under contract NNC10BA05B, Task NNC11TA80T to identify beneficial arrangements of the turboshaft engine, transmissions and related systems within the propulsion pod nacelle of NASA's Large Civil Tilt-Rotor 2nd iteration (LCTR2) vehicle. Propulsion pod layouts were used to investigate potential advantages, disadvantages, as well as constraints of various arrangements assuming front or aft shafted engines. Results from previous NASA LCTR2 propulsion system studies and tasks performed by Boeing under NASA contracts are used as the basis for this study. This configuration consists of two Fixed Geometry Variable Speed Power Turbine Engines and related drive and rotor systems (per nacelle) arranged in tilting nacelles near the wing tip. Entry-into-service (EIS) 2035 technology is assumed for both the engine and drive systems. The variable speed rotor system changes from 100 percent speed for hover to 54 percent speed for cruise by the means of a two speed gearbox concept developed under previous NASA contracts. Propulsion and drive system configurations that resulted in minimum vehicle gross weight were identified in previous work and used here. Results reported in this study illustrate that a forward shafted engine has a slight weight benefit over an aft shafted engine for the LCTR2 vehicle. Although the aft shafted engines provide a more controlled and centered CG (between hover and cruise), the length of the long rotor shaft and complicated engine exhaust arrangement outweighed the potential benefits. A Multi-Disciplinary Analysis and Optimization (MDAO) approach for transmission sizing was also explored for this study. This tool offers quick analysis of gear loads, bearing lives, efficiencies, etc., through use of commercially available RomaxDESIGNER software. The goal was to create quick methods to explore various concept models. The output results from RomaxDESIGNER have been successfully linked to Boeing spreadsheets that generate gear tooth geometry in Catia 3D environment. Another initial goal was to link information from RomaxDESIGNER (such as hp, rpm, gear ratio) to populate Boeing's parametric weight spreadsheet and create an automated method to estimate drive system weight. This was only partially achieved due to the variety of weight models, number of manual inputs, and qualitative assessments required. A simplified weight spreadsheet was used with data inputs from RomaxDESIGNER along with manual inputs to perform rough weight calculations.

Robuck, Mark↗

NASA NTRS2019

A Control Strategy for Turbine Electrified Energy Management

Hybrid electric propulsion architectures provide the infrastructure to enable additional benefits to the propulsion system that are otherwise unrealizable with the sole use of the current, state-of-the-art, gas-driven, turbine engines. The presence of electric machines (EMs) coupled to the shaft(s) of the turbine engine provide the ability to actively alter the operation of the engine to the benefit of the propulsion system and the aircraft it propels. This is the goal of the Turbine Electrified Energy Management (TEEM) concept, which at its broadest level addresses the management of energy across the electrified propulsion system. Prior work has demonstrated the use of this concept to alter steady-state operation and improve transient operability of a hybrid-electric propulsion system. The main benefits previously illustrated include the elimination of stability bleeds and expansion of the turbomachinery design space in order to enable more efficient designs. This paper focuses on the development of control strategies to implement the TEEM concept, and it explores several possible architecture variants for applying this concept. Comparison studies are conducted between a purely gas-driven turbofan (baseline engine configuration) and TEEM augmented variants of the baseline engine. The variants are distinguished by the shaft(s) that possess an EM. The configurations consider EMs on both shafts, an EM on the high pressure spool (HPS) only, and an EM on the low pressure spool (LPS) only. These configurations are referred to as the dual-spool configuration, the HPS configuration, and LPS configuration, respectively. The studies expose several options in configuring and controlling the system, including the use of a single EM coupled to a single shaft of a two-spool engine to positively impact the operability of both shafts. The studies also demonstrate the use of independently designed controllers for the electric machine(s) that allow for a decoupled control design process.

Electrified↗

NASA NTRS2019

A Control Strategy for Turbine Electrified Energy Management

Energy management↗

NASA NTRS1972

Adjustable locking device

Adjustable locking device is used for taking up end play of shaft without displacing shaft radially. Coincidentally threaded collars fastened to one or both ends of shaft are threaded in and out of one another for adjustment of end play. Intrinsic feature is its ability to be locked in any translatory position without axial displacement of shaft.

Fincannon, O. J.↗

NASA NTRS1970

Design of aircraft turbine fan drive gear transmission system

The following basic types of gear reduction concepts were studied as being feasible power train systems for a low-bypass-ratio, single-spool, geared turbofan engine for general aircraft use: (1) single-stage external-internal reduction, (2) gears (offset shafting), (3) multiple compound idler gear system (concentric shafting), and (4) star gear planetary system with internal ring gear final output member (concentric shafting-counterrotation). In addition, studies were made of taking the accessories drive power off both the high-speed and low-speed shafting, using either face gears or spiral bevel gears. Both antifriction and sleeve-type bearings were considered for the external-internal and star-planet reduction concepts.

Dent, E.↗

NASA NTRS1973

Test stand system for vacuum chambers

A test stand system for supporting test items in a vacuum chamber is described. The system consists of a frame adapted to conform to the inside of the vacuum chamber and supporting a central vertical shaft. The shaft rotates on bearings located at each end of the shaft. Several vertically spaced plates which fixed to the vertical shaft may be adjusted for height to support the test equipment as required. The test equipment may be rotated during tests without disturbing the vacuum by a manually actuated drive external to the vacuum chamber.

Newman, D. F.↗