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Two companion reports deal with design considerations for improving performance of mechanical face seals, one of family of devices used in general area of fluid sealing of rotating shafts. One report deals with basic seal configuration and other with lubrication of seal.
Sound engineering practice requires that fasteners and bolted joints maintain preload in service. NASA recently concluded a series of vibration tests of a multicomponent structure intended to simulate an upper stage section of a launch vehicle. The stacked components were joined through six circumferentially placed bolted cup-cone-style pyrotechnic joint mechanisms designed to share spacecraft structural loads and then enable separation during ascent. Over the course of the vibration test campaign, all six bolted cup-cone mechanisms experienced some degree of preload loss with two mechanisms losing half of their original bolt preload. A subsequent forensic anomaly investigation concluded that vibration-induced unwinding of the preload nut-and-bolt assemblies occurred despite the use of safety wire and high levels of thread friction. A series of experiments were done to better understand how large, heavily preloaded fasteners could unwind. Additionally, thread friction torque was measured and the fastener locking capability of safety wire was evaluated. The friction coefficient between the clamped cup-cone components was characterized and finally a highly instrumented mechanism-level vibration test was done to reproduce the unwinding phenomenon to better understand the mechanism's behavior. The conclusion drawn was that vibration and structural forces led to relative motion (sliding) of the clamped components, resulting in self-loosening and unwinding effects on the nut-and-bolt assembly. To counter this phenomenon, more effective fastener locking methodologies were recommended and a follow-on effort was initiated to quantify the relationship between preload, component motion, and resulting unwinding forces. It is hoped that elucidation of these effects can be used to design more effective fastener locking features.
The goal of these efforts was the development of an ultra-low emissions, lean-burn combustor for the High Speed Civil Transport. The HSCT Mach 2.4 FLADE C1 Cycle was selected as the baseline engine cycle. A preliminary compilation of performance requirements for the HSCT combustor system was developed. The emissions goals of the program, baseline engine cycle, and standard combustor performance requirements were considered in developing the compilation of performance requirements. Seven combustor system designs were developed. The development of these system designs was facilitated by the use of spreadsheet-type models which predicted performance of the combustor systems over the entire flight envelope of the HSCT. A chemical kinetic model was developed for an LPP combustor and employed to study NO(x) formation kinetics, and CO burnout. These predictions helped to define the combustor residence time. Five fuel-air mixer concepts were analyzed for use in the combustor system designs. One of the seven system designs, one using the Swirl-Jet and Cyclone Swirler fuel-air mixers, was selected for a preliminary mechanical design study.
The figure presents a cross-sectional view of a supercharged, variable-compression, two-cycle, internal-combustion engine that offers significant advantages over prior such engines. The improvements are embodied in a combination of design changes that contribute synergistically to improvements in performance and economy. Although the combination of design changes and the principles underlying them are complex, one of the main effects of the changes on the overall engine design is reduced (relative to prior two-cycle designs) mechanical complexity, which translates directly to reduced manufacturing cost and increased reliability. Other benefits include increases in the efficiency of both scavenging and supercharging. The improvements retain the simplicity and other advantages of two-cycle engines while affording increases in volumetric efficiency and performance across a wide range of operating conditions that, heretofore have been accessible to four-cycle engines but not to conventionally scavenged two-cycle ones, thereby increasing the range of usefulness of the two-cycle engine into all areas now dominated by the four-cycle engine. The design changes and benefits are too numerous to describe here in detail, but it is possible to summarize the major improvements: Reciprocating Shuttle Inlet Valve The entire reciprocating shuttle inlet valve and its operating gear is constructed as a single member. The shuttle valve is actuated in a lost-motion arrangement in which, at the ends of its stroke, projections on the shuttle valve come to rest against abutments at the ends of grooves in a piston skirt. This shuttle-valve design obviates the customary complex valve mechanism, actuated from an engine crankshaft or camshaft, yet it is effective with every type of two-cycle engine, from small high-speed single cylinder model engines, to large low-speed multiple cylinder engines.
The design and preliminary test results for the spectropolarimeter for the Faint Object Spectrograph (FOS) for the Space Telescope are presented. The mechanical design and optical specifications of the spectropolarimeter are described noting that a Wollaston prism with an internal wedge angle of 20 deg is fixed behind each of two rotatable waveplate retarders of different retardations. Either waveplate/prism combination can be positioned at either of the two FOS entrance ports. Magnesium fluoride is chosen as the birefringent crystal for the polarizing elements to allow linear and circular polarization measurements down to Lyman-alpha at 1216 A. Mechanical stability and repeatability were determined by operational testing to give polarization-position angles of + or - 0.5 deg, corresponding to degree-of-polarization measurements of + or - 0.1 percent. Faint-object accuracy, dependent on photoelectron statistics and hence on observation time, is calculated to be one percent in each 100-A-wide spectral band for a 20-min observation of an AO star with V = 15th magnitude.
Summaries are given of design characteristics and various advantages of FCC use. The information is presented in tables that include the following headings: (1) mechanical design, (2) electrical design, (3) manufacturing advantages, (4) inspection and reliability, and (5) cost savings. In addition, the results are summarized of a Saturn 4B FCC-RWC comparison study.
The development of an advanced-design black-and-white solid-state television camera which can survive exposure to space environmental conditions was undertaken. A 380 x 488 element buried-channel CCD is utilized as the image sensor to ensure compatibility with 525-line transmission and display equipment. Specific camera design approaches selected for study and analysis included: (1) component and circuit sensitivity to temperature; (2) circuit board thermal and mechanical design; and (3) CCD temperature control. Preferred approaches were determined and integrated into the final design for two deliverable solid-state TV cameras. One of these cameras was subjected to environmental tests to determine stress limits for exposure to vibration, shock, acceleration, and temperature-vacuum conditions. These tests indicate performance at the design goal limits can be achieved for most of the specified conditions.
NASA Glenn initiated a satellite propellant pump technology demonstration program. The goal was to demonstrate the technologies for a 60 percent efficient pump at 1 gpm flow rate and 500 psia pressure rise. The pump design and analysis used the in-house developed computer codes named PUMPA and HPUMP3D. The requirements lead to a 4-stage impeller type pump design with a tip diameter of 0.54 inches and a rotational speed of 57,000 rpm. Analyses indicated that flow cavitation was not a problem in the design. Since the flow was incompressible, the stages were identical. Only the 2-stage pump was designed, fabricated, assembled, and tested for demonstration. Water was selected as the surrogate fluid for hydrazine in this program. Complete mechanical design including stress and dynamic analyses were conducted. The pump was driven by an electric motor directly coupled to the impellers. Runs up to 57,000 rpm were conducted, where a pressure rise of 200 psia at a flow rate of 0.8 gpm was measured to validate the design effort.
Design considerations for mechanical configuration of Mariner Mars 1964 spacecraft
Design, fabrication and test of partially populated prototype recorder using 100 kilobit serial chips is described. Electrical interface, operating modes, and mechanical design of several module configurations are discussed. Fabrication and test of the module demonstrated the practicality of multiplexing resulting in lower power, weight, and volume. This effort resulted in the completion of a module consisting of a fully engineered printed circuit storage board populated with 5 of 8 possible cells and a wire wrapped electronics board. Interface of the module is 16 bits parallel at a maximum of 1.33 megabits per second data rate on either of two interface buses.
We propose a new facility instrument, the Airborne Infrared Echelle Spectrometer or 'AIRES'. The scientific rationale, a preliminary optical and mechanical design, and the instrument's estimated performance are presented. Some of the major technical challenges are discussed.
In pursuit of an acoustically acceptable, high performance exhaust system capable of meeting Federal Aviation Regulation 36 Stage 3 noise goals for the High Speed Civil Transport application, General Electric Aircraft Engines conducted a design study to incorporate a fluid shield into a 36-chute suppressor exhaust-nozzle system. After a full scale preliminary mechanical design of the resulting fluid shield exhaust system, scale model aerodynamic performance tests and acoustic tests were conducted to establish both aerodynamic performance and acoustic characteristics. Data are presented as thrust coefficients, discharge coefficients, chute-base pressure drags, and plug static pressure distributions.
The gamma-ray Large Area Telescope (GLAST) with LAT as its main instrument is now in the final stage of integration into the spacecraft and is scheduled for launch in November 2007. The Anti-Coincidence Detector (ACD) is one of the key telescope systems, providing much of the charged particle background rejection. Taking into account the required large ACD detecting area (more than 8 sq m) and high efficiency of relativistic single charged particle detection (greater than 0.9997 over the entire ACD area), the design was very challenging. It included the choice of conceptual design, extensive Monte Carlo simulations and trade-offs of the experimental techniques, supported by numerous bench tests, custom electronics, careful mechanical design and extensive mechanical/environmental tests, precision fabrication and finally the decisive step- final integration and system-level tests. Currently the LAT (with ACD integrated) is integrated into the spacecraft and undergoing the numerous spacecraft-level tests
The dynamic properties at various temperatures of braids impregnated with polymer can be measured by using the braid as the suspension of a torsion pendulum. This report describes the electronic and mechanical design of a torsional braid pendulum displacement transducer which is an advance in the state of the art. The transducer uses a unique optical design consisting of refracting quartz windows used in conjunction with a differential photocell to produce a null signal. The release mechanism for initiating free torsional oscillation of the pendulum has also been improved. Analysis of the precision and accuracy of the transducer indicated that the maximum relative error in measuring torsional amplitude was approximately 0. A serious problem inherent in all instruments which use a torsional suspension was analyzed: misalignment of the physical and torsional axes of the torsional member which results in modulation of the amplitude of the free oscillation.
A mast vibration damping system was developed for the Shuttle Radar Topography mission. The damping system development is considered from both a system perspective, and a detailed mechanism design viewpoint.
A high resolution, long life angle-encoded scanning mirror, built for application in an infrared attitude sensor, is described. The mirror uses a Moire' fringe type optical encoder and unique torsion bar suspension together with a magnetic drive to meet stringent operational and environmental requirements at a minimum weight and with minimum power consumption. Details of the specifications, design, and construction are presented with an analysis of the mirror suspension that allows accurate prediction of performance. The emphasis is on mechanical design considerations, and brief discussions are included on the encoder and magnetic drive to provide a complete view of the mirror system and its capabilities.
The design and economic evaluation of a low cost high temperature two axis sun tracking solar energy collector are described. The collector design is specifically intended for solar energy use with the freedom of motion about its two control axes being limited only to the amplitude required to track the sun. An examination of the performance criteria required in order to track the sun and perform the desired solar energy conversion is used as the starting point and guide to the design. This factor, along with its general configuration and structural aspect ratios, is the significant contributor to achieving low cost. The unique mechanical design allows the control system to counter wide tolerances that will be specified for the fabrication of the azimuth frame and perform within a small tracking error.
The design and economic evaluation of a low cost high temperature two-axis, sun tracking solar energy collector is described. The collector design was specifically intended for solar energy use with the freedom of motion about its two control axes limited only to the amplitude required to track the sun. An examination of the performance criteria required in order to track the sun and perform the desired solar energy conversion was used as the starting point and guide to the design. This factor, along with its general configuration and structural aspect ratios, was the significant contributor to achieving low cost. The unique mechanical design allowed the control system to counter wide tolerances specified for the fabrication of the azimuth frame and to perform within a small tracking error.