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All sourcesNASA NTRSDOE OSTI
NASA NTRSDate not supplied

An Initial Vibro-Acoustic Model for Predicting Electric Motor Noise

A system-level tool to predict electric motor noise, suitable for trade studies of eVTOL and UAM aircraft, does not exist. This work describes the ongoing effort to develop such a tool. It utilizes a 3 phase prediction routine that models the electro-magnetic interactions of the electric motor, the resulting structural vibrations of the motor rotor, and finally the acoustic propagation generated by those structural vibrations.

Electric Motor Noise↗
NASA NTRS2005

Modal Survey of ETM-3, A 5-Segment Derivative of the Space Shuttle Solid Rocket Booster

The complex interactions between internal motor generated pressure oscillations and motor structural vibration modes associated with the static test configuration of a Reusable Solid Rocket Motor have potential to generate significant dynamic thrust loads in the 5-segment configuration (Engineering Test Motor 3). Finite element model load predictions for worst-case conditions were generated based on extrapolation of a previously correlated 4-segment motor model. A modal survey was performed on the largest rocket motor to date, Engineering Test Motor #3 (ETM-3), to provide data for finite element model correlation and validation of model generated design loads. The modal survey preparation included pretest analyses to determine an efficient analysis set selection using the Effective Independence Method and test simulations to assure critical test stand component loads did not exceed design limits. Historical Reusable Solid Rocket Motor modal testing, ETM-3 test analysis model development and pre-test loads analyses, as well as test execution, and a comparison of results to pre-test predictions are discussed.

Nielsen, D.↗
NASA NTRSDate not supplied

Progress on Electric Motor Noise Modeling

Progress toward the development of a motor noise model for system type studies is presented. The presentation focuses on efforts to model the motor shell vibrations and the resulting acoustic radiation. Finite element and experimental modal analysis results for a 4 kW motor are presented and compared. An analytical model for the acoustic radiation is presented.

Urban Air Mobility↗
NASA NTRS2002

Observer-Based Magnetic Bearing Controller Developed for Aerospace Flywheels

A prototype of a versatile, observer-based magnetic bearing controller for aerospace flywheels was successfully developed and demonstrated on a magnetic bearing test rig (see the photograph) and an actual flywheel module. The objective of this development included a fast, yet low risk, control development process, and a robust, high-performance controller for a large variety of flywheels. This required a good system model, an efficient development procedure, and a model-based controller that addressed the key problems associated with flywheel and bearing imbalance, sensor error, and vibration. The model used in this control development and tuning procedure included the flexible rotor dynamics and motor-induced vibrations. Such a model was essential for low-risk scheduling of speed-dependent control parameters and for reliable evaluation of novel control strategies. The successfully tested control prototype utilized an extended Kalman filter to estimate the true rotor principal-axis motion from the raw sensor position feedback. For control refinement, the extended Kalman filter also estimated and eliminated the combined effects of mass-imbalance and sensor runouts from the input data. A key advantage of the design based on the extended Kalman filter is its ability to accurately estimate both the rotor's principal-axis position and gyroscopic rates with the least amount of phase lag. This is important for control parameter scheduling to dampen the gyroscopic motions. Because of large uncertainties in the magnetic bearing and imbalance characteristics, this state-estimation scheme alone is insufficient for containing the rotor motion within the desired 1-mil excursion radius. A nonlinear gain adjustment based on an estimation of the principal-axis orbit size was needed to provide a coarse (nonoptimal), but robust, control of the orbit growth. Control current minimization was achieved with a (steepest gradient) search of synchronous errors in the principal-axis position input data. Actual flywheel tests of this observer-based controller (developed entirely in-house) at the NASA Glenn Research Center showed that the model correctly predicted the rotor orbit growth as a function of rotational speed, and it demonstrated the capability of gain adjustments to arrest this growth. Data from these tests on an actual flywheel module spun to 26,000 rpm proved that the controller was able to contain the shaft motion to within much less than 0.5 mils of radial excursion with axis currents less than 300 mA in root-mean-square estimate. The test speed range was limited because of thermal expansion concerns for this particular flywheel unit, not because of any deficiency in the controller. Simulations for this unit indicated that the controller should be robust up to its top operating speed of 60,000 rpm. Aside from these important achievements, and most significantly, it took less than 1 week to adapt this controller from the simple test rig to the actual flywheel and to demonstrate full five-axis levitation and control. This demonstration showed that both the controller and the model-based development and tuning framework are easily adaptable to a wide range of rotors and bearing configurations and, hence, are capable of reducing design risks and costs for many future flywheel technology developments.

Le, Dzu K.↗
NASA NTRS1972

Effects of experimentally measured pressure oscillations on the vibration of a solid rocket motor

Results are presented of firing a Nike rocket against a backstop for the purpose of obtaining pressure fluctuations in the rocket case and determining their relationship to structural vibrations of the case. Special care was required to obtain these pressure fluctuations because of the much higher static pressure generated in the rocket. Very small pressure fluctuations within the rocket case can cause significant vibration levels. A previously observed high frequency was shown to decrease with time before completely disappearing at about 1 second of burning time. The vibration of the case itself is probably related to the longitudinal structural modes at frequencies below 500 Hz and is dependent on local structural conditions at frequencies above this value.

Schoenster, J. A.↗
NASA NTRSDate not supplied

Vertical Lunar Regolith Conveying as a Flight Experiment in Simulated Lunar-Gravity

Regolith conveying will be an essential task for supplying regolith feedstock to In-Situ Resource Utilization (ISRU) reactor systems for regolith processing on the Moon and Mars. The Vertical Lunar Regolith Conveyor (VLRC) is a technology being developed at NASA Kennedy Space Center (KSC) as a regolith transport task for the GCD ISRU FLEET project led by NASA Glenn Research Center (GRC). Single test loop versions of the VLRC are being developed at NASA KSC as a technology demonstration for a flight experiment. The NASA Flight Opportunities program selected the VLRC for a technology demonstration opportunity on a future Blue Origin New Shepard suborbital launch vehicle to study regolith transport physics in a relevant environment in a vacuum chamber under simulated lunar gravity conditions in order to advance its technology readiness level (TRL) for future space applications. The VLRC system includes four primary subsystems to achieve the objectives of the lunar gravity (Lunar-G) flight experiment. (1) An eccentric vibratory conveyor stack to convey regolith particles consisting of three single-loop helical surface conveyors with each actuated by two vibratory motors that vibrate in unison. One of the three single-loops contains a 0.8°-3.1° inclined helical path and the other two contain a 1.6°-6.2° incline. (2) A stick-slip conveyor stack to convey regolith particles consisting of three single-loop helical surface conveyors with each actuated by the same motor to move in unison in a stick-slip motion. One of the three single-loops contains a 0.8°-3.1° inclined helical path and the other two contain a 1.6°-6.2° incline. (3) A regolith containment system to contain the regolith in each single-loop track during launch before the start of the experiment using containment caps that will be lifted in unison at the start of Lunar-G. (4) COTS cameras will record the motion of regolith and tracer particles. Post-flight analysis of the videos will be used to determine convey speeds and flow rates. The VLRC experiment will use the well-known technique of Particle Image Velocimetry (PIV) image analysis to determine the velocity of tracer particles entrained in the regolith flow. This velocity will be used to calculate the mass flow rate of the regolith being conveyed.

ISRU↗
NASA NTRSDate not supplied

Surface Vibration Measurement and Analysis for UAM/UAS Electric Motor Noise

Urban Air Mobility vehicles are an emerging class of vertical lift vehicles using electric motors to drive multiple rotors for lift. The outrunner electric motors that are commonly used, may be capable of generating noise that could contribute to the vehicle’s overall noise profile and could generate cabin noise. Understanding and predicting the noise requires more knowledge of the rotor vibrations and eventually a model to predict the frequencies of those vibrations. This work presents a measurement of the rotor vibrations of two different small-scale motors. Two techniques to measure the surface vibration were used. The displacement spectra are compared with acoustic measurements. A finite element analysis model is used to predict the rotor resonance frequencies. The predicted frequencies are in fair agreement with the experimentally observed vibration frequencies, but requires further work to understand discrepancies.

Electric Motor Noise↗
NASA NTRS1973

Design assurance test of the Thiokol Te-M-521-5 apogee kick motor tested in the spin mode at simulated altitude conditions

One Thiokol Chemical Corporation TE-M-521-5 solid-propellant apogee rocket motor was successfully fired at an average simulated altitude of about 108,000 ft while spinning at 46 rpm. The general program objectives were to verify compliance of motor performance with the manufacturer's specifications. Specific primary objectives were to determine vacuum ballistic performance of the motor after prefire vibration conditioning and temperature conditioning at 40F, altitude ignition characteristics, motor structural integrity, and motor temperature-time history during and after motor operation. Additional objectives were to measure the lateral (nonaxial) thrust component during motor operation and to measure radiation heat flux in the vicinity of the nozzle exit plane.

Cimino, A. A.↗
NASA NTRS2012

Implementation of a Non-Metallic Barrier in an Electric Motor

Electric motors that run in pure oxygen must be sealed, or "canned," for safety reasons to prevent the oxygen from entering into the electrical portion of the motor. The current canning process involves designing a metallic barrier around the rotor to provide the separation. This metallic barrier reduces the motor efficiency as speed is increased. In higher-speed electric motors, efficiency is greatly improved if a very thin, nonmetallic barrier can be utilized. The barrier thickness needs to be approximately 0.025-in. (.0.6-mm) thick and can be made of a brittle material such as glass. The motors, however, designed for space applications are typically subject to high-vibration environments. A fragile, non-metallic barrier can be utilized in a motor assembly if held in place by a set of standard rubber O-ring seals. The O-rings provide the necessary sealing to keep oxygen away from the electrical portion of the motor and also isolate the fragile barrier from the harsh motor vibration environment. The compliance of the rubber O-rings gently constrains the fragile barrier and isolates it from the harsh external motor environment. The use of a non-metallic barrier greatly improves motor performance, especially at higher speeds, while isolating the electronics from the working fluid with an inert liner.

M?Sadoques, George↗
NASA NTRS2004

Smart Structures for Vibration Control on Long-Term Space Exploration and Habitation Missions

The current vision for space exploration focuses on human missions to the Moon, Mars, and beyond. To support these goals, it is certain that new vehicles and intermediate bases will be developed, whether that means simply re-direction of the ISS as a "mission research facility" or construction of a lunar base. Since these facilities are expected to be constructed from inherently light-weight materials, this work examines some of the potential sources of vibration and noise as well as means for controlling these vibrations. Many of the operating components within these facilities, such as pumps, fans, and motors, will produce vibrations during operation. These vibrations become structure in which they are housed. Resonances can impact acoustic noise levels and noise quality within the environment, possibly affecting crew health and productivity. For long-term missions in particular, it is expected that crew members will spend significant portions of their time restrained in the structure, such as in seats. As a result, the general health and well-being of the crew can be improved by limiting the harmful effects of human exposure to long-term audible and tactile vibration input. Besides the human factor, this work also examines some operational considerations in which vibrations play an important role. Vibrations can impact the environment for science and in-situ manufacturing research within these vehicles. Since a benign vibratory environment is beneficial for most types of science experiments, there is a need for various forms of vibration control. Because the operational characteristics of a vehicle can change during a long-term mission, it is further expected that the characteristics of many of the vibratory excitations will change with time. Consequently, the form of vibration control needed to improve overall habitability and usefulness of the vehicle or element for exploration missions will rely to some degree on the vibration control system's ability to adapt. To address these needs, this work also examines the development and use of smart materials to tune the dynamic characteristics of the structure in a passive sense. One prime example is the use of an adaptive electrical shunt connected to a piezoelectric patch in order to provide tuned passive vibration damping. The work also examines the use of active vibration control, such as by applying power to that same piezoelectric patch. The overall goal is to examine the use of smart structures that can react to the environment thereby improving the overall living, working, and learning environment for these long-term missions.

Gattis, Christy B.↗
NASA NTRS1990

Inertia-Wheel Vibration-Damping System

Proposed electromechanical system would damp vibrations in large, flexible structure. In active vibration-damping system motors and reaction wheels at tips of appendages apply reaction torques in response to signals from accelerometers. Velocity signal for vibrations about one axis processes into control signal to oppose each of n vibrational modes. Various modes suppressed one at a time. Intended primarily for use in spacecraft that has large, flexible solar panels and science-instrument truss assembly, embodies principle of control interesting in its own right and adaptable to terrestrial structures, vehicles, and instrument platforms.

Fedor, Joseph V.↗
NASA NTRS1996

Finite-Element Vibration Analysis and Modal Testing of Graphite Epoxy Tubes and Correlation Between the Data

Structural materials in the form of graphite epoxy composites with embedded rubber layers are being used to reduce vibrations in rocket motor tubes. Four filament-wound, graphite epoxy tubes were studied to evaluate the effects of the rubber layer on the modal parameters (natural vibration frequencies, damping, and mode shapes). Tube 1 contained six alternating layers of 30-degree helical wraps and 90-degree hoop wraps. Tube 2 was identical to tube 1 with the addition of an embedded 0.030-inch-thick rubber layer. Tubes 3 and 4 were identical to tubes 1 and 2, respectively, with the addition of a Textron Kelpoxy elastomer. This report compares experimental modal parameters obtained by impact testing with analytical modal parameters obtained by NASTRAN finite-element analysis. Four test modes of tube 1 and five test modes of tube 3 correlate highly with corresponding analytical predictions. Unsatisfactory correlation of test and analysis results occurred for tubes 2 and 4 and these comparisons are not shown. Work is underway to improve the analytical models of these tubes. Test results clearly show that the embedded rubber layers significantly increase structural modal damping as well as decrease natural vibration frequencies.

Taleghani, Barmac K.↗
NASA NTRS1980

Prediction of finite pressure oscillations in stable rocket motors

A methodology is outlined for predicting the amplitude of forced vibrations in the acoustic cavity of a solid rocket motor. The equation for forced vibration of the motor cavity acoustic system is written by parallel with the acoustic mechanical analogy. Acoustic and aeroacoustic theory are used to predict the frequency and intensity of vortex systems or turbulence created by passage of the mean flow over geometric discontinuities in the motor port. Approximate methods are presented for coupling the acoustic field due to the flow noise with the chamber acoustics and for summing the effect upon the multiple acoustic modes.

Hessler, R. O.↗
NASA NTRS2004

The Morrison Bearingless Switched Reluctance Motor

Switched reluctance motors typically consist of pairs of poles protruding outward from a central rotor, surrounded by pairs of coils protruding inward from a stator. The pairs of coils, positioned a short distance from opposing sides of the rotor, are connected in series. A current runs through the coils, generating a magnetic flux between the coils. This attracts the protruding poles on the rotor, and just as the poles on the rotor approach the coils, the current to the coils is inverted, repelling the rotor s poles as they pass the coils. This current switching, back and forth, provides a continuous rotational torque to the rotor. reliability, durability, low cost, and operation in adverse environments such as high temperatures, extreme temperature variations, and high rotational speeds. However, because rotors are often manufactured with minute flaws due to imperfections in the machining process, traditional switched reluctance motors often suffer from substantial amounts of vibration. In addition, the current in the coils imparts a strong radial magnetic force on the rotor; the continuous alternating of the direction of this force also causes vibration. As a result, switched reluctance motors require bearings that, run at high speeds, can require lubrication apparatus and are subject to problems with heat and wear. My mentor s recent invention, the "Bearingless" Switched Reluctance Motor, actually uses magnetic bearings instead of traditional physical bearings. Sensors are used to continuously determine the position of the rotor. A computer reads the position sensor input, performs calculations, and outputs a current to a set of extra coils (in addition to the coils rotating the rotor). This current provides a magnetic force that counters and damps the vibration. The sense-calculate-update loop iterates more than thirty thousand times per second. For now, our goal is to have the rotor rotate at about 6000 rprn, and at that speed, the magnetic bearing is adjusting the rotor s position more than 300 times per rotation. and vibration-suppression capacity for the switched reluctance motor. Traditional switched reluctance motors possess many positive traits, including It is hoped that this new invention will increase load-carrying capacity, stiffness, and vibration-suppression capacity for the switched reluctance motor.

Wong, David S.↗
NASA NTRS1996

Pressure Oscillations in Shuttle Solid Rocket Motors

All Shuttle Solid Rocket Motors (SRM's) exhibit low amplitude longitudinal pressure oscillations during motor burn. Although the oscillations have no known deleterious effect on motor ballistics, the acoustic pressure variations cause thrust oscillations that might affect Shuttle systems or components. The acoustic mode of greatest interest is the first or fundamental mode which, in the SRM, has a nominal frequency of 14-Hz. Oscillations in the SRM are believed to be caused by coupling between large scale vortices and the acoustic modes of the motor chamber. The vortices are thought to be created in the region of the motor segment interfaces and are inherent in the design of the motor. In such a situation the usual approach is to measure the oscillations and assess their impact on any sensitive components through tests and analysis. Questionable components can be altered to survive the vibration environment. As motor firings occur, oscillations are monitored to determine whether there are changes in the nature of the oscillations. Since the first static test, SRM's have been equipped with instrumentation especially designed to acquire chamber pressure oscillation data. Data from the first SRM static tests were used to establish predicted upper bounds for the maximum amplitudes in the latter half of burn. Those bounds have been used as a basis for worst-case simulation scenarios by specialists in structural dynamics at NASA and Rockwell International and to provide a basis for evaluating data from individual motors which were tested subsequent to the original SRM's. This paper updates the upper bounds prediction the High Performance Motors (HPM) by including data from all static tests performed to date including both original SRM's and post Challenger SRM's or Reusable Solid Rocket Motors (RSRM) in which the joint design was changed. All together, this study examines 27 SRM motors, 16 HPM motors and 11 RSRM motors. Predicted upper bounds will be made for both the first and second longitudinal modes. The first mode upper bounds will be compared to the original seven standard rocket motors (STD). The results indicate that, although the upper bounds have increased, they are still within acceptable bounds.

Blomshield, Fred S.↗
NASA NTRS1995

Superconductivity devices: Commercial use of space

The work described in this report covers various aspects of the Rainbow solid-state actuator technology. It is presented in six parts dealing with materials, processing, fabrication, properties and associated phenomena. The Rainbow actuator technology is a relatively new materials development which had its inception in 1992. It consists of a new processing technology for preparing piezoelectric and electrostrictive ceramic materials. It involves a high temperature chemical reduction process which leads to an internal pre-stressing of the oxide wafer, thus the name Rainbow, an acronym for Reduced And INternally Biased Oxide Wafer. Ceramics fabricated by this method produce bending-mode actuator devices which possess several times more displacement and load bearing capacity than present-day benders (unimorphs, bimorphs). It is anticipated that these solid-state, electromechanical actuators which can be used in a number of applications in space such as cryopump motors, anti-vibration active structures, autoleveling platforms, telescope mirror correctors and autofocusing devices. When considering any of these applications, the key to the development of a successful device is the successful development of a ceramic material which can produce maximum displacement per volt input; hence, this initiative involving a solid-state means for achieving unusually high electromechanical displacement can be significant and far reaching. An additional benefit obtained from employing the piezoelectric effect in these actuator devices is the ability to also utilize them as sensors; and, indeed, they can be used as both motor (actuator) and generator (sensor) in multifunction devices.

Haertling, Gene↗