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The Tribological Properties of Several Silahydrocarbons for Use in Space Mechanisms

Silahydrocarbons are members of a relatively new class of liquid lubricants with great potential for use in space mechanisms. They are unimolecular species consisting of silicon, carbon, and hydrogen. They possess unique wear, viscosity, and volatility properties while retaining the ability to solubilize conventional additives. The tribological properties of several members of this class, including tri, tetra- and penta-compounds, are presented. These properties include: viscosity-temperature (ASTM D446), viscosity-pressure coefficient, vapor pressure, volatility, lubricant lifetimes, traction, reciprocating and four ball wear rates and bearing performance. Lubricant lifetimes were determined using a vacuum ball bearing simulator, the spiral orbit tribometer (SOT). Wear was measured using a Cameron Plint reciprocating tribometer and wear rates with a vacuum four ball tribometer. Conventional viscometry was used for viscosity-temperature measurements and a Knudsen cell for vapor pressure. Vacuum Thermogravimetric Analysis (TGA) was also used for volatility measurements. Pressure viscosity coefficients (a values) were estimated from EHL (elastohydrodynamic lubrication) film thickness measurements. Traction coefficients were measured with a twin disk traction rig. Bearing tests were performed in a vacuum bearing test facility. These properties are compared to existing state-of-the-art space lubricants.

Jones, W. R., Jr.

Custom Space Mechanisms and Deployable Structures

MIT LL has experience in the design, analysis, building, testing, and deployment of custom mechanisms and structures for space systems. Previous work includes deployable structures and mechanisms for CubeSats and small satellites in LEO, GEO, and deep space applications.

mechanisms

Tribomaterial factors in space mechanism brake performance

The asbestos/phenolic pads of Shuttle Remote Manipulator System (SRMS) brakes are unsuitable for use in long life space mechanisms because their friction decreases on extended sliding in high vacuum. Dehydration of the material and accumulation of wear debris in the conforming interface of this tribosystem induces the permanent friction changes. Other polymer and some ceramic based materials exhibit similar frictional torque behavior due to the development of minimal contact patches by the interfacial debris. In contrast, high friction occurs when other ceramics form many small contacts throughout fine debris beds. Generating this latter interfacial structure during run-in ensures that the in-vacuo friction remains stable thereafter. Such materials with low wear rates are potential candidates for friction elements in SSRMS and similar mechanisms.

Hawthorne, H. M.

Space Mechanisms Technology Workshop

The Mechanical Components Branch at NASA Glenn Research Center hosted a workshop to discuss the state of drive systems technology needed for space exploration. The Workshop was held Thursday, November 2, 2000. About 70 space mechanisms experts shared their experiences from working in this field and considered technology development that will be needed to support future space exploration in the next 10 to 30 years.

Oswald, Fred B.

Development of a Magneto-Resistive Angular Position Sensor for Space Mechanisms

Magnetic microsystems in the form of magneto-resistive (MR) sensors are firmly established in automobiles and industrial applications. They are used to measure travel, angle, electrical current, or magnetic fields. MR technology opens up new sensor possibilities in space applications and can be an enabling technology for optimal performance, high robustness and long lifetime at reasonable costs. In some science missions, the technology is already applied, however, the designs are proprietary and case specific, for instance in case of the angular sensors used for JPL/NASA's Mars rover Curiosity [1]. Since 2013 HTS GmbH and Sensitec GmbH have teamed up to develop and qualify a standardized yet flexible to use MR angular sensor for space mechanisms. Starting with a first assessment study and market survey performed under ESA contract, a very strong industry interest in novel, contactless position measurement means was found. Currently a detailed and comprehensive development program is being performed by HTS and Sensitec. The objective of this program is to advance the sensor design up to Engineering Qualification Model level and to perform qualification testing for a representative space application. The paper briefly reviews the basics of magneto-resistive effects and possible sensor applications and describes the key benefits of MR angular sensors with reference to currently operational industrial and space applications. The key applications and specification are presented and the preliminary baseline mechanical and electrical design will be discussed. An outlook on the upcoming development and test stages as well as the qualification program will be provided.

Hahn, Robert

Development and Testing of a High-Precision Position and Attitude Measuring System for a Space Mechanism

This paper describes a high-precision optical metrology system - a unique ground test equipment which was designed and implemented for simultaneous precise contactless measurements of 6 degrees-of-freedom (3 translational + 3 rotational) of a space mechanism end-effector [1] in a thermally controlled ISO 5 clean environment. The developed contactless method reconstructs both position and attitude of the specimen from three cross-sections measured by 2D distance sensors [2]. The cleanliness is preserved by the hermetic test chamber filled with high purity nitrogen. The specimen's temperature is controlled by the thermostat [7]. The developed method excludes errors caused by the thermal deformations and manufacturing inaccuracies of the test jig. Tests and simulations show that the measurement accuracy of an object absolute position is of 20 micron in in-plane measurement (XY) and about 50 micron out of plane (Z). The typical absolute attitude is determined with an accuracy better than 3 arcmin in rotation around X and Y and better than 10 arcmin in Z. The metrology system is able to determine relative position and movement with an accuracy one order of magnitude lower than the absolute accuracy. Typical relative displacement measurement accuracies are better than 1 micron in X and Y and about 2 micron in Z. Finally, the relative rotation can be measured with accuracy better than 20 arcsec in any direction.

Khanenya, Nikolay

Space Mechanisms Lessons Learned Study. Volume 1: Summary

Hundreds of satellites have been launched to date. Some have operated extremely well and others have not. In order to learn from past operating experiences, a study was conducted to determine the conditions under which space mechanisms (mechanically moving components) have previously worked or failed. The study consisted of: (1) an extensive literature review that included both government contractor reports and technical journals; (2) communication and visits (when necessary) to the various NASA and DOD centers and their designated contractors (this included contact with project managers of current and prior NASA satellite programs as well as their industry counterparts); (3) requests for unpublished information to NASA and industry; and (4) a mail survey designed to acquire specific mechanism experience. The information obtained has been organized into two volumes. Volume 1 provides a summary of the lessons learned, the results of a needs analysis, responses to the mail survey, a listing of experts, a description of some available facilities and a compilation of references. Volume 2 contains a compilation of the literature review synopsis.

Shapiro, Wilbur

Space Mechanisms Lessons Learned Study. Volume 2: Literature Review

Hundreds of satellites have been launched to date. Some have operated extremely well and others have not. In order to learn from past operating experiences, a study was conducted to determine the conditions under which space mechanisms (mechanically moving components) have previously worked or failed. The study consisted of an extensive literature review that included both government contractor reports and technical journals, communication and visits (when necessary) to the various NASA and DOD centers and their designated contractors (this included contact with project managers of current and prior NASA satellite programs as well as their industry counterparts), requests for unpublished information to NASA and industry, and a mail survey designed to acquire specific mechanism experience. The information obtained has been organized into two volumes. Volume 1 provides a summary of the lesson learned, the results of a needs analysis, responses to the mail survey, a listing of experts, a description of some available facilities, and a compilation of references. Volume 2 contains a compilation of the literature review synopsis.

Shapiro, Wilbur

Lunar Dust Effects on Space Mechanism Ball Bearings for Sustained Human Lunar Operations

NASA has plans to send humans back to the moon under the Artemis Mission. In 2024, the first humans will set foot on the lunar surface since Apollo 17 in 1972. Additionally, extended plans include a sustained human presence on the moon for long duration habitation. These lofty goals will require many different kinds of space mechanisms including: life support, mobility, excavation, scientific instrumentation, etc. Many of these types of systems utilize rotating machinery which require rolling element bearings. As such, dust tolerance of bearings is a major concern for long life in these critical systems. A research activity has been undertaken to characterize and reduce the damage lunar soil (called regolith) dust causes to bearings. The present work details some preliminary results of ball bearings running with grease intentionally contaminated with known quantities and sizes of lunar simulant particles to assess damage. Various bearing material combinations were tested to determine how certain typical bearing materials respond.

BEARINGS

Space Mechanisms Lessons Learned and Accelerated Testing Studies

A number of mechanism (mechanical moving component) failures and anomalies have recently occurred on satellites. In addition, more demanding operating and life requirements have caused mechanism failures or anomalies to occur even before some satellites were launched (e.g., during the qualification testing of GOES-NEXT, CERES, and the Space Station Freedom Beta Joint Gimbal). For these reasons, it is imperative to determine which mechanisms worked in the past and which have failed so that the best selection of mechanically moving components can be made for future satellites. It is also important to know where the problem areas are so that timely decisions can be made on the initiation of research to develop future needed technology. To chronicle the life and performance characteristics of mechanisms operating in a space environment, a Space Mechanisms Lessons Learned Study was conducted. The work was conducted by the NASA Lewis Research Center and by Mechanical Technologies Inc. (MTI) under contract NAS3-27086. The expectation of the study was to capture and retrieve information relating to the life and performance of mechanisms operating in the space environment to determine what components had operated successfully and what components had produced anomalies.

Fusaro, Robert L.

Evaluation of an In-Situ, Liquid Lubrication System for Space Mechanisms Using a Vacuum Spiral Orbit Tribometer

Many moving mechanical assemblies (MMAs) for space applications rely on a small, initial charge of lubricant for the entire mission lifetime, often in excess of five years. In many cases, the premature failure of a lubricated component can result in mission failure. If lubricant could be resupplied to the contact in-situ, the life of the MMA could be extended. A vacuum spiral orbit tribometer (SOT) was modified to accept a device to supply re-lubrication during testing. It was successfully demonstrated that a liquid lubricant (Pennzane (Registered Trademark)/Nye 2001A) could be evaporated into a contact during operation, lowering the friction coefficient and therefore extending the life of the system.

Jansen, Mark J.

Application and use of Multi Body Dynamic Simulations for In Space Mechanisms

The Thermal and Mechanical Analysis Branch of the Space System Department (ES22) is actively growing and expanding a new mechanical analysis capability. In recent years, there has been an increase in the demand for Multi Body Dynamics (MBD) analysis to support small ESPA ring size spacecraft, cubesats, lunar surface operations and large spacecraft with complex operations or deployables. Requirements can be balanced for both needs to ensure mechanism is verified for launch. Multi-body dynamics is the study of multiple rigid or flexible bodies that are linked together or are in contact and the associated kinematics and dynamics of the system. The typical outputs include performance information, loads, and deflections of mechanical systems. They routinely support the development of robotic mechanisms, deployment mechanisms, landing simulations, control systems, and conops planning.

Multi Body Dynamics Analysis

Magnetic Levitation for Long-Life Space Mechanisms: Technology Assessment and Remaining Challenges

Spacecraft mechanisms and mechanical systems must operate reliably and without failure to enable successful, long-term space missions. Such requirements place demands upon the tribological elements, especially bearings, which are frequently difficult or impossible to satisfy. Several recent, high-profile bearing failures in coolant fluid pumps and attitude control system (ACS) momentum wheels provided the impetus to assess the state-of-the-art non-contacting magnetic levitation-based, rotor support technologies.Magnetic levitation technology continues to gain acceptance for terrestrial applications and has been spaceflight demonstrated in mechanical systems such as reaction wheels (RWs) but is not in widespread use. The specific reasons inhibiting this new technology are not readily clear but include cost, weight, performance, and perceived risk. These reasons arise from a variety of real and perceived technical limitations in areas like materials, controls, sensors, thermal management and others. This white paper seeks to determine, define, and quantify the technical hurdles and gaps that must be overcome to enable the broad adoption of non-contacting bearings for long-life space mechanisms. It is anticipated that a better understanding of this complex topic may guide resource investments and clear the path to improved performance mechanical systems for spacecraft.

Samuel A Howard

Perception of the Body in Space: Mechanisms

The principal topic is the perception of body orientation and motion in space and the extent to which these perceptual abstraction can be related directly to the knowledge of sensory mechanisms, particularly for the vestibular apparatus. Spatial orientation is firmly based on the underlying sensory mechanisms and their central integration. For some of the simplest situations, like rotation about a vertical axis in darkness, the dynamic response of the semicircular canals furnishes almost enough information to explain the sensations of turning and stopping. For more complex conditions involving multiple sensory systems and possible conflicts among their messages, a mechanistic response requires significant speculative assumptions. The models that exist for multisensory spatial orientation are still largely of the non-rational parameter variety. They are capable of predicting relationships among input motions and output perceptions of motion, but they involve computational functions that do not now and perhaps never will have their counterpart in central nervous system machinery. The challenge continues to be in the iterative process of testing models by experiment, correcting them where necessary, and testing them again.

Young, Laurence R.

Robotic Materials Handling in Space: Mechanical Design of the Robot Operated Materials Processing System HitchHiker Experiment

The Goddard Space Flight Center has developed the Robot Operated Materials Processing System (ROMPS) that flew aboard STS-64 in September, 1994. The ROMPS robot transported pallets containing wafers of different materials from their storage racks to a furnace for thermal processing. A system of tapered guides and compliant springs was designed to deal with the potential misalignments. The robot and all the sample pallets were locked down for launch and landing. The design of the passive lockdown system, and the interplay between it and the alignment system are presented.

Voellmer, George

Comparison of Environmentally Friendly Space Compatible Grease to its Predecessor in a Space Mechanism Bearing Test Rig

Perfluoroakylpolyether (PFPE) greases are used extensively in critical flight hardware in a space environment. In the past, these greases have been processed using chlorofluorocarbon (CFC) based solvents. In response to the recent ban of CFC's, new formulations of environmentally friendly PFPE greases that are not processed with CFC based solvents were developed. The purpose of this study was to compare the performance of a new environmentally friendly formulation PFPE grease to a previously proven space compatible formulation PFPE grease. A one year test using 20 small electrical motors (two bearings per motor) was conducted in a high vacuum environment(2.0 x 10(exp 4)) Torr at a temperature of 90 C. Twenty bearings were lubricated with a new environmentally friendly formulation, and twenty bearings were lubricated with an old formulation. The mass of each lubricated bearing was measured both pre and post test. Along with mass loss measurements a profilometer trace was taken to measure post test wear of the bearings. In addition the bearings were visually examined and analyzed using an optical microscope.

T R Jett