Mariner 4 and 5 disturbance torques and limit cycles, addendum
Computer printouts of torque limits and limit cycles affecting Mariner 4 and 5 spacecraft at selected positions
Prelewicz, D. A.↗
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Mariner 4 and 5 disturbance torques and limit cycles
Disturbance torque effects on cruise mode operations of Mariner 4 and Mariner 5
Prelewicz, D. A.↗
Wire Rope Failure on the Guppy Winch
On January 6, 2016 at El Paso, the Guppy winch motor was changed. After completion of the operational checks, the load bar was being reinstalled on the cargo pallet when the motor control FORWARD relay failed in the energized position. The pallet was pinned at all locations (each pin has a load capacity of 16,000 lbs.) while the winch was running. The wire rope snapped before aircraft power could be removed. After disassembly, the fractured wire rope was shipped to ES4 lab for further characterization of the wire rope portion of the failure. The system was being operated without a clear understanding of the system capability and function. The proximate cause was the failure of the K48 -Forward Winch Control Relay in the energized position, which allowed the motor to continuously run without command from the hand controller, and operation of the winch system with both controllers connected to the system. This prevented the emergency stop feature on the hand controller from functioning as designed. An electrical checkout engineering work instruction was completed and identified the failed relay and confirmed the emergency stop only paused the system when the STOP button on both connected hand controllers were depressed simultaneously. The winch system incorporates a torque limiting clutch. It is suspected that the clutch did not slip and the motor did not stall or overload the current limiter. Aircraft Engineering is looking at how to change the procedures to provide a checkout of the clutch and set to a slip torque limit appropriate to support operations.
Figert, John↗
Extended torsional tests of an interlocked bi-stem satellite boom
The effect is reported of continued oscillations of a 1.27-cm interlocked bi-stem satellite boom. The test setup oscillated a boom continuously between set torque limits and periodically recorded its hysteresis characteristics. Results showed that repeated oscillations affected torsional characteristics and that torsional rigidity changed as a function of the number of cycles oscillated within certain torque limits. Torsional characteristics changes caused by repeated oscillations were retained.
Abercrombie, R. A.↗
Two gimbal bearing case studies: Some lessons learned
Two troublesome, torque related problems associated with gimbal actuators are discussed. Large, thin section angular contact bearings can have a surprisingly high torque sensitivity to radial thermal gradients. A predictive thermal-mechanical bearing analysis, as described, was helpful in establishing a safe temperature operating envelope. In the second example, end-of-travel torque limits of an oscillatory gimbal bearing appoached motor stall during limit cycling life tests. Bearing modifications required to restore acceptable torque performance are described. The lessons learned from these case studies should benefit designers of precision gimbals where singular bearing torque related problems are not uncommon.
Loewenthal, Stuart H.↗
Evaluation of several additional dry lubricants for spacecraft applications
Four transfer-film ball-bearing retainer materials were evaluated for their lubricating ability and wear capability under conditions of 120-gram radial load, 450-gram axial load, 3600-rpm unidirectional rotation, 23 C ambient temperature, and less than .1 microtorr pressure, using R-2 sized unshielded ball bearings. The 'stop-test' criterion was a total of one billion revolutions or a torque buildup greater than 18 gm-cm per bearing pair. A PTFE-fiberglass-MoS2 composite, a PTFE-bronze composite, and a tantalum-molybdenum-MoS2 composite operated for one billion revolutions without reaching the 18-gram torque limit. A p-oxybenzoyl polymer-MoS2 composite operated sixteen million revolutions before reaching the 18-gm cm stop-test torque. The first three materials are considered as suitable lubricants under the test conditions employed.
Vest, C. E.↗
Approximate minimum-time trajectories for two-link flexible manipulators
The method of recursive quadratic programming was used to generate approximate minimum-time tip trajectories for two-link semi-rigid and flexible manipulator movements in the horizontal plane. The manipulator is modeled with an efficient finite-element scheme for an n-link, m-joint system with bending only in the horizontal plane. Constraints on the trajectory include boundary conditions on position and energy for a rest-to-rest maneuver, straight-line tracking between boundary positions, and motor torque limits. Trajectory comparisons utilize a change in the link stiffness to compare a semi-rigid configuration to a flexible one. The level of bending flexibility necessary to excite significant modal behavior is demonstrated. Applied torques for minimum-time maneuvers are shown to be very similar between configurations and retain much of the qualitative character of rigid-body slewing motion.
Eisler, G. R.↗
Upper limit of the torque of the solar wind on the earth.
An upper limit is presented for the torque exerted on the earth by the solar wind. It is found that the maximum possible torque is 3 or 4 orders of magnitude too small to be responsible for the slowing of the earth's rotation, contrary to Coleman's (1971) suggestion.
Hirshberg, J.↗
Development and Flight Demonstration of a HUMS-Based Helicopter Limit Cueing (HLC) System
A prototype helicopter limit cueing (HLC) system was designed, installed, and evaluated in flight test in early 2002. This paper describes the design, cueing methodology, and interim flight test results of this project. The system described in this paper used available Health and Usage Monitoring System (HUMS) parameters and a simple and cost-effective mechanical spring/electric motor combination to achieve a tactile cue that warned the pilot of impending exceedences of the transmission torque limit. Three high-workload maneuvers were used to evaluate the prototype HLC system. Results indicate that with an appropriate design, inadvertent over-torque events could be eliminated with a HLC system while reducing pilot workload.
Augustin, M.↗
TRIDENT Drill Validation at Mars and Lunar Analog Field Sites
Drilling on Earth is typically a human-intensive activity. Drilling on other planets is further complicated by the lack of prior local field surveys of their target area, hence blindly drilling into uncertain target rocks. Field conditions on the Moon or Mars are also different than for shallow drilling on Earth: lower temperatures and pressures, less power available, low masses (hence less weight-on-bit). Given the cost of transport from Earth, no drilling muds or working fluids are likely to be available to carry away cuttings. And impact-gardened regolith and dust vary mechanically and texturally from most terrestrial soils. The Regolith and Ice Drill for Exploration of New Terrains (TRIDENT) is a rotary-percussive 1m-class drill from Honeybee Robotics. It is low-power (rotary and percussive actuators are 200 W each) and lightweight (<20 kg) with the maximum weight on bit limited to 200 N. TRIDENT has been manifested for the Volatiles Investigating Polar Exploration Rover (VIPER) and PRIME-1 lunar south pole missions in 2024, has previously been field tested at a hot, dry analog site in the Atacama Desert, and in lunar conditions in thermal vacuum chamber tests. TRIDENT was also part of the 2019 Icebreaker Mars Discovery proposal, as well as in the Mars Life Explorer concept. During ARADS tests, drill control and fault recovery automation software enabled hands-off operations of a rover-mounted TRIDENT drill. TRIDENT Drill Analog Site Validation: Past TRIDENT tests in thermal vacuum (TVAC) chambers targeted containers of manufactured lunar simulants with added volatiles. 2022 TRIDENT ambient testing at NASA Ames drilled into cemented lunar simulant materials. Low cuttings-permeability led to cuttings buildup, and drill choking and binding was observed. The Atacama analog site in ARADS had desiccated unconsolidated sediments that did not challenge the TRIDENT design. However, lunar polar regolith is expected to be diverse and heterogeneous with varying clast sizes, with abundant impactites and perhaps subsurface ice deposits. Neither the simulants nor Atacama testing had completely covered the TRIDENT-targeted field characteristics, motivating further analog tests prior to the planned lunar missions. To gain more insight into the behavior of the TRIDENT hardware in diverse impactites and subsurface ice, and to verify the software automation in that environment, in August 2023 TRIDENT was brought to Haughton Crater, a field analog site in the Canadian Arctic. In September 2023 the same drill was brought to the Bishop Tuff in southern California to verify whether drilling binding behaviors previously seen in lunar simulant testing would be observed in naturally occurring fine-grained massive layers. The ~22 Ma Haughton Crater impact structure is located at 75 ̊22’ N, 89 ̊41’ W, on northwestern Devon Island, Nunavut, Canada. Numerous deposits of pale-grey crater-fill polymictic impact-melt breccia are found within the crater with a typical thickness reaching ~125 m or greater and covering ~60 km -2 . An approximately 600m-thick permafrost layer is also present with ice typically found within 0.5-0.6m of the surface. The volcanic tableland north of Bishop, CA exposes densely welded tuff laid down during the eruption that created the Long Valley Caldera at approximately 0.76 Ma. Extensional faults and the Owens River gorge expose cross-sections across the plateau. The area is viewed as an analog site for Mars features believed to be of pyroclastic origin. Results: Haughton Crater.Drilling tests were conducted 8-13 August 2023 at a previously undisturbed area separated 5-10 m from past years’ Drill Hill test sites (75.4208, -089.7613). In six days, TRIDENT drilled 8 holes to nearly 1 m depth each, totaling 7.80 m. The active layer/ice boundary was at ~67 cm depth, with a total of approximately 2.4 m drilled into ice or ice-cemented impact breccia. During drilling, five drill fault states were observed and successfully recovered. Holes 23-1, 4 and 7 were drilled under manual control, using Honeybee’s Thorax user interface. Holes 23-5, 6, and 8 were drilled with the Ames IBexec automated drilling control software. TRIDENT was observed to have little difficulty in the thawed uncemented impact breccia above the active layer boundary, but required percussion to make slower headway in the ice-cemented breccia. In Hole 23-7 (Fig.1), drilling slowed down in a massive unit just above the active-layer boundary (perhaps a large rock extending into the ice-cementation?), with only 7cm progress made in 27 minutes of high auger torque and constant percussion, leading to a choking fault and then a binding fault. A similar pattern had been observed in TRIDENT Rio Tinto test data from 2017 [6] as well as in the 2022laboratory tests.Bishop Tuff.A team from NASA Ames and the US Geological Survey deployed the same TRIDENT drill to Bishop Sites 1B and 1C (37.4203, -118.4289; 37.4265, -118.4215) on 13-16 September 2023, on the Bishop Tuff plateau. A third drill site was used 17-18 September 2023(37.4598, -118.3667) in an abandoned pumice mine. Four holes (totaling 2.5m depth) were drilled into the fine-grained, meters-thick tuff units at Sites 1B and 1C, and a further two boreholes (totaling 1.98m depth) were made at the pumice site. Drill behavior in the tuff below 10 cm depth was similar to that seen at 65-74 cm depth in Haughton Hole 23-7 (Fig. 1) and that seen in the 2022 lab simulant drilling. Drill safety torque limits were exceeded multiple times resulting in drill stops downhole. These freezes then required external added torques (with a pipe wrench) to resume rotation, to unstick the drill for withdrawal. To prevent this choking and binding behavior we found that more-frequent cuttings removal was necessary, e.g., reducing the “drill bite” size from the nominal 10 cm to 2 cm per bite --bringing the auger up to the surface more frequently, as seen in Bishop Site 1C Hole 2 (Fig.2). This permitted slow progress without drill binding and without external interventions. Conversely, TRIDENT drilling in the more porous pumice target material showed no cuttings buildup issue, and single bites as large as 40 cm were demonstrated. Discussion: We observed that TRIDENT easily penetrated unconsolidated heterogeneous soils (both above the active layer boundary at Haughton and previously in the Atacama). Cemented or consolidated targets that were cuttings-permeable (icy impact breccia, pumice) required more energy applied and percussion. However, in non-cuttings-permeable targets (welded microporous tuff, cemented simulants, boulder) TRIDENT was observed to be prone to excessive cuttings accumulation leading to choking/binding faults and stalling. The wedge cutting bit, used by TRIDENT in field tests and in its flight versions, pulverizes the target rock and creates fine cuttings that ideally are transported up the auger spirals for removal. In porous, fractured or vesicular target materials (such as at the Bishop pumice site) a significant portion of the cuttings are pushed aside, but for non-fractured, microporous targets the cuttings remain in the borehole and accumulate. Rock powder is relatively incompressible as a working fluid at only 100-200N downward force (TRIDENT limits) and hence eventual drilling progress slows or stops. Our recommended strategy for improving TRIDENT cuttings removal in massive target units with low cuttings-permeability is to reduce TRIDENT bite sizes when encountering these units, from 10cm to as little as 1-2cm, to effectively bail the accumulating cuttings. This approach was demonstrated to reduce choking and allowed slow progress to continue in cuttings-impermeable microporous target units (viz. the Bishop tuff in our September 2023 tests or cemented simulants in 2022 ambient tests).
robotic drilling↗
NDARC NASA Design and Analysis of Rotorcraft - Input, Appendix 4
The NDARC code performs design and analysis tasks. The design task involves sizing the rotorcraft to satisfy specified design conditions and missions. The analysis tasks can include off-design mission performance analysis, flight performance calculation for point operating conditions, and generation of subsystem or component performance maps. The principal tasks (sizing, mission analysis, flight performance analysis) are shown in the figure as boxes with heavy borders. Heavy arrows show control of subordinate tasks. The aircraft description consists of all the information, input and derived, that denes the aircraft. The aircraft consists of a set of components, including fuselage, rotors, wings, tails, and propulsion. This information can be the result of the sizing task; can come entirely from input, for a fixed model; or can come from the sizing task in a previous case or previous job. The aircraft description information is available to all tasks and all solutions. The sizing task determines the dimensions, power, and weight of a rotorcraft that can perform a specified set of design conditions and missions. The aircraft size is characterized by parameters such as design gross weight, weight empty, rotor radius, and engine power available. The relations between dimensions, power, and weight generally require an iterative solution. From the design flight conditions and missions, the task can determine the total engine power or the rotor radius (or both power and radius can be fixed), as well as the design gross weight, maximum takeoff weight, drive system torque limit, and fuel tank capacity. For each propulsion group, the engine power or the rotor radius can be sized. Missions are defined for the sizing task, and for the mission performance analysis. A mission consists of a number of mission segments, for which time, distance, and fuel burn are evaluated. For the sizing task, certain missions are designated to be used for design gross weight calculations; for transmission sizing; and for fuel tank sizing. The mission parameters include mission takeoff gross weight and useful load. For specified takeoff fuel weight with adjustable segments, the mission time or distance is adjusted so the fuel required for the mission equals the takeoff fuel weight. The mission iteration is on fuel weight or energy. Flight conditions are specified for the sizing task, and for the flight performance analysis. For the sizing task, certain flight conditions are designated to be used for design gross weight calculations; for transmission sizing; for maximum takeoff weight calculations; and for anti-torque or auxiliary thrust rotor sizing. The flight condition parameters include gross weight and useful load. For flight conditions and mission takeoff, the gross weight can be maximized, such that the power required equals the power available. A flight state is defined for each mission segment and each flight condition. The aircraft performance can be analyzed for the specified state, or a maximum effort performance can be identified. The maximum effort is specified in terms of a quantity such as best endurance or best range, and a variable such as speed, rate of climb, or altitude.
Rotorcraft Input↗
Further observations on the relationship of EMG and muscle force
Human skeletal muscle may be regarded as an electro-mechanical transducer. Its physiological input is a neural signal originating at the alpha motoneurons in the spinal cord and its output is force and muscle contraction, these both being dependent on the external load. Some experimental data taken during voluntary efforts around the ankle joint and by direct electrical stimulation of the nerve are described. Some of these experiments are simulated by an analog model, the input of which is recorded physiological soleus muscle EMG. The output is simulated foot torque. Limitations of a linear model and effect of some nonlinearities are discussed.
Agarwal, G. C.↗
Time-optimal bang-bang slew of rigidized SCOLE configuration
This paper addresses: (1) an application of the well-known time-optimal bang-bang control theory to the design of minimal-time limited-torque single-axis slew maneuvers for the rigidized configuration of NASA Langley Research Center's Spacecraft Control Laboratory Experiment (SCOLE) and (2) the associated generic side effects due to spillover of slew motions and applied torques. Numerical experiments that helped pinpoint the specific causes of performance degradation are discussed. Analytical as well as scientifically interesting numerical research results are given.
Lin, J. G.↗
High-Pressure Valve With Controlled Seating Force
Poppet and seat less likely to be damaged by faulty operation. Improvements in widely-used high-pressure valve increase accuracy of preloading of poppet. Redesigned valve prevents metal shavings and other debris from developing during operation, installation, or removal. New features include secondary seal in cap. Belleville washers create precise value of seating force. If installer attempts to exceed force, torque limiter gives tactile and aural warning and makes further force increases difficult.
Bradley, R. H.↗
Approximate minimum-time trajectories for 2-link flexible manipulators
Powell's nonlinear programming code, VF02AD, was used to generate approximate minimum-time tip trajectories for 2-link semi-rigid and flexible manipulator movements in the horizontal plane. The manipulator is modeled with an efficient finite-element scheme for an n-link, m-joint system with horizontal-plane bending only. Constraints on the trajectory include boundary conditions on position and energy for a rest-to-rest maneuver, straight-line tracking between boundary positions, and motor torque limits. Trajectory comparisons utilize a change in the link stiffness, EI, to transition from the semi-rigid to flexible case. Results show the level of compliance necessary to excite significant modal behavior. Quiescence of the final configuration is examined with the finite-element model.
Eisler, G. R.↗
Magnetostrictive direct drive motors
A new rare earth alloy, Terfenol-D, combines low frequency operation and extremely high energy density with high magnetostriction. Its material properties make it suitable as a drive element for actuators requiring high output torque. The high strains, the high forces and the high controllability of Terfenol alloys provide a powerful and challenging basis for new ways to generate motion in actuators. Two prototypes of motors using Terfenol-D rods were developed at NASA Goddard. The basic principles of operation are provided of the motor along with other relevant details. A conceptual design of a torque limiting safety clutch/brake under development is illustrated. Also, preliminary design drawings of a linear actuator using Terfenol-D is shown.
Naik, Dipak↗
Miniature linear-to-rotary motion actuator
A miniature hydraulic actuation system capable of converting linear actuator motion to control surface rotary motion has been designed for application to active controls on dynamic wind tunnel models. Due to space constraints and the torque requirements of an oscillating control surface at frequencies up to 50 Hertz, a new actuation system was developed to meet research objectives. This new actuation system was designed and developed to overcome the output torque limitations and fluid loss/sealing difficulties associated with an existing vane type actuator. Static control surface deflections and dynamic control surface oscillations through a given angle are provided by the actuation system. The actuator design has been incorporated into a transonic flutter model with an active trailing edge flap and two active spoilers. The model is scheduled for testing in the LaRC 16 Foot Transonic Dynamics Tunnel during Summer 1993. This paper will discuss the actuation system, its design, development difficulties, test results, and application to aerospace vehicles.
Sorokach, Michael R., Jr.↗
Combination Space Station Handrail Clamp and Pointing Device
A device for attaching an experiment carrier to a space station handrail is provided. The device has two major components, a clamping mechanism for attachment to a space station handrail, and a pointing carrier on which an experiment package can be mounted and oriented. The handrail clamp uses an overcenter mechanism and the carrier mechanism uses an adjustable preload ball and socket for carrier positioning. The handrail clamp uses a stack of disk springs to provide a spring loaded button. This configuration provides consistent clamping force over a range of possible handrail thicknesses. Three load points are incorporated in the clamping mechanism thereby spreading the clamping load onto three separate points on the handrail. A four bar linkage is used to provide for a single actuation lever for all three load points. For additional safety, a secondary lock consisting of a capture plate and push lock keeps the clamp attached to the handrail in the event of main clamp failure. For the carrier positioning mechanism, a ball in a spring loaded socket uses friction to provide locking torque; however. the ball and socket are torque limited so that the ball ran slip under kick loads (125 pounds or greater). A lead screw attached to disk spring stacks is used to provide an adjustable spring force on the socket. A locking knob is attached to the lead screw to allow for hand manipulation of the lead screw.
Hughes, Stephen J.↗