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Analysis and Evaluation of NASA's MK40B Six-Component TASK Balance

The paper discusses the physical characteristics NASA's MK40B TASK balance. It is NASA's newest TASK balance that was optimized for the testing of wind tunnel models in the NASA Ames 11-ft Transonic Wind Tunnel. The calibration data of the MK40B balance was obtained in Calspan's Automatic Balance Calibration System. A machine load schedule design was used for the calibration that was developed at the NASA Ames Balance Calibration Laboratory. The calibration data was analyzed using both the Non-Iterative Method and the Iterative Method. Then, the chosen regression models of the calibration data were assessed and compared using the percent contribution, the variance inflation factor, and the calibration load residuals. Interactions of single-component loads were also quantified. In addition, the bi-directional characteristics of the six gage outputs of the balance were assessed by applying a semi-empirical test that was developed at the Ames Balance Calibration Laboratory. It was concluded that four of the six gages of the balance have bi-directional characteristics. Finally, the accuracy of the load prediction equations of the balance was tested by applying the equations to independent check load data that was obtained at the NASA Ames Balance Calibration Laboratory. The standard deviation of the check load residuals met expectations. The check load data also confirmed that the interactions of the forward and aft normal forces on the axial force gage output are very small. - This paper is to be presented in the invited special session titled: "65 Years of TASK Wind Tunnel Balances - Past, Present, and Future".

wind tunnel balance↗

NASA NTRS1995

Automatic force balance calibration system

A system for automatically calibrating force balances is provided. The invention uses a reference balance aligned with the balance being calibrated to provide superior accuracy while minimizing the time required to complete the calibration. The reference balance and the test balance are rigidly attached together with closely aligned moment centers. Loads placed on the system equally effect each balance, and the differences in the readings of the two balances can be used to generate the calibration matrix for the test balance. Since the accuracy of the test calibration is determined by the accuracy of the reference balance and current technology allows for reference balances to be calibrated to within +/-0.05% the entire system has an accuracy of +/-0.2%. The entire apparatus is relatively small and can be mounted on a movable base for easy transport between test locations. The system can also accept a wide variety of reference balances, thus allowing calibration under diverse load and size requirements.

Ferris, Alice T.↗

NASA NTRS1996

Automatic force balance calibration system

A system for automatically calibrating force balances is provided. The invention uses a reference balance aligned with the balance being calibrated to provide superior accuracy while minimizing the time required to complete the calibration. The reference balance and the test balance are rigidly attached together with closely aligned moment centers. Loads placed on the system equally effect each balance, and the differences in the readings of the two balances can be used to generate the calibration matrix for the test balance. Since the accuracy of the test calibration is determined by the accuracy of the reference balance and current technology allows for reference balances to be calibrated to within .+-.0.05%, the entire system has an accuracy of a .+-.0.2%. The entire apparatus is relatively small and can be mounted on a movable base for easy transport between test locations. The system can also accept a wide variety of reference balances, thus allowing calibration under diverse load and size requirements.

Ferris, Alice T.↗

NASA NTRS2013

Calibration Variable Selection and Natural Zero Determination for Semispan and Canard Balances

Independent calibration variables for the characterization of semispan and canard wind tunnel balances are discussed. It is shown that the variable selection for a semispan balance is determined by the location of the resultant normal and axial forces that act on the balance. These two forces are the first and second calibration variable. The pitching moment becomes the third calibration variable after the normal and axial forces are shifted to the pitch axis of the balance. Two geometric distances, i.e., the rolling and yawing moment arms, are the fourth and fifth calibration variable. They are traditionally substituted by corresponding moments to simplify the use of calibration data during a wind tunnel test. A canard balance is related to a semispan balance. It also only measures loads on one half of a lifting surface. However, the axial force and yawing moment are of no interest to users of a canard balance. Therefore, its calibration variable set is reduced to the normal force, pitching moment, and rolling moment. The combined load diagrams of the rolling and yawing moment for a semispan balance are discussed. They may be used to illustrate connections between the wind tunnel model geometry, the test section size, and the calibration load schedule. Then, methods are reviewed that may be used to obtain the natural zeros of a semispan or canard balance. In addition, characteristics of three semispan balance calibration rigs are discussed. Finally, basic requirements for a full characterization of a semispan balance are reviewed.

Ulbrich, Norbert M.↗

NASA NTRS2020

Development of a Non-Iterative Balance Load Prediction Algorithm for the NASA Ames Unitary Plan Wind Tunnel

A non-iterative load prediction algorithm for strain-gage balances was developed for the NASA Ames Unitary Plan Wind Tunnels that computes balance loads from the electrical outputs of the balance bridges and a set of state variables. A state variable could be, for example, a balance temperature difference or the bellows pressure of a flow-through balance. The algorithm directly uses regression models of the balance loads for the load prediction that were obtained by applying global regression analysis to balance calibration data. This choice greatly simplifies both implementation and use of the load prediction process for complex balance configurations as no load iteration needs to be performed. The regression model of a balance load is constructed by using terms from a total of nine term groups. Four term groups are derived from a Taylor Series expansion of the relationship between the load, gage outputs, and state variables. The remaining five term groups are defined by using absolute values of the gage outputs and state variables. Terms from these groups should only be included in the regression model if calibration data from a balance with known bi-directional outputs is analyzed. It is illustrated in detail how global regression analysis may be applied to obtain the coefficients of the chosen regression model of a load component assuming that no linear or massive near-linear dependencies between the regression model terms exist. Data from the machine calibration of a six-component force balance is used to illustrate both application and accuracy of the non-iterative load prediction process.

Ulbrich, Norbert M.↗

NASA NTRS1988

Spray automated balancing of rotors: Methods and materials

The work described consists of two parts. In the first part, a survey is performed to assess the state of the art in rotor balancing technology as it applies to Army gas turbine engines and associated power transmission hardware. The second part evaluates thermal spray processes for balancing weight addition in an automated balancing procedure. The industry survey reveals that: (1) computerized balancing equipment is valuable to reduce errors, improve balance quality, and provide documentation; (2) slow-speed balancing is used exclusively, with no forseeable need for production high-speed balancing; (3) automated procedures are desired; and (4) thermal spray balancing is viewed with cautious optimism whereas laser balancing is viewed with concern for flight propulsion hardware. The FARE method (Fuel/Air Repetitive Explosion) was selected for experimental evaluation of bond strength and fatigue strength. Material combinations tested were tungsten carbide on stainless steel (17-4), Inconel 718 on Inconel 718, and Triballoy 800 on Inconel 718. Bond strengths were entirely adequate for use in balancing. Material combinations have been identified for use in hot and cold sections of an engine, with fatigue strengths equivalent to those for hand-ground materials.

Smalley, Anthony J.↗

NASA NTRS1993

Dynamic Balancing Of Turbomachinery Shafts And Rotors

Method for dynamic balancing of turbomachinery shafts and rotors developed with view toward reducing time spent in balancing process. Improved method based on existing dynamic-balancing techniques and equipment, incorporating use of balancing arbor, which is mandrel duplicating mounting geometry and dynamic-balance properties of shaft balanced. Once shaft balanced, not necessary to disassemble machinery and/or shaft completely and rebalance shaft when replacing rotor on shaft. Instead, one balances replacement rotor on balancing arbor, then installs balanced rotor on shaft.

Verhoff, Vincent G.↗

NASA NTRS1999

Development of a 5-Component Balance for Water Tunnel Applications

The principal objective of this research/development effort was to develop a multi-component strain gage balance to measure both static and dynamic forces and moments on models tested in flow visualization water tunnels. A balance was designed that allows measuring normal and side forces, and pitching, yawing and rolling moments (no axial force). The balance mounts internally in the model and is used in a manner typical of wind tunnel balances. The key differences between a water tunnel balance and a wind tunnel balance are the requirement for very high sensitivity since the loads are very low (typical normal force is 90 grams or 0.2 lbs), the need for water proofing the gage elements, and the small size required to fit into typical water tunnel models. The five-component balance was calibrated and demonstrated linearity in the responses of the primary components to applied loads, very low interactions between the sections and no hysteresis. Static experiments were conducted in the Eidetics water tunnel with delta wings and F/A-18 models. The data were compared to forces and moments from wind tunnel tests of the same or similar configurations. The comparison showed very good agreement, providing confidence that loads can be measured accurately in the water tunnel with a relatively simple multi-component internal balance. The success of the static experiments encouraged the use of the balance for dynamic experiments. Among the advantages of conducting dynamic tests in a water tunnel are less demanding motion and data acquisition rates than in a wind tunnel test (because of the low-speed flow) and the capability of performing flow visualization and force/moment (F/M) measurements simultaneously with relative simplicity. This capability of simultaneous flow visualization and for F/M measurements proved extremely useful to explain the results obtained during these dynamic tests. In general, the development of this balance should encourage the use of water tunnels for a wider range of quantitative and qualitative experiments, especially during the preliminary phase of aircraft design.

Suarez, Carlos J.↗

NASA NTRS2004

Structural Integrity of a Wind Tunnel Balance

The National Aeronautics and Space Administration (NASA) Langley Research Center (LaRC) has been designing strain-gage balances for utilization in wind tunnels since its inception. The utilization of balances span over a wide variety of aerodynamic tests. A force balance is an inherently critically stressed component due to the requirements of measurement sensitivity. Research and analyses are done in order to investigate the structural integrity of the balances as well as developing an understanding of their performance in order to enhance their capability. Maximum loading occurs when all 6 components of the loads are applied simultaneously with their maximum value allowed (limit load). This circumstance normally does not occur in the wind tunnel. However, if it occurs, is the balance capable of handling the loads with an acceptable factor of safety? LaRC Balance 1621 was modeled and meshed in PATRAN for analysis in NASTRAN. For a complete analysis, it is necessary to consider all the load cases as well as use dense mesh near all the edges. Because of computer limitations, it is not possible to have one model with the dense mesh near all edges. In the present study, a dense mesh is limited to the surface corners where the cage and axial sections meet. Four different load combinations are used for the current analysis. Linear analysis is performed for each load case. In the case where the stress value is above linear elastic region, it is necessary to perform nonlinear analysis. It is also important to investigate the variables limiting the structural integrity of the balances. In order to investigate the possibility of modifying the existing balances to enhance the structural integrity, some modifications are done on this balance. The structural integrity of the balance after modification is investigated.

Karkehabadi, R.↗

NASA NTRS2008

Balanced Flow Meters without Moving Parts

Balanced flow meters are recent additions to an established class of simple, rugged flow meters that contain no moving parts in contact with flow and are based on measurement of pressure drops across objects placed in flow paths. These flow meters are highly accurate, minimally intrusive, easily manufacturable, and reliable. A balanced flow meter can be easily mounted in a flow path by bolting it between conventional pipe flanges. A balanced flow meter can be used to measure the flow of any of a variety of liquids or gases, provided that it has been properly calibrated. Relative to the standard orifice-plate flow meter, the balanced flow meter introduces less turbulence and two times less permanent pressure loss and is therefore capable of offering 10 times greater accuracy and repeatability with less dissipation of energy. A secondary benefit of the reduction of turbulence is the reduction of vibration and up to 15 times less acoustic noise generation. Both the balanced flow meter and the standard orifice-plate flow meter are basically disks that contain holes and are instrumented with pressure transducers on their upstream and downstream faces. The most obvious difference between them is that the standard orifice plate contains a single, central hole while the balanced flow meter contains multiple holes. The term 'balanced' signifies that in designing the meter, the sizes and locations of the holes are determined in an optimization procedure that involves balancing of numerous factors, including volumetric flow, mass flow, dynamic pressure, kinetic energy, all in an effort to minimize such undesired effects as turbulence, pressure loss, dissipation of kinetic energy, and non-repeatability and nonlinearity of response over the anticipated range of flow conditions. Due to proper balancing of these factors, recent testing demonstrated that the balanced flow-meter performance was similar to a Venturi tube in both accuracy and pressure recovery, but featured reduced cost and pipe-length requirements.

Kelley, Anthony R.↗

NASA NTRS2009

Medical Devices Assess, Treat Balance Disorders

You may have heard the phrase as difficult as walking and chewing gum as a joking way of referring to something that is not difficult at all. Just walking, however, is not all that simple physiologically speaking. Even standing upright is an undertaking requiring the complex cooperation of multiple motor and sensory systems including vision, the inner ear, somatosensation (sensation from the skin), and proprioception (the sense of the body s parts in relation to each other). The compromised performance of any of these elements can lead to a balance disorder, which in some form affects nearly half of Americans at least once in their lifetimes, from the elderly, to those with neurological or vestibular (inner ear) dysfunction, to athletes with musculoskeletal injuries, to astronauts returning from space. Readjusting to Earth s gravity has a significant impact on an astronaut s ability to balance, a result of the brain switching to a different "model" for interpreting sensory input in normal gravity versus weightlessness. While acclimating, astronauts can experience headaches, motion sickness, and problems with perception. To help ease the transition and study the effects of weightlessness on the body, NASA has conducted many investigations into post-flight balance control, realizing this research can help treat patients with balance disorders on Earth as well. In the 1960s, the NASA-sponsored Man Vehicle Laboratory at the Massachusetts Institute of Technology (MIT) studied the effects of prolonged space flight on astronauts. The lab s work intrigued MIT doctoral candidate Lewis Nashner, who began conducting NASA-funded research on human movement and balance under the supervision of Dr. Larry Young in the MIT Department of Aeronautics and Astronautics. In 1982, Nashner s work resulted in a noninvasive clinical technique for assessing the cooperative systems that allow the body to balance, commonly referred to as computerized dynamic posturography (CDP). CDP employs a series of dynamic protocols to isolate and assess balance function deficiencies. The technology was based on Nashner s novel, engineering-inspired concept of balance as an adaptable collaboration between multiple sensory and motor systems. CDP proved useful not only for examining astronauts, but for anyone suffering from balance problems. Today, CDP is the standard medical tool for objectively evaluating balance control.

Source record↗

NASA NTRS2003

Single-Vector Calibration of Wind-Tunnel Force Balances

An improved method of calibrating a wind-tunnel force balance involves the use of a unique load application system integrated with formal experimental design methodology. The Single-Vector Force Balance Calibration System (SVS) overcomes the productivity and accuracy limitations of prior calibration methods. A force balance is a complex structural spring element instrumented with strain gauges for measuring three orthogonal components of aerodynamic force (normal, axial, and side force) and three orthogonal components of aerodynamic torque (rolling, pitching, and yawing moments). Force balances remain as the state-of-the-art instrument that provide these measurements on a scale model of an aircraft during wind tunnel testing. Ideally, each electrical channel of the balance would respond only to its respective component of load, and it would have no response to other components of load. This is not entirely possible even though balance designs are optimized to minimize these undesirable interaction effects. Ultimately, a calibration experiment is performed to obtain the necessary data to generate a mathematical model and determine the force measurement accuracy. In order to set the independent variables of applied load for the calibration 24 NASA Tech Briefs, October 2003 experiment, a high-precision mechanical system is required. Manual deadweight systems have been in use at Langley Research Center (LaRC) since the 1940s. These simple methodologies produce high confidence results, but the process is mechanically complex and labor-intensive, requiring three to four weeks to complete. Over the past decade, automated balance calibration systems have been developed. In general, these systems were designed to automate the tedious manual calibration process resulting in an even more complex system which deteriorates load application quality. The current calibration approach relies on a one-factor-at-a-time (OFAT) methodology, where each independent variable is incremented individually throughout its full-scale range, while all other variables are held at a constant magnitude. This OFAT approach has been widely accepted because of its inherent simplicity and intuitive appeal to the balance engineer. LaRC has been conducting research in a "modern design of experiments" (MDOE) approach to force balance calibration. Formal experimental design techniques provide an integrated view to the entire calibration process covering all three major aspects of an experiment; the design of the experiment, the execution of the experiment, and the statistical analyses of the data. In order to overcome the weaknesses in the available mechanical systems and to apply formal experimental techniques, a new mechanical system was required. The SVS enables the complete calibration of a six-component force balance with a series of single force vectors.

Parker, P. A.↗

NASA NTRS2012

Influence of Primary Gage Sensitivities on the Convergence of Balance Load Iterations

The connection between the convergence of wind tunnel balance load iterations and the existence of the primary gage sensitivities of a balance is discussed. First, basic elements of two load iteration equations that the iterative method uses in combination with results of a calibration data analysis for the prediction of balance loads are reviewed. Then, the connection between the primary gage sensitivities, the load format, the gage output format, and the convergence characteristics of the load iteration equation choices is investigated. A new criterion is also introduced that may be used to objectively determine if the primary gage sensitivity of a balance gage exists. Then, it is shown that both load iteration equations will converge as long as a suitable regression model is used for the analysis of the balance calibration data, the combined influence of non linear terms of the regression model is very small, and the primary gage sensitivities of all balance gages exist. The last requirement is fulfilled, e.g., if force balance calibration data is analyzed in force balance format. Finally, it is demonstrated that only one of the two load iteration equation choices, i.e., the iteration equation used by the primary load iteration method, converges if one or more primary gage sensitivities are missing. This situation may occur, e.g., if force balance calibration data is analyzed in direct read format using the original gage outputs. Data from the calibration of a six component force balance is used to illustrate the connection between the convergence of the load iteration equation choices and the existence of the primary gage sensitivities.

Ulbrich, Norbert Manfred↗

NASA NTRS2016

Assessment of the Uniqueness of Wind Tunnel Strain-Gage Balance Load Predictions

A new test was developed to assess the uniqueness of wind tunnel strain-gage balance load predictions that are obtained from regression models of calibration data. The test helps balance users to gain confidence in load predictions of non-traditional balance designs. It also makes it possible to better evaluate load predictions of traditional balances that are not used as originally intended. The test works for both the Iterative and Non-Iterative Methods that are used in the aerospace testing community for the prediction of balance loads. It is based on the hypothesis that the total number of independently applied balance load components must always match the total number of independently measured bridge outputs or bridge output combinations. This hypothesis is supported by a control volume analysis of the inputs and outputs of a strain-gage balance. It is concluded from the control volume analysis that the loads and bridge outputs of a balance calibration data set must separately be tested for linear independence because it cannot always be guaranteed that a linearly independent load component set will result in linearly independent bridge output measurements. Simple linear math models for the loads and bridge outputs in combination with the variance inflation factor are used to test for linear independence. A highly unique and reversible mapping between the applied load component set and the measured bridge output set is guaranteed to exist if the maximum variance inflation factor of both sets is less than the literature recommended threshold of five. Data from the calibration of a six{component force balance is used to illustrate the application of the new test to real-world data.

strain-gage balance↗

NASA NTRS1996

Calcium Balance in Mature Rats Exposed to a Space Flight Model

Negative calcium balances are seen in humans during spaceflight and bed rest, an analog of space flight. Due to the infrequency and costliness of space flight and the difficulties, cost, and restraints in using invasive procedures in bed rest studies, several ground based animal models of space flight have been employed. The most useful and well developed of these models is hind limb unloading in the rat. In this model the hind limbs are non-weight bearing (unloaded) but still mobile; there is a cephalad fluid shift similar to that seen in astronauts in flight; the animals are able to feed, groom and locomote using their front limbs; the procedure is reversible; and, importantly, the model has been validated by comparison to space flight. Several laboratories have studied calcium balance using rats in hind limb unweighting. Roer and Dillaman used young male rats to study calcium balance in this model for 25 days. They found no differences in dietary calcium intake, percent calcium absorption, urinary and fecal excretion, hence indicating no differences in calcium balance between control and unloaded rats. In another study, employing 120 day old females, rats' hind limbs were unloaded for 28 days. While negative calcium balances were observed during a 25 day recovery period no balance measurements were possible during unweighting since the researchers did not employ appropriate metabolic cages. In a recent study from this laboratory, using 200 g rats in the space flight model for two weeks, we found depressed intestinal calcium absorption and increased fecal calcium excretion (indicating less positive calcium balances) and lower circulating 1,25-dihydroxyvitamin D. The above studies indicate that there remains a dearth of information on calcium balance during the hind limb unloading rat space flight model, especially in mature rats, whose use is a better model for planned manned space flight than juvenile or growing animals. With the aid of a newly designed metabolic cage developed in our laboratory it is now possible to accurately measure urinary and fecal calcium excretions in this space flight model. The purpose of this study, then, was to extend and enlarge our previous findings viz: to measure calcium balances in mature rats exposed to a space flight model.

Wolinsky, Ira↗

NASA NTRS2001

Estimates of Ice Sheet Mass Balance from Satellite Altimetry: Past and Future

A major uncertainty in predicting sea level rise is the sensitivity of ice sheet mass balance to climate change, as well as the uncertainty in present mass balance. Since the annual water exchange is about 8 mm of global sea level equivalent, the 20% uncertainty in current mass balance corresponds to 1.6 mm/yr in sea level change. Furthermore, estimates of the sensitivity of the mass balance to temperature change range from perhaps as much as - 10% to + 10% per K. A principal purpose of obtaining ice sheet elevation changes from satellite altimetry has been estimation of the current ice sheet mass balance. Limited information on ice sheet elevation change and their implications about mass balance have been reported by several investigators from radar altimetry (Seasat, Geosat, ERS-1&2). Analysis of ERS-1&2 data over Greenland for 7 years from 1992 to 1999 shows mixed patterns of ice elevation increases and decreases that are significant in terms of regional-scale mass balances. Observed seasonal and interannual variations in ice surface elevation are larger than previously expected because of seasonal and interannUal variations in precipitation, melting, and firn compaction. In the accumulation zone, the variations in firn compaction are modeled as a function of temperature leaving variations in precipitation and the mass balance trend. Significant interannual variations in elevation in some locations, in particular the difference in trends from 1992 to 1995 compared to 1995 to 1999, can be explained by changes in precipitation over Greenland. Over the 7 years, trends in elevation are mostly positive at higher elevations and negative at lower elevations. In addition, trends for the winter seasons (from a trend analysis through the average winter elevations) are more positive than the corresponding trends for the summer. At lower elevations, the 7-year trends in some locations are strongly negative for summer and near zero or slightly positive for winter. These observations also demonstrate the potential for relating the variability in mass balance to changes in precipitation, temperature, and melting. Beginning in January 2002, NASA's ICESat laser altimeter mission will provide significantly better elevation accuracy and spatial coverage to 86E latitude and to the margins of the ice sheets.

Zwally, H. Jay↗

NASA NTRS2009

Construction of Low Dissipative High Order Well-Balanced Filter Schemes for Non-Equilibrium Flows

The goal of this paper is to generalize the well-balanced approach for non-equilibrium flow studied by Wang et al. [26] to a class of low dissipative high order shock-capturing filter schemes and to explore more advantages of well-balanced schemes in reacting flows. The class of filter schemes developed by Yee et al. [30], Sjoegreen & Yee [24] and Yee & Sjoegreen [35] consist of two steps, a full time step of spatially high order non-dissipative base scheme and an adaptive nonlinear filter containing shock-capturing dissipation. A good property of the filter scheme is that the base scheme and the filter are stand alone modules in designing. Therefore, the idea of designing a well-balanced filter scheme is straightforward, i.e., choosing a well-balanced base scheme with a well-balanced filter (both with high order). A typical class of these schemes shown in this paper is the high order central difference schemes/predictor-corrector (PC) schemes with a high order well-balanced WENO filter. The new filter scheme with the well-balanced property will gather the features of both filter methods and well-balanced properties: it can preserve certain steady state solutions exactly; it is able to capture small perturbations, e.g., turbulence fluctuations; it adaptively controls numerical dissipation. Thus it shows high accuracy, efficiency and stability in shock/turbulence interactions. Numerical examples containing 1D and 2D smooth problems, 1D stationary contact discontinuity problem and 1D turbulence/shock interactions are included to verify the improved accuracy, in addition to the well-balanced behavior.

Wang, Wei↗

NASA NTRS2013

Hidden Connections between Regression Models of Strain-Gage Balance Calibration Data

Hidden connections between regression models of wind tunnel strain-gage balance calibration data are investigated. These connections become visible whenever balance calibration data is supplied in its design format and both the Iterative and Non-Iterative Method are used to process the data. First, it is shown how the regression coefficients of the fitted balance loads of a force balance can be approximated by using the corresponding regression coefficients of the fitted strain-gage outputs. Then, data from the manual calibration of the Ames MK40 six-component force balance is chosen to illustrate how estimates of the regression coefficients of the fitted balance loads can be obtained from the regression coefficients of the fitted strain-gage outputs. The study illustrates that load predictions obtained by applying the Iterative or the Non-Iterative Method originate from two related regression solutions of the balance calibration data as long as balance loads are given in the design format of the balance, gage outputs behave highly linear, strict statistical quality metrics are used to assess regression models of the data, and regression model term combinations of the fitted loads and gage outputs can be obtained by a simple variable exchange.

Ulbrich, Norbert↗