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At least 37 records · Page 2

Superelastic Ball Bearings: Materials and Design to Avoid Mounting and Dismounting Brinell Damage in an Inaccessible Press-fit Application-: Detailed Analysis - II

Rolling element bearings utilized in precision rotating machines require proper alignment, preload, and interference fits to ensure overall optimum performance. Hence, careful attention must be given to bearing installation and disassembly procedures to ensure the above conditions are met. Usually, machines are designed in such a way that bearings can be pressed into housings or onto shafts through the races without loading the rolling elements. However, in some instances, either due to limited size or access, a bearing must be installed or removed in such a way that the load path travels through the rolling elements. This can cause high contact stresses between the rolling elements and the races and introduces the potential for Brinell denting of the races. This paper is a companion to the Part I paper by the authors that discusses material selection and the general design philosophy for the bearing. Here, a more in-depth treatment is given to the design of a dent-resistant bearing utilizing a superelastic alloy, 60NiTi, for the races. A common bearing analysis tool based on rigid body dynamics is used in combination with finite element simulations to design the superelastic bearing. The primary design constraints are prevention of denting and avoiding the balls riding over the edge of the race groove during a blind disassembly process where the load passes through the rolling elements. Through an iterative process, the resulting bearing geometry is tailored to improve axial static load capability compared to a deep-groove ball bearing of the same size. The results suggest that careful selection of materials and bearing geometry can enable blind disassembly without damage to the raceways, which is necessary in the current application (a compressor in the International Space Station Environmental Control and Life Support System), and results in potential design flexibility for other applications, especially small machines with miniature bearings.

metals↗

A simple hindlimb suspension apparatus

This paper describes the assembly of a simple, inexpensive apparatus for application of the hindlimb suspension model to studies of the effects of unloading on mammalian physiology. Construction of a cage and suspension assembly is described using materials that can be obtained from most hardware stores. The design is kept simple for easy assembly and disassembly to facilitate cleaning and storage. The suspension assembly allows the animals full access to all portions of the floor area and provides an effective environment to study the effects of unloading.

Park, E.↗

Digital redesign of the control system for the Robotics Research Corporation model K-1607 robot

The analog control system for positioning each link of the Robotics Research Corporation Model K-1607 robot manipulator was redesigned for computer control. In order to accomplish the redesign, a linearized model of the dynamic behavior of the robot was developed. The parameters of the model were determined by examination of the input-output data collected in closed-loop operation of the analog control system. The robot manipulator possesses seven degrees of freedom in its motion. The analog control system installed by the manufacturer of the robot attempts to control the positioning of each link without feedback from other links. Constraints on the design of a digital control system include: the robot cannot be disassembled for measurement of parameters; the digital control system must not include filtering operations if possible, because of lack of computer capability; and criteria of goodness of control system performing is lacking. The resulting design employs sampled-data position and velocity feedback. The criteria of the design permits the control system gain margin and phase margin, measured at the same frequencies, to be the same as that provided by the analog control system.

Carroll, Robert L.↗

Evolutionary Design of a Robotic Material Defect Detection System

During the post-flight inspection of SSME engines, several inaccessible regions must be disassembled to inspect for defects such as cracks, scratches, gouges, etc. An improvement to the inspection process would be the design and development of very small robots capable of penetrating these inaccessible regions and detecting the defects. The goal of this research was to utilize an evolutionary design approach for the robotic detection of these types of defects. A simulation and visualization tool was developed prior to receiving the hardware as a development test bed. A small, commercial off-the-shelf (COTS) robot was selected from several candidates as the proof of concept robot. The basic approach to detect the defects was to utilize Cadmium Sulfide (CdS) sensors to detect changes in contrast of an illuminated surface. A neural network, optimally designed utilizing a genetic algorithm, was employed to detect the presence of the defects (cracks). By utilization of the COTS robot and US sensors, the research successfully demonstrated that an evolutionarily designed neural network can detect the presence of surface defects.

Ballard, Gary↗

A strategy planner for NASA robotics applications

Automatic strategy or task planning is an important element of robotics systems. A strategy planner under development at Goddard Space Flight Center automatically produces robot plans for assembly, disassembly, or repair of NASA spacecraft from computer aided design descriptions of the individual parts of the spacecraft.

Brodd, S. S.↗

Heavily loaded joints for assembling aerobrake support trusses

The major emphasis was to develop erectable joints for large aerobrake support trusses. The truss joints must be able to withstand the large forces experienced by the truss during the aero-pass, as well as be easily assembled and disassembled on orbit by astronauts or robots. Other important design considerations include; strength, stiffness, and allowable error in strut length. Six mechanical joint designs, as well as a seventh joint design, where a high strength epoxy is injected to make the connection rigid, are presented.

Bandel, Hannskarl↗

Micro regulating ball valve

Ball valve of simple, rugged configuration overcomes leakage because there are no critical wear areas. Design has stable and precise calibration. Device can be assembled or disassembled in seconds and needs no lubrication.

Hawkins, J. W.↗

Badger COMET Compartmentalized Onboard Material Extrusion Technology

In response to the 2014 NASA Academic Innovation Challenge, the University of Wisconsin – Madison team presents the design of a collapsible Fused Deposition Modeling (FDM) system for in situ manufacturing in a space habitat environment, the Badger Compartmentalized Onboard Material Extrusion Technology (COMET). The proposed mechanism incorporates one year of design and testing on an array of current additive manufacturing techniques, with the goal of providing a reliable and maintainable manufacturing solution. Seven Level 1 requirements were employed to guide the design process, based on information in the challenge, communications with NASA, and the evolving systems feedback of project work groups. These requirements provided a baseline for the development of the System Requirements Document (SRD, Appendix I), which framed the design of the system. The design requirements deemed critical to the success of the systems are as follows: - The system shall compose an FDM workstation capable of producing parts within industry standard tolerances. - The system shall reduce to a minimum of 50 percent or less of its deployed volume when not in use, and must collapse without the need for disassembly. - The system shall meet all relevant NASA safety and functional standards. The final design for the Badger COMET was selected from multiple design iterations, which balanced the critical design requirements listed above with system reliability, with the final goal of providing a minimal system weight. The system collapses in the vertical direction, allowing for a maximum reduction in volume. Guide rods and precision, anti-backlash lead screws provide all linear movement in the device. Stepper motors were chosen to actuate each system axis, due to their high precision and repeatable accuracy. The system is controlled through an on-board computer system and embedded electronics package.

Frederick T. Elder↗

Space Shuttle Main Engine - The Relentless Pursuit of Improvement

The Space Shuttle Main Engine (SSME) is the only reusable large liquid rocket engine ever developed. The specific impulse delivered by the staged combustion cycle, substantially higher than previous rocket engines, minimized volume and weight for the integrated vehicle. The dual pre-burner configuration permitted precise mixture ratio and thrust control while the fully redundant controller and avionics provided a very high degree of system reliability and health diagnosis. The main engine controller design was the first rocket engine application to incorporate digital processing. The engine was required to operate at a high chamber pressure to minimize engine volume and weight. Power level throttling was required to minimize structural loads on the vehicle early in flight and acceleration levels on the crew late in ascent. Fatigue capability, strength, ease of assembly and disassembly, inspectability, and materials compatibility were all major considerations in achieving a fully reusable design. During the multi-decade program the design evolved substantially using a series of block upgrades. A number of materials and manufacturing challenges were encountered throughout SSME s history. Significant development was required for the final configuration of the high pressure turbopumps. Fracture control was implemented to assess life limits of critical materials and components. Survival in the hydrogen environment required assessment of hydrogen embrittlement. Instrumentation systems were a challenge due to the harsh thermal and dynamic environments within the engine. Extensive inspection procedures were developed to assess the engine components between flights. The Space Shuttle Main Engine achieved a remarkable flight performance record. All flights were successful with only one mission requiring an ascent abort condition, which still resulted in an acceptable orbit and mission. This was achieved in large part via extensive ground testing to fully characterize performance and to establish acceptable life limits. During the program over a million seconds of accumulated test and flight time was achieved. Post flight inspection and assessment was a key part of assuring proper performance of the flight hardware. By the end of the program the predicted reliability had improved by a factor of four. These unique challenges, evolution of the design, and the resulting reliability will be discussed in this paper.

VanHooser, Katherine P.↗

Design considerations for large space antennas

Performance requirements and costs for transportation, fabrication, and orbital assembly are the drivers in the design of large space antennas will range in size from approximately 30 m to 1 km in diameter and include radiometers, multibeam lens antennas, and microwave power transmission systems. Research and development is required to define comprehensive structural criteria for specific missions, to determine optimized geometries for truss elements and truss configurations and to establish requirements for joint design with consideration of tolerances, load transfer, thermal compatibility, and assembly and disassembly. Candidate structural elements, materials systems for the low pressure rapid cure of advanced composite materials, and various on orbit assembly and fabrication techniques must also be developed.

Johnson, R., Jr.↗

Low and High-Power Inductive Pulsed Plasma Thruster Development Testing at NASA-MSFC

The inductive pulsed plasma thruster (IPPT) is an electromagnetic plasma accelerator that has been identified in NASA roadmaps as an enabling propulsion technology for some niche low-power missions and for high-power in-space propulsion needs. The IPPT is an electrodeless space propulsion device where a capacitor is charged to an initial voltage and then discharged producing a high current pulse through a coil. The field produced by this pulse ionizes propellant, inductively driving current in a plasma located near the face of the coil. Once the plasma is formed it can be accelerated and expelled at a high exhaust velocity by the electromagnetic Lorentz body force arising from the interaction of the induced plasma current and the magnetic field produced by the current in the coil. Thrusters of this type possess many demonstrated and potential benefits that make them worthy of continued investigation. The electrodeless nature of these thrusters eliminates the lifetime and contamination issues associated with electrode erosion in conventional electric thrusters. Also, a wider variety of propellants are accessible when compatibility with metallic electrodes in no longer an issue. IPPTs have been successfully operated using propellants like ammonia, hydrazine, and CO2, and there is no fundamental reason why they would not operate on other in situ propellants like H2O. It is well-known that pulsed accelerators can maintain constant specific impulse (I(sub sp)) and thrust efficiency (eta(sub t)) over a wide range of input power levels by adjusting the pulse rate to hold the discharge energy per pulse constant. It has also been demonstrated that an inductive pulsed plasma thruster can operate in a regime where eta(sub t) is relatively constant over a wide range of I(sub sp) values (3000-8000 s). Finally, thrusters in this class have operated in single-pulse mode at high energy per pulse, and by increasing the pulse rate they offer the potential to process very high levels of power using a single thruster. There has been significant previous research on IPPTs designed around a planar-coil (flat-plate) geometry. The most notable of these was the Pulsed Inductive Thruster (PIT), with the PIT MkV presently representing the state-of- the-art in pulsed high-power IPPT technological development. In this paper, we focus on two planar-geometry devices that operate at significantly different power levels. Most work performed at NASA-Marshall Space Flight Center (MSFC) has, to date, focused on lower power thruster operation (approx. = 10s to 100s of J/pulse, up to 2-2.5 kW average power throughput) and previously described. The most recent work aimed to assemble a device that could be tested in cyclic mode on a thrust-stand, and which could augment the existing data set for IPPTs. In addition, the thruster was designed to serve as a test-bed for solid state switching circuitry and pulsed gas valves, with the modular design of the device allowing for variation in or upgrades to test configuration. Recently, MSFC obtained on loan from the Georgia Institute of Technology (Atlanta, GA) the PIT MkVI, successor to the PIT MkV. The MkV and MkVI are similar in design with much of the hardware from the former, specifically the capacitors and spark-gap switches, being reused in the latter. The coil is similar in geometry but has bent copper rods used in the latest iteration in place of the Litz wire windings found in the MkV. The MkVI master switch for the spark gaps is located in the vacuum chamber contained within a sealed, pressurized vessel fastened to the back of the thruster. This is different from the MkV where many capacitor charging lines and spark gap-triggering delay lines ran to the thruster from a master trigger located outside the vacuum chamber. The MkVI was damaged during testing soon after its fabrication was completed. The thruster arrived at MSFC still-damaged and mostly disassembled into many individual pieces. The device has been repaired, with a few additional design changes implemented after discussions with the late Prof. Lovberg regarding the initial testing results and issues encountered. In the present work, we present results from testing of both the small IPPT and the larger MkVI thruster. The smaller device (Fig. 1) is tested on a thrust stand on multiple gases to demonstrate its capability to operate in a repetition-rate mode and serve as a IPPT technology-development testbed. The larger MkVI (Fig. 2) is operated for the first time in its newly reconstituted state, demonstrating full-power pulsed operation and, for the first time, repetition-rate operation of a high-power IPPT. The additional upgrades required for synchronous operation of all the pulsed systems in single-pulse and repetition-rate mode are described in detail.

Polzin, Kurt A.↗

Inductive Pulsed Plasma Thruster Development Testing at NASA-MSFC

The inductive pulsed plasma thruster (IPPT) is an electromagnetic plasma accelerator that has been identified in NASA roadmaps as an enabling propulsion technology for some niche low-power missions and for high-power in-space propulsion needs. The IPPT is an electrodeless space propulsion device where a capacitor is charged to an initial voltage and then discharged producing a high current pulse through a coil. The field produced by this pulse ionizes propellant, inductively driving current in a plasma located near the face of the coil. Once the plasma is formed it can be accelerated and expelled at a high exhaust velocity by the electromagnetic Lorentz body force arising from the interaction of the induced plasma current and the magnetic field produced by the current in the coil. Thrusters of this type possess many demonstrated and potential benefits that make them worthy of continued investigation. The electrodeless nature of these thrusters eliminates the lifetime and contamination issues associated with electrode erosion in conventional electric thrusters. Also, a wider variety of propellants are accessible when compatibility with metallic electrodes in no longer an issue. IPPTs have been successfully operated using propellants like ammonia, hydrazine, and CO2, and there is no fundamental reason why they would not operate on other in situ propellants like H2O. It is well-known that pulsed accelerators can maintain constant specific impulse (I(sub sp)) and thrust efficiency (η(sub t)) over a wide range of input power levels by adjusting the pulse rate to hold the discharge energy per pulse constant. It has also been demonstrated that an inductive pulsed plasma thruster can operate in a regime where η(sub t) is relatively constant over a wide range of I(sub sp) values (3000-8000 s). Finally, thrusters in this class have operated in single-pulse mode at high energy per pulse, and by increasing the pulse rate they offer the potential to process very high levels of power using a single thruster. There has been significant previous research on IPPTs designed around a planar-coil (flat-plate) geometry. The most notable of these was the Pulsed Inductive Thruster (PIT), with the PIT MkV presently representing the state of- the-art in pulsed high-power IPPT technological development. In this paper, we focus on two planar-geometry devices that operate at significantly different power levels. Most work performed at NASA-Marshall Space Flight Center (MSFC) has, to date, focused on lower power thruster operation (≈ 10s to 100s of J/pulse, up to 2-2.5 kW average power throughput) and previously described in Refs. [5,6]. The most recent work aimed to assemble a device that could be tested in cyclic mode on a thrust-stand, and which could augment the existing data set for IPPTs. In addition, the thruster was designed to serve as a test-bed for solid state switching circuitry and pulsed gas valves, with the modular design of the device allowing for variation in or upgrades to test configuration. Recently, MSFC obtained on loan from the Georgia Institute of Technology (Atlanta, GA) the PIT MkVI, successor to the PIT MkV. The MkV and MkVI are similar in design with much of the hardware from the former, specifically the capacitors and spark-gap switches, being reused in the latter. The coil is simliar in geometry but has bent copper rods used in the latest iteration in place of the Litz wire windings found in the MkV. The MkVI master switch for the spark gaps is located in the vacuum chamber contained within a sealed, pressurized vessel fastened to the back of the thruster. This is different from the MkV where many capacitor charging lines and spark gap-triggering delay lines ran to the thruster from a master trigger located outside the vacuum chamber. The MkVI was damaged during testing soon after its fabrication was completed. The thruster arrived at MSFC still-damaged and mostly disassembled into many individual pieces. The device has been repaired, with a few additional design changes implemented after discussions with the late Prof. Lovberg regarding the initial testing results and issues encountered.

Polzin, Kurt A.↗

Failure Analysis of Nickel-hydrogen Cell Subjected to Simulated Low Earth Orbit Cycling

A nickel-hydrogen cell completed 10,080 simulated low earth orbit charge/discharge cycles at depths-of-discharge ranging from 50 to 80 percent prior to failure. The cell is of the Air Force design, rated at 50 ampere-hours, 8.9 cm (3.5 inches) in diameter. Upon disassembly, the end of the polysulfone core supporting the electrode stack was found to have fractured. This allowed the electrode stack to expand. A massive short was found at the inner diameter of the electrodes centered roughly at plate set 34 to 37 from the positive end of the electrode stack. The damaged area extended through approximately one third of the electrode stack, with the effect becoming progressively less with distance from plate set 34 to 37. Measured thicknesses of the positive plates were significantly greater than the initial specification values. The postulated cause of failure is that positive plate growth caused fracture of the shoulder from the end of the polysulfone core on which the electrodes are mounted. The electrode stack relieved and pressure points were created at the area near the inner diameter of the plates at the tab attachment. A short occurred at a pressure point between opposing plates and propagated to other electrode sets due to thermal and mechanical stresses caused by the short.

Mueller, V. C.↗

High-Temperature Surface-Acoustic-Wave Transducer

Aircraft-engine rotating equipment usually operates at high temperature and stress. Non-invasive inspection of microcracks in those components poses a challenge for the non-destructive evaluation community. A low-profile ultrasonic guided wave sensor can detect cracks in situ. The key feature of the sensor is that it should withstand high temperatures and excite strong surface wave energy to inspect surface/subsurface cracks. As far as the innovators know at the time of this reporting, there is no existing sensor that is mounted to the rotor disks for crack inspection; the most often used technology includes fluorescent penetrant inspection or eddy-current probes for disassembled part inspection. An efficient, high-temperature, low-profile surface acoustic wave transducer design has been identified and tested for nondestructive evaluation of structures or materials. The development is a Sol-Gel bismuth titanate-based surface-acoustic-wave (SAW) sensor that can generate efficient surface acoustic waves for crack inspection. The produced sensor is very thin (submillimeter), and can generate surface waves up to 540 C. Finite element analysis of the SAW transducer design was performed to predict the sensor behavior, and experimental studies confirmed the results. One major uniqueness of the Sol-Gel bismuth titanate SAW sensor is that it is easy to implement to structures of various shapes. With a spray coating process, the sensor can be applied to surfaces of large curvatures. Second, the sensor is very thin (as a coating) and has very minimal effect on airflow or rotating equipment imbalance. Third, it can withstand temperatures up to 530 C, which is very useful for engine applications where high temperature is an issue.

Zhao, Xiaoliang↗

PROPULSE 980: A Hydrogen Peroxide Enrichment System

The PROPULSE 980 unit is a transportable processing plant that enriches aerospace grade hydrogen peroxide from 90% to 98% final concentration. The unit was developed by Degussa-H Is, in cooperation with Orbital, NASA Marshall Space Center, and NASA Stennis Space Center. The system is a self-contained unit that houses all of the process equipment, instrumentation and controls to perform the concentration operation nearly autonomously. It is designed to produce non-bulk quantities of 98% hydrogen peroxide. The enrichment unit design also maintains system, personnel and environmental safety during all aspects of the enrichment process and final product storage. As part of the Propulse 980 checkout and final buyoff, it will be disassembled at the Degussa-H Is Corporation plant in Theodore, AL, transported to the Stennis Space Center, reassembled and subjected to a series of checkout tests to verify design objectives have been met. This paper will summarize the basic project elements and provide an update on the present status of the project.

Boxwell, Robert↗

A lightweight, high strength dexterous manipulator for commercial applications

The concept, design, and features are described of a lightweight, high strength, modular robot manipulator being developed for space and commercial applications. The manipulator has seven fully active degrees of freedom and is fully operational in 1 G. Each of the seven joints incorporates a unique drivetrain design which provides zero backlash operation, is insensitive to wear, and is single fault tolerant to motor or servo amplifier failure. Feedback sensors provide position, velocity, torque, and motor winding temperature information at each joint. This sensing system is also designed to be single fault tolerant. The manipulator consists of five modules (not including gripper). These modules join via simple quick-disconnect couplings and self-mating connectors which allow rapid assembly and/or disassembly for reconfiguration, transport, or servicing. The manipulator is a completely enclosed assembly, with no exposed components or wires. Although the initial prototype will not be space qualified, the design is well suited to meeting space requirements. The control system provides dexterous motion by controlling the endpoint location and arm pose simultaneously. Potential applications are discussed.

Marzwell, Neville I.↗

Assembly Test Article (ATA)

The assembly test article (ATA) consisted of two live loaded redesigned solid rocket motor (RSRM) segments which were assembled and disassembled to simulate the actual flight segment stacking process. The test assembly joint was flight RSRM design, which included the J-joint insulation design and metal capture feature. The ATA test was performed mid-November through 24 December 1987, at Kennedy Space Center (KSC), Florida. The purpose of the test was: certification that vertical RSRM segment mating and separation could be accomplished without any damage; verification and modification of the procedures in the segment stacking/destacking documents; and certification of various GSE to be used for flight assembly and inspection. The RSRM vertical segment assembly/disassembly is possible without any damage to the insulation, metal parts, or seals. The insulation J-joint contact area was very close to the predicted values. Numerous deviations and changes to the planning documents were made to ensure the flight segments are effectively and correctly stacked. Various GSE were also certified for use on flight segments, and are discussed in detail.

Ricks, Glen A.↗

Knowledge acquisition for autonomous systems

Knowledge-based capabilities for autonomous aerospace systems, such as the NASA Space Station, must encompass conflict-resolution functions comparable to those of human operators, with all elements of the system working toward system goals in a concurrent, asynchronous-but-coordinated fashion. Knowledge extracted from a design database will support robotic systems by furnishing geometric, structural, and causal descriptions required for repair, disassembly, and assembly. The factual knowledge for these databases will be obtained from a master database through a technical management information system, and it will in many cases have to be augmented by domain-specific heuristic knowledge acquired from domain experts.

Lum, Henry↗