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Space Shuttle Rudder Speed Brake Actuator-A Case Study Probabilistic Fatigue Life and Reliability Analysis

The U.S. Space Shuttle fleet was originally intended to have a life of 100 flights for each vehicle, lasting over a 10-year period, with minimal scheduled maintenance or inspection. The first space shuttle flight was that of the Space Shuttle Columbia (OV-102), launched April 12, 1981. The disaster that destroyed Columbia occurred on its 28th flight, February 1, 2003, nearly 22 years after its first launch. In order to minimize risk of losing another Space Shuttle, a probabilistic life and reliability analysis was conducted for the Space Shuttle rudder/speed brake actuators to determine the number of flights the actuators could sustain. A life and reliability assessment of the actuator gears was performed in two stages: a contact stress fatigue model and a gear tooth bending fatigue model. For the contact stress analysis, the Lundberg-Palmgren bearing life theory was expanded to include gear-surface pitting for the actuator as a system. The mission spectrum of the Space Shuttle rudder/speed brake actuator was combined into equivalent effective hinge moment loads including an actuator input preload for the contact stress fatigue and tooth bending fatigue models. Gear system reliabilities are reported for both models and their combination. Reliability of the actuator bearings was analyzed separately, based on data provided by the actuator manufacturer. As a result of the analysis, the reliability of one half of a single actuator was calculated to be 98.6 percent for 12 flights. Accordingly, each actuator was subsequently limited to 12 flights before removal from service in the Space Shuttle.

Rudder↗

Wind tunnel tests of the dynamic characteristics of the fluidic rudder

The fourth phase is given of a continuing program to develop the means to stabilize and control aircraft without moving parts or a separate source of power. Previous phases have demonstrated the feasibility of (1) generating adequate control forces on a standard airfoil, (2) controlling those forces with a fluidic amplifier and (3) cascading non-vented fluidic amplifiers operating on ram air supply pressure. The foremost objectives of the fourth phase covered under Part I of this report were to demonstrate a complete force-control system in a wind tunnel environment and to measure its static and dynamic control characteristics. Secondary objectives, covered under Part II, were to evaluate alternate configurations for lift control. The results demonstrate an overall response time of 150 msec, confirming this technology as a viable means for implementing low-cost reliable flight control systems.

Belsterling, C. A.↗

Measurements of Rudder Moments on an Airplane During Flight

Tests indicated that: 1) C airplanes with two struts are extremely susceptible to aileron maneuvers, slight alterations of the aileron sufficing to compensate great unequalized moments; 2) great unequalized moments can be produced or neutralized by the unequalized alternation of the angle of attack below the outer and inner struts. Adjustment below the outer strut is the more effective of the two. 3) When a load of bombs is suspended beyond the center of the airplane, below the wings, the bombs need not be dropped simultaneously. 4) The propeller wash of a wide open engine has considerable influence on the position and operation of the elevator. The elevator is more susceptible in flight with the engine running than in gliding flight. 5) Adjustable tail planes are not advisable for D airplanes, nor for the C type, but they are, on the other hand, to be recommended for large size and giant airplanes in which the center of gravity changes during flight. 6) The aileron values obtained by wind tunnel measurements are about 10 percent too low, though otherwise applicable. For the elevator, the results of such measurements should be taken as mean values between flight with the engine running and gliding flight.

Heidelberg, Ing V↗