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SMART Rotor Wind Tunnel Test Report

The Boeing Company, Mesa Arizona, has been developing smart material actuated rotor technology (SMART) under in-house, DARPA (Defense Advanced Research Projects Agency), NASA and Army funding. A whirl tower test of the SMART active flap rotor system was successfully conducted at the remote test facility (RTF) in Mesa, Arizona, in 2003. Under DARPA and NASA funding, the SMART rotor system was tested in the NASA Ames National Full Scale Aerodynamic Complex (NFAC) 40- by 80-Foot Wind Tunnel in 2008. The DARPA program objectives were to demonstrate the active flap impact on rotor acoustics in forward flight and establish a validation database for noise prediction tools. Under NASA funding, additional wind tunnel tests were conducted, with the objective to demonstrate and quantify vibration, noise, and performance improvements.Wind tunnel testing was successfully and safely concluded, meeting all high priority objectives. The authority, effectiveness, and reliability of the flap actuation system were demonstrated in 65 hours of testing at up to 155 knots and 7,700 pound thrust. Validation data was successfully acquired for four test conditions; blade loads were too high for the high speed condition. The effectiveness of the flap for noise and vibration control was demonstrated conclusively, with results showing significant reductions in BVI (Blade-Vortex Interaction) and in-plane noise as well as vibratory hub loads. The impact of the flap on control power and rotor smoothing was also demonstrated. Data evaluating any benefits in aerodynamic performance and impact on flight controls were acquired, but will need more detailed evaluation. Both open loop control and closed loop feedback control, using continuous time and higher harmonic controllers, were applied.The purpose of the Test Report is to provide a comprehensive document that describes the preparation for and conduct of the wind tunnel test and summarizes the processing and evaluation of wind tunnel test data for the DARPA and the NASA portion of the test. An overview of the wind tunnel test and results can be found in Reference 1. Details on the testing and results for BVI noise, in-plane noise, and vibrations can be found in References 2-4, respectively. These references are four papers, presented at the American Helicopter Society Annual Forum in 2009. A brief description of the delivered electronic data is provided in Reference 5.

Rotor

Ultrasonic/sonic drilling/coring (USDC) for planetary applications

One of the major limitations of sampling on Mars and other low gravity environments is the need for high axial force when using conventional drilling. To address this limitation an ultrasonic/sonic drilling/coring (USDC) mechanism has been developed that employs an ultrasonic horn driven by a piezoelectric stack. The horn dnves a free mass that resonates between the horn and drill stein. Tests have shown that the USDC addresses some of the key challenges to the NASA sampling objectives. The USDC is lightweight (450 g), requires low preload (<5N) and can be driven at low power (5W), The device has been shown to drill rocks with various levels of hardness including granite, diorite, basalt and limestone. The hammering action involved with the coring process can produce cores of various shapes, which need not necessarily be round. Because it is driven by piezoelectric ceramics, the USDC is highly tolerant to changes in its operating environment. These actuation materials can be designed to operate at a wide range of temperatures including those expected on Mars and Venus. Although the drill is driven electrically at 20 kHz, a substantial sub-harmonic acoustic component is found that is crucial to drilling performance. An analytical model has been developed to explain this low frequency coupling in the horn, free mass, drill stem and rock.

Peterson, Thomas

Recent Progress in Adaptive Structures for Space

Within the past 10 years, substantial research in Adaptive Structures is evident and continues its integration into various space experiments and missions. The rapid integration is attributable to solutions Adaptive Structures potentially provides to many anticipated space challenges in large precision space structures and commercial availability of reliable actuator materials. The emphasis of the paper is on space experiments related to Adaptive Structures within the past two years.

Adaptive

Actuation Using Piezoelectric Materials: Application in Augmenters, Energy Harvesters, and Motors

Piezoelectric actuators are used in many manipulation, movement, and mobility applications as well as transducers and sensors. When used at the resonance frequencies of the piezoelectric stack, the actuator performs at its maximum actuation capability. In this Space Grant internship, three applications of piezoelectric actuators were investigated including hammering augmenters of rotary drills, energy harvesters, and piezo-motors. The augmenter shows improved drill performance over rotation only. The energy harvesters rely on moving fluid to convert mechanical energy into electrical power. Specific designs allow the harvesters more freedom to move, which creates more power. The motor uses the linear movement of the actuator with a horn applied to the side of a rotor to create rotational motion. Friction inhibits this motion and is to be minimized for best performance. Tests and measurements were made during this internship to determine the requirements for optimal performance of the studied mechanisms and devices.

drills

Cobalt ferrite based magnetostrictive materials for magnetic stress sensor and actuator applications

Magnetostrictive material based on cobalt ferrite is described. The cobalt ferrite is substituted with transition metals (such manganese (Mn), chromium (Cr), zinc (Zn) and copper (Cu) or mixtures thereof) by substituting the transition metals for iron or cobalt to form substituted cobalt ferrite that provides mechanical properties that make the substituted cobalt ferrite material effective for use as sensors and actuators. The substitution of transition metals lowers the Curie temperature of the material (as compared to cobalt ferrite) while maintaining a suitable magnetostriction for stress sensing applications.

Jiles, David C.

Computational Nanotechnology of Molecular Materials, Electronics, and Actuators with Carbon Nanotubes and Fullerenes

The role of computational nanotechnology in developing next generation of multifunctional materials, molecular scale electronic and computing devices, sensors, actuators, and machines is described through a brief review of enabling computational techniques and few recent examples derived from computer simulations of carbon nanotube based molecular nanotechnology.

Srivastava, Deepak

Advanced silicone materials for soft actuator applications

Soft actuators are at the forefront of the innovation tide in medicine, manufacturing, and aerospace because they are able to mimic the behavior of biological tissue and adapt to complex, unstructured environments. Of all the materials used, silicone-based elastomers have drawn enormous attention since they offer a superb combination of mechanical flexibility, biocompatibility, thermal stability, and long-term durability. In the past few years, there has also been a rapid pace of material evolution, additive manufacturing, and biointegration that has enhanced the performance and applications of silicone-based soft actuators. However, there is no focused and timely review compiling these advances. This review seeks to address that need by critically discussing recent advancements in advanced silicone materials, exploring new fabrication methodologies, and discussing emerging applications that range from wearable devices to implantable robotics. We also present suggestions for directions and the problems which must be addressed in order to further develop the performance and potential of silicone-based soft actuators, justifying the relevance and urgency of this effort.

biocompatibility

Overview of Honeywell electromechanical actuation programs

Materials illustrating a presentation on electromechanical actuation programs (EMA) are presented. The development history is outlined. Space shuttle flight control systems and the advantages of EMAS, and EMA technology status and development requirements are outlined.

Wyllie, C.

Analysis and Testing of Plates with Piezoelectric Sensors and Actuators

Piezoelectric material inherently possesses coupling between electrostatics and structural dynamics. Utilizing linear piezoelectric theory results in an intrinsically coupled pair of piezoelectric constitutive equations. One equation describes the direct piezoelectric effect where strains produce an electric field and the other describes the converse effect where an applied electrical field produces strain. The purpose of this study is to compare finite element analysis and experiments of a thin plate with bonded piezoelectric material. Since an isotropic plate in combination with a thin piezoelectric layer constitutes a special case of a laminated composite, the classical laminated plate theory is used in the formulation to accommodated generic laminated composite panels with multiple bonded and embedded piezoelectric layers. Additionally, the von Karman large deflection plate theory is incorporated. The formulation results in laminate constitutive equations that are amiable to the inclusion of the piezoelectric constitutive equations yielding in a fully electro-mechanically coupled composite laminate. Using the finite element formulation, the governing differential equations of motion of a composite laminate with embedded piezoelectric layers are derived. The finite element model not only considers structural degrees of freedom (d.o.f.) but an additional electrical d.o.f. for each piezoelectric layer. Comparison between experiment and numerical prediction is performed by first treating the piezoelectric as a sensor and then again treating it as an actuator. To assess the piezoelectric layer as a sensor, various uniformly distributed pressure loads were simulated in the analysis and the corresponding generated voltages were calculated using both linear and nonlinear finite element analyses. Experiments were carried out by applying the same uniformly distributed loads and measuring the resulting generated voltages and corresponding maximum plate deflections. It is found that a highly nonlinear relationship exists between maximum deflection and voltage versus pressure loading. In order to assess comparisons of predicted and measured piezoelectric actuation, sinusoidal excitation voltages are simulated/applied and maximum deflections are calculated/measured. The maximum deflection as a function of time was determined using the linear finite elements analysis. Good correlation between prediction and measurement was achieved in all cases.

Bevan, Jeffrey S.

Performance of Integrated Fiber Optic, Piezoelectric, and Shape Memory Alloy Actuators/Sensors in Thermoset Composites

Recently, scientists and engineers have investigated the advantages of smart materials and structures by including actuators in material systems for controlling and altering the response of structural environments. Applications of these materials systems include vibration suppression/isolation, precision positioning, damage detection and tunable devices. Some of the embedded materials being investigated for accomplishing these tasks include piezoelectric ceramics, shape memory alloys, and fiber optics. These materials have some benefits and some shortcomings; each is being studied for use in active material design in the SPICES (Synthesis and Processing of Intelligent Cost Effective Structures) Consortium. The focus of this paper concerns the manufacturing aspects of smart structures by incorporating piezoelectric ceramics, shape memory alloys and fiber optics in a reinforced thermoset matrix via resin transfer molding (RTM).

Trottier, C. Michael

An analytical and experimental investigation of flutter suppression via piezoelectric actuation

The objective of this research was to analytically and experimentally study the capabilities of adaptive material plate actuators for suppressing flutter. Piezoelectrics are materials which are characterized by their ability to produce voltage when subjected to a mechanical strain. The converse piezoelectric effect can be utilized to actuate a structure by applying a voltage. For this investigation, a two degree of freedom wind-tunnel model was designed, analyzed, and tested. The model consisted of a rigid wing and a flexible mount system which permitted translational and rotational degrees of freedom. Actuators, made of piezoelectric material were affixed to leaf springs on the mount system. Command signals, applied to the piezoelectric actuators, exerted control over the closed-loop damping and stiffness properties. A mathematical aeroservoelastic model was constructed using finite element and stiffness properties. A mathematical aeroservoelastic model was constructed using finite element methods, laminated plate theory, and aeroelastic analysis tools. A flutter suppression control law was designed, implemented on a digital control computer, and tested to conditions 20 percent above the passive flutter speed of the model. The experimental results represent the first time that adaptive materials have been used to actively suppress flutter. It demonstrates that small, carefully-placed actuating plates can be used effectively to control aeroelastic response.

Heeg, Jennifer

An analytical and experimental study to investigate flutter suppression via piezoelectric actuation

The objective was to analytically and experimentally study the capabilities of adaptive material plate actuators for suppressing flutter. The validity of analytical modeling techniques for piezoelectric materials was also investigated. Piezoelectrics are materials which are characterized by their ability to produce voltage when subjected to a mechanical strain. The converse piezoelectric effect can be utilized to actuate a structure by applying a voltage. For this investigation, a two degree of freedom wind tunnel model was designed, analyzed, and tested. The model consisted of a rigid airfoil and a flexible mount system which permitted a translational and a rotational degree of freedom. It was designed such that flutter was encounted within the testing envelope of the wind tunnel. Actuators, made of piezoelectric material were affixed to leaf springs of the mount system. Each degree of freedom was controlled by a separate leaf spring. Command signals, applied to the piezoelectric actuators, exerted control over the damping and stiffness properties. A mathematical aeroservoelastic model was constructed using finite element methods, laminated plate theory, and aeroelastic analysis tools. Plant characteristics were determined from this model and verified by open loop experimental tests. A flutter suppression control law was designed and implemented on a digital control computer. Closed loop flutter testing was conducted. The experimental results represent the first time that adaptive materials have been used to actively suppress flutter. It demonstrates that small, carefully placed actuating plates can be used effectively to control aeroelastic response.

Heeg, Jennifer

Cylindrical Piezoelectric Fiber Composite Actuators

The use of piezoelectric devices has become widespread since Pierre and Jacques Curie discovered the piezoelectric effect in 1880. Examples of current applications of piezoelectric devices include ultrasonic transducers, micro-positioning devices, buzzers, strain sensors, and clocks. The invention of such lightweight, relatively inexpensive piezoceramic-fiber-composite actuators as macro fiber composite (MFC) actuators has made it possible to obtain strains and displacements greater than those that could be generated by prior actuators based on monolithic piezoceramic sheet materials. MFC actuators are flat, flexible actuators designed for bonding to structures to apply or detect strains. Bonding multiple layers of MFC actuators together could increase force capability, but not strain or displacement capability. Cylindrical piezoelectric fiber composite (CPFC) actuators have been invented as alternatives to MFC actuators for applications in which greater forces and/or strains or displacements may be required. In essence, a CPFC actuator is an MFC or other piezoceramic fiber composite actuator fabricated in a cylindrical instead of its conventional flat shape. Cylindrical is used here in the general sense, encompassing shapes that can have circular, elliptical, rectangular or other cross-sectional shapes in the planes perpendicular to their longitudinal axes.

Allison, Sidney G.

Humanoids and the Potential Role of Electroactive Materials/Mechanisms in Advancing Their Capability

Humanoids are increasingly becoming capable biologically inspired robots that are appearing and behaving lifelike. Making humanlike robots is the ultimate challenge to biomimetics and, while for many years they were considered a science fiction, such robots are increasingly becoming engineering reality. Progress in producing such robots are allowing them to perform impressive functions and tasks. In 2012, in an effort to promote significant advances in developing humanoids, DARPA (Defense Advanced Research Projects Agency) posed a Robotic Challenge to produce such robots that operate in disaster scenarios towards making society more resilient. The challenge was focused on the requirements that have been needed after the Fukushima accident in Japan, hoping to advance the field of disaster robotics. This disaster posed significant challenges to emergency responders since radiation prevented people from going into the station and venting the explosive gas. Another significant development in this field is the fact that major US corporations have entered into the race to produce commercial humanoids. As a result, one can expect significant and rapid progress in this field. Developing humanoids is critically dependent of the use of highly efficient, compact, lightweight actuators and electroactive materials are offering great potential. This paper reviews the state-of-theart of humanlike robots, potential applications and challenges, as well as the actuation materials that are used or could be used.

Electroactive Polymer Actuators

Humanoids and the Potential Role of Electroactive Materials/Mechanisms in Advancing Their Capability

Humanoids are increasingly becoming capable biologically inspired robots that are appearing and behaving lifelike. Making humanlike robots is the ultimate challenge to biomimetics and, while for many years they were considered a science fiction, such robots are increasingly becoming engineering reality. Progress in producing such robots are allowing them to perform impressive functions and tasks. In 2012, in an effort to promote significant advances in developing humanoids, DARPA posed a Robotic Challenge to produce such robots that operate in disaster scenarios towards making society more resilient. The challenge was focused on the requirements that have been needed after the Fukushima accident in Japan, hoping to advance the field of disaster robotics. This disaster posed significant challenges to emergency responders since radiation prevented people from going into the station and venting the explosive gas. Another significant development in this field is the fact that major US corporations have entered into the race to produce commercial humanoids. As a result, one can expect significant and rapid progress in this field. Developing humanoids is critically dependent of the use of highly efficient, compact, lightweight actuators and electroactive materials are offering great potential. This paper reviews the state-of-theart of humanlike robots, potential applications and challenges, as well as the actuation materials that are used or could be used.

Electroactive Polymer Actuators

Spline Approximation of Thin Shell Dynamics

A spline-based method for approximating thin shell dynamics is presented here. While the method is developed in the context of the Donnell-Mushtari thin shell equations, it can be easily extended to the Byrne-Flugge-Lur'ye equations or other models for shells of revolution as warranted by applications. The primary requirements for the method include accuracy, flexibility and efficiency in smart material applications. To accomplish this, the method was designed to be flexible with regard to boundary conditions, material nonhomogeneities due to sensors and actuators, and inputs from smart material actuators such as piezoceramic patches. The accuracy of the method was also of primary concern, both to guarantee full resolution of structural dynamics and to facilitate the development of PDE-based controllers which ultimately require real-time implementation. Several numerical examples provide initial evidence demonstrating the efficacy of the method.

delRosario, R. C. H.

Optically Driven Deformable Mirrors

Optically driven deformable mirrors may eventually supplant electrically driven deformable mirrors in some adaptive-optics and active-optics applications. Traditionally, the mirror facets in electrically driven deformable mirrors are actuated, variously, by means of piezoelectric, electrostrictive, microelectromechanical, liquid-crystal, or thermal devices. At least one such device must be dedicated to each facet, and there must be at least one wire carrying a control or drive signal to the device. If a deformable mirror comprises many (e.g., thousands) of facets, then wiring becomes a major problem for design, and the problem is compounded in cases of piezoelectric or other actuators for which high drive voltages are required. In contrast, in optically driven mirrors, the wiring problem is eliminated. The basic principle of actuation of an optically driven deformable mirror is to use a laser beam to actuate a material. For example, a laser beam can be used to heat a material to make the material thermally expand to displace a mirror facet. In an experiment to demonstrate this principle, the actuator was a Golay cell having a diameter of approximately equal to 6 mm and a length of approximately equal to 10 mm. The beam from a laser diode was aimed at an absorber in the cell, thereby heating the gas in the cell. A mirror mounted on a 12.5-micron-thick polyethylene terephthalate diaphragm at one end of the cell became displaced as the gas expanded against the diaphragm. In one representative pair of experiments at a laser beam power of 0.23 W, the beam was mechanically chopped at frequencies of 1 and 5 Hz. The mirror exhibited corresponding oscillating displacements having amplitudes of 373 and 83 micron, respectively

Hemmati, Hamid