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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 73 records · Page 4
All sourcesNASA NTRSDOE OSTI
NASA NTRSDate not supplied

Challenges and Considerations When Using Hydraulic Modal Shaking in Large-Scale Modal Testing

As test articles become dimensionally larger, more complex, and massive in weight, combined with the need to excite them to higher than traditional levels in order to identify their nonlinear characteristics, modal shakers that can generate significantly higher force levels, have longer stroke lengths, and possess higher velocity limits are required. While large scale modal tests may be performed with electrodynamic modal shakers, hydraulic modal shakers become attractive since they can generate higher force levels at lower unit cost with a smaller spatial footprint. While test engineers familiar with electrodynamic modal shakers are familiar with the challenges of displacement and velocity limits and the relatively mild shaker nonlinear distortion due to amplifier gains and shaker flexure structural geometric nonlinearities, they probably are not as familiar with the unique set of challenges hydraulic modal shakers present. These unique challenges include significant nonlinear distortion in the shaker force, issues with the setup of the hydraulic power supply and the associated hydraulic hosing, velocity limits as they relate to potentially damaging the hydraulic actuator piston, and safety issues with operating high-pressure hydraulic systems. This paper addresses these unique challenges to help the test engineer to better utilize hydraulic modal shakers on large-scale modal tests.

Distortion↗
NASA NTRSDate not supplied

Challenges and Considerations When Using Hydraulic Modal Shaking in Large-Scale Modal Testing IMAC-XL

As test articles become dimensionally larger, more complex, and massive in weight, combined with the need to excite them to higher than traditional levels in order to identify their nonlinear characteristics, modal shakers that can generate significantly higher force levels, have longer stroke lengths, and possess higher velocity limits are required. While large scale modal tests may be performed with electrodynamic modal shakers, hydraulic modal shakers become attractive since they can generate higher force levels at lower unit cost with a smaller spatial footprint. While test engineers familiar with electrodynamic modal shakers are familiar with the challenges of displacement and velocity limits and the relatively mild shaker nonlinear distortion due to amplifier gains and shaker flexure structural geometric nonlinearities, they probably are not as familiar with the unique set of challenges hydraulic modal shakers present. These unique challenges include significant nonlinear distortion in the shaker force, issues with the setup of the hydraulic power supply and the associated hydraulic hosing, velocity limits as they relate to potentially damaging the hydraulic actuator piston, and safety issues with operating high-pressure hydraulic systems. This paper addresses these unique challenges to help the test engineer to better utilize hydraulic modal shakers on large-scale modal tests.

Distortion↗
NASA NTRS1979

Dynamic modeling of brushless dc motor-power conditioner unit for electromechanical actuator application

A comprehensive digital model for the analysis of the dynamic-instantaneous performance of a power conditioner fed samarium-cobalt permanent magnet brushless DC motor is presented. The particular power conditioner-machine system at hand, for which this model was developed, is a component of an actual prototype electromechanical actuator built for NASA-JSC as a possible alternative to hydraulic actuators as part of feasibility studies for the shuttle orbiter applications. Excellent correlation between digital simulated and experimentally obtained performance data was achieved for this specific prototype. This is reported on in this paper. Details of one component of the model, its applications and the corresponding results are given in this paper.

Demerdash, N. A.↗
NASA NTRS1992

Resonant mode controllers for launch vehicle applications

Electro-mechanical actuator (EMA) systems are currently being investigated for the National Launch System (NLS) as a replacement for hydraulic actuators due to the large amount of manpower and support hardware required to maintain the hydraulic systems. EMA systems in weight sensitive applications, such as launch vehicles, have been limited to around 5 hp due to system size, controller efficiency, thermal management, and battery size. Presented here are design and test data for an EMA system that competes favorably in weight and is superior in maintainability to the hydraulic system. An EMA system uses dc power provided by a high energy density bipolar lithium thionyl chloride battery, with power conversion performed by low loss resonant topologies, and a high efficiency induction motor controlled with a high performance field oriented controller to drive a linear actuator.

Schreiner, Ken E.↗
NASA NTRS1978

A study of low-cost reliable actuators for light aircraft. Part A: Chapters 1-8

An analysis involving electro-mechanical, electro-pneumatic, and electro-hydraulic actuators was performed to study which are compatible for use in the primary and secondary flight controls of a single engine light aircraft. Actuator characteristics under investigation include cost, reliability, weight, force, volumetric requirements, power requirements, response characteristics and heat accumulation characteristics. The basic types of actuators were compared for performance characteristics in positioning a control surface model and then were mathematically evaluated in an aircraft to get the closed loop dynamic response characteristics. Conclusions were made as to the suitability of each actuator type for use in an aircraft.

Eijsink, H.↗
NASA NTRS1980

Dynamic modeling of brushless dc motors for aerospace actuation

A discrete time model for simulation of the dynamics of samarium cobalt-type permanent magnet brushless dc machines is presented. The simulation model includes modeling of the interaction between these machines and their attached power conditioners. These are transistorized conditioner units. This model is part of an overall discrete-time analysis of the dynamic performance of electromechanical actuators, which was conducted as part of prototype development of such actuators studied and built for NASA-Johnson Space Center as a prospective alternative to hydraulic actuators presently used in shuttle orbiter applications. The resulting numerical simulations of the various machine and power conditioner current and voltage waveforms gave excellent correlation to the actual waveforms collected from actual hardware experimental testing. These results, numerical and experimental, are presented here for machine motoring, regeneration and dynamic braking modes. Application of the resulting model to the determination of machine current and torque profiles during closed-loop actuator operation were also analyzed and the results are given here. These results are given in light of an overall view of the actuator system components. The applicability of this method of analysis to design optimization and trouble-shooting in such prototype development is also discussed in light of the results at hand.

Demerdash, N. A.↗
NASA NTRS2020

Electric Six Degree of Freedom Installation Timelapse (Six Degree of Freedom Dynamic Test System)

The Six-degree-of-freedom Dynamic Test System (SDTS) is a short-range real-time motion based testing platform. Its primary use at NASA/JSC has been for development and qualification testing of docking systems, robotic assisted berthing mechanisms, and dynamic attachment systems. The SDTS is a closed-loop force feedback system that can simulate on-orbit contact dynamics between two vehicles utilizing the actual mechanical interfaces for testing. The facility is controlled by interconnected computers running real-time simulation software that takes measured contact forces, integrates the equations of motion in real time, and provide those states back into the motion table. This infrastructure can also be used for non-mating applications such as relative position sensor testing/evaluations. The SDTS facility provides a superstructure for mounting test articles, multiple test sensors, an intercom network for voice communications, and a synchronized timing system for data acquisition that includes HD video. This time-lapse video shows the buildup and testing of a modern electric actuation system created by Mikrolar, Inc. at the Johnson Space Center. This motion base will replace the current hydraulic actuator system, which is been in use since the 1970s, for all-future NASA testing. Once the system goes through customization to provide JSC’s unique closed-loop environment, the facility will help certify docking system and attach mechanisms on the ground before we send the first woman and the next man to the lunar surface

hexapod↗
NASA NTRS1986

Static test of an ultralight airplane

This paper describes all of the work necessary to perform the static test of an ultralight airplane. A steel reaction gantry was designed first, then all of the loading whiffletrees, the hydraulic actuation system, and instrumentation systems were designed. Loads and stress analyses were performed on the airplane and the gantry and whiffletrees. Components tested to date are: tubing samples, cables, and two-by-four whiffletrees. A hydraulic system consisting of a 3000-psi hand pump, 10,000-pound actuator, pressure gage and lines, and a Barksdale valve are described. Load cell calibration and pressure indicator calibration procedures are also described. A description of the strain and deflection measurement system is included. Preliminary data obtained to date are compared to the analytical predictions.

Smith, H. W.↗
NASA NTRS1979

Space transportation system solid rocket booster thrust vector control system

The Solid Rocket Booster, Thrust Vector Control (TVC) system was designed in accordance with the following requirements: self-contained power supply, fail-safe operation, 20 flight uses after exposure to seawater landings, optimized cost, and component interchangeability. Trade studies were performed which led to the selection of a recirculating hydraulic system powered by Auxiliary Power Units (APU) which drive the hydraulic actuators and gimbal the solid rocket motor nozzle. Other approaches for the system design were studied in arriving at the recirculating hydraulic system powered by an APU. These systems must withstand the imposed environment and be usable for a minimum of 20 Space Transportation System flights with a minimum of refurbishment. The TVC system has completed the major portion of qualification and verification tests and is prepared to be cleared for the first Shuttle flight (STS-1). Substantiation data will include analytical and test data.

Verble, A. J., Jr.↗
NASA NTRS1980

Space Transportation System solid rocket booster thrust vector control system

The Solid Rocket Booster, Thrust Vector Control (TVC) system was designed in accordance with the following requirements: self-contained power supply, failsafe operation, 20 flight uses after exposure to seawater landings, optimized cost, and component interchangeability. Trade studies were performed which led to the selection of a recirculating hydraulic system powered by Auxiliary Power Units (APU) which drive the hydraulic actuators and gimbal the solid rocket motor nozzle. Other approaches for the system design were studied in arriving at the recirculating hydraulic system powered by an APU. These systems must withstand the imposed environment and be usable for a minimum of 20 Space Transportation System flights with a minimum of refurbishment. The TVC system completed the required qualification and verification tests and is certified for the intended application. Substantiation data include analytical and test data.

Verble, A. J., Jr.↗
NASA NTRS1994

Actuator Exerts Tensile Or Compressive Axial Load

Compact, manually operated mechanical actuator applies controlled, limited tensile or compressive axial force. Designed to apply loads to bearings during wear tests in clean room. Intended to replace hydraulic actuator. Actuator rests on stand and imparts axial force to part attached to clevis inside or below stand. Technician turns control screw at one end of lever. Depending on direction of rotation of control screw, its end of lever driven downward (for compression) or upward (for tension). Lever pivots about clevis pin at end opposite of control screw; motion drives downward or upward link attached via shearpin at middle of lever. Link drives coupling and, through it, clevis attached to part loaded.

Nozzi, John↗
NASA NTRS1995

Circuit For Control Of Electromechanical Prosthetic Hand

Proposed circuit for control of electromechanical prosthetic hand derives electrical control signals from shoulder movements. Updated, electronic version of prosthesis, that includes two hooklike fingers actuated via cables from shoulder harness. Circuit built around favored shoulder harness, provides more dexterous movement, without incurring complexity of computer-controlled "bionic" or hydraulically actuated devices. Additional harness and potentiometer connected to similar control circuit mounted on other shoulder. Used to control stepping motor rotating hand about prosthetic wrist to one of number of angles consistent with number of digital outputs. Finger-control signals developed by circuit connected to first shoulder harness transmitted to prosthetic hand via sliprings at prosthetic wrist joint.

Bozeman, Richard J., Jr.↗
NASA NTRS1979

Supercritical tests of a self-optimizing, variable-Camber wind tunnel model

A testing procedure was used in a 16-foot Transonic Propulsion Wind Tunnel which leads to optimum wing airfoil sections without stopping the tunnel for model changes. Being experimental, the optimum shapes obtained incorporate various three-dimensional and nonlinear viscous and transonic effects not included in analytical optimization methods. The method is a closed-loop, computer-controlled, interactive procedure and employs a Self-Optimizing Flexible Technology wing semispan model that conformally adapts the airfoil section at two spanwise control stations to maximize or minimize various prescribed merit functions subject to both equality and inequality constraints. The model, which employed twelve independent hydraulic actuator systems and flexible skins, was also used for conventional testing. Although six of seven optimizations attempted were at least partially convergent, further improvements in model skin smoothness and hydraulic reliability are required to make the technique fully operational.

Levinsky, E. S.↗
NASA NTRS1980

Closed loop performance of a brushless dc motor powered electromechanical actuator for flight control applications

A comprehensive digital model for the analysis and possible optimization of the closed loop dynamic (instantaneous) performance of a power conditioner fed, brushless dc motor powered, electromechanical actuator system (EMA) is presented. This model was developed for the simulation of the dynamic performance of an actual prototype EMA built for NASA-JSC as a possible alternative to hydraulic actuators for consideration in Space Shuttle Orbiter applications. Excellent correlation was achieved between numerical model simulation and experimental test results obtained from the actual hardware. These results include: various current and voltage waveforms in the machine-power conditioner (MPC) unit, flap position as well as other control loop variables in response to step commands of change of flap position. These results with consequent conclusions are detailed in the paper.

Demerdash, N. A.↗
NASA NTRS2004

Space Shuttle Upgrades Advanced Hydraulic Power System

Three Auxiliary Power Units (APU) on the Space Shuttle Orbiter each provide 145 hp shaft power to a hydraulic pump which outputs 3000 psi hydraulic fluid to 41 hydraulic actuators. A hydrazine fuel powered APU utilized throughout the Shuttle program has undergone many improvements, but concerns remain with flight safety, operational cost, critical failure modes, and hydrazine related hazards. The advanced hydraulic power system (AHPS), also known as the electric APU, is being evaluated as an upgrade to replace the hydrazine APU. The AHPS replaces the high-speed turbine and hydrazine fuel supply system with a battery power supply and electric motor/pump that converts 300 volt electrical power to 3000 psi hydraulic power. AHPS upgrade benefits include elimination of toxic hydrazine propellant to improve flight safety, reduction in hazardous ground processing operations, and improved reliability. Development of this upgrade provides many interesting challenges and includes development of four hardware elements that comprise the AHPS system: Battery - The battery provides a high voltage supply of power using lithium ion cells. This is a large battery that must provide 28 kilowatt hours of energy over 99 minutes of operation at 300 volts with a peak power of 130 kilowatts for three seconds. High Voltage Power Distribution and Control (PD&C) - The PD&C distributes electric power from the battery to the EHDU. This 300 volt system includes wiring and components necessary to distribute power and provide fault current protection. Electro-Hydraulic Drive Unit (EHDU) - The EHDU converts electric input power to hydraulic output power. The EHDU must provide over 90 kilowatts of stable, output hydraulic power at 3000 psi with high efficiency and rapid response time. Cooling System - The cooling system provides thermal control of the Orbiter hydraulic fluid and EHDU electronic components. Symposium presentation will provide an overview of the AHPS upgrade, descriptions of the four hardware elements, and a summary of development results to date.

Source record↗
NASA NTRS1985

The Solid Rocket Booster Auxiliary Power Unit: Meeting the Challenge

The thrust vector control systems of the solid rocket boosters are turbine-powered, electrically controlled hydraulic systems which function through hydraulic actuators to gimbal the nozzles of the solid rocket boosters and provide vehicle steering for the Space Shuttle. Turbine power for the thrust vector control systems is provided through hydrazine fueled auxiliary power units which drive the hydraulic pumps. The solid rocket booster auxiliary power unit resulted from trade studies which indicated significant advantages would result if an existing engine could be found to meet the program goal of 20 missions reusability and adapted to meet the seawater environments associated with ocean landings. During its maturation, the auxiliary power unit underwent many design iterations and provided its flight worthiness through full qualification programs both as a component and as part of the thrust vector control system. More significant, the auxiliary power unit has successfully completed six Shuttle missions.

Hughes, R. W.↗
DOE OSTI2022

Hybrid Hydraulic-Electric Architecture (HHEA) for Mobile Machines (Final Report)

Traditionally, off-road mobile machines such as excavators and wheel loaders are primarily powered by hydraulics, and throttling valves are used to control their work circuits. In recent years, two general trends are towards more energy efficient systems and electrification. With electrification, both efficiency and control performance can be improved by the elimination of throttling losses and the use of high-bandwidth inverter control. Electrification is generally accomplished with Electro-hydraulic actuators (EHA) but they are limited to lower powered systems due to the high cost of electric machines capable of high power or high torque. This project proposes a new system architecture for off-road vehicles - Hybrid Hydraulic Electric Architecture (HHEA) to improve efficiency and control performance without requiring large electric machines. The widely applicable architecture combines hydraulic power and electric power in such a way that the majority of power is provided hydraulically while electric drives are used to modulate this power. In particular, HHEA utilizes multiple common pressure rails to transmit the majority of power and small electric machines to modulate the power. The energy-saving potential of the the HHEA has been validated for the work circuits of a variety of mobile machines, from small 5-ton excavators to medium sized 20-ton excavators and wheel loaders, and representative duty cycles to reduce energy input by 50-80% compared to the commercial state-of-art load-sensing systems. In addition, the corner power requirements of the electrical machines can be downsized by 85% compared to the EHA approach. Various tradeoff studies have also been conducted, including sensitivities to individual components performances, controllers, accumulator sizes, and variations of the system architecture etc. A control strategy has been developed to maintain or exceed the motion control precision compared to current systems. The motion control strategy consists of a nominal controller, based on a passivity-based backstepping design, and a transition controller, based on least-norn feedforward design. The nominal controller is used in between common pressure rail switches whereas the transition controller compensates for any disturbance that common pressure rail switchings inflict on the system. The control strategy has been experimentally validated on both a medium pressure (200bar) hardware-in-the-loop (HIL) testbed and a high pressure (300+bar) HIL testbed. An efficient and power-dense integrated electric-hydraulic machine consisting of an axial flux electric machine and a radial hydrostatic piston hydraulic machine has been designed, constructed and tested. The machine has an active material power density of 6.1kW/kg, a rated speed of 12500 RPM, and a design efficiency of 85%. This is among the highest power density electric machines using conventional materials. While the integrated machine was designed for modulating the hydraulic power within the HHEA, it can also be used in other applications.

24 POWER TRANSMISSION AND DISTRIBUTION↗