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Motion and force controlled vibration testing
A technique for controlling both the input acceleration and force in vibration tests is proposed to alleviate the overtesting risks and the problems associated with response limiting in conventional vibration tests of aerospace hardware. Previous research on impedance and force controlled vibration tests is reviewed and a simple equation governing the dual control of acceleration and force is derived. A practical method for implementing the dual control technique in random vibration tests has been demonstrated in JPL's environmental test facility using a conventional digital controller operating in the extremal mode. The dual control technique provides appropriate real-time notching of the input acceleration and a corresponding reduction of the test item response at resonances. Issues concerning the need for force and acceleration phase information, the adequacy of specifying the blocked force, and the derivation of the total force for multipoint supports are discussed.
Viking 1975 Orbiter Development Test Model/Lander Dynamic Test Model dynamic environmental testing - An overview
The current work presents an overview of the Viking 1975 environmental testing from an engineering standpoint. An extremely large vibration test fixture had to be designed, analyzed, and integrated into a test setup that employed hydrostatic bearings in a new fashion. A vibration control system was also required that would allow for thirty-six channels of sine-wave peak select control from acceleration, force-of-strain transducers. In addition, some 68 channels of peak limiting shutdown capability were needed for backup and monitoring of other data during the forced vibration test. Pretesting included analyses of the fixture design, overturning moment, control system capabilities, and response of the entire spacecraft/fixture/exciter system to the test environment. Closed-loop control for acoustic testing was a necessity due to the fact that the Viking spacecraft took up a major portion of the volume of the 10,000 cu ft chamber. The spacecraft emerged from testing undamaged.
Experimental and theoretical investigation of passive damping concepts for member forced and free vibration
Potential passive damping concepts for use in space structures are identified. The effectiveness of copper brush, wool swab, and silly putty in chamber dampers is investigated through natural vibration tests on a tubular aluminum member. The member ends have zero translation and possess partial rotational restraints. The silly putty in chamber dampers provide the maximum passive damping efficiency. Forced vibration tests are then conducted with one, two, and three damper chambers containing silly putty. Owing to the limitation of the vibrator used, the performance of these dampers could not be evaluated experimentally until the forcing function was disengaged. Nevertheless, their performance is evaluated through a forced dynamic finite element analysis conducted as a part of this investigation. The theoretical results based on experimentally obtained damping ratios indicate that the passive dampers are considerably more effective under member natural vibration than during forced vibration. Also, the maximum damping under forced vibration occurs at or near resonance.
CM-2 Environmental / Modal Testing of Spacehab Racks
Combined environmental/modal vibration testing has been implemented at the NASA Glenn Research Center's Structural Dynamics Laboratory. The benefits of combined vibration testing are that it facilitates test article modal characterization and vibration qualification testing. The Combustion Module-2 (CM-2) is a space experiment that launches on Shuttle mission STS 107 in the SPACEHAB Research Double Module. The CM-2 flight hardware is integrated into a SPACEHAB single and double rack. CM-2 rack level combined vibration testing was recently completed on a shaker table to characterize the structure's modal response and verify the random vibration response. Control accelerometers and limit force gauges, located between the fixture and rack interface, were used to verify the input excitation. Results of the testing were used to verify the loads and environments for flight on the Shuttle.
CM-2 Environmental/Modal Testing of SPACEHAB Racks
Combined environmental/modal vibration testing has been implemented at the NASA Glenn Research Center's Structural Dynamics Laboratory. The benefits of combined vibration testing are that it facilitates test article modal characterization and vibration qualification testing. The Combustion Module-2 (CM-2) is a space experiment that will launch on shuttle mission STS-107 in the SPACEHAB Research Double Module. The CM-2 flight hardware is integrated into a SPACEHAB single and double rack. CM-2 rack-level combined vibration testing was recently completed on a shaker table to characterize the structure's modal response and verify the random vibration response. Control accelerometers and limit force gauges, located between the fixture and rack interface, were used to verify the input excitation. Results of the testing were used to verify the loads and environments for flight on the shuttles.
Global Ecosystem Dynamics Investigation (GEDI) Structural Verification Unit (SVU) Vibration Test
This presentation describes the vibration test campaign of the Structural Verification Unit for the Global Ecosystem Dynamics Investigation (GEDI) mission The Structural Verification Unit test campaign served multiple purposes including the qualification of the instrument primary structure, verification of the structure's stiffness, Aperture Control Mechanism assembly level verification, and validation of the control approach for protoflight instrument vibration testing. Testing included three axes of sine burst, random, and sine vibration excitation. This test sequence required a high number of response instrumentation sensors that included tri-axial accelerometers and tri-axial force gauges. Multiple response limiting methods that included acceleration, force, and moment measurements were used to ensure the safety of the flight hardware. The lessons and specific test details learned on the structural verification unit test campaign will reduce test risks for the upcoming instrument-level vibration tests.
Application of the Bootstrap Statistical Method in Deriving Vibroacoustic Specifications
This paper discusses the Bootstrap Method for specification of vibroacoustic test specifications. Vibroacoustic test specifications are necessary to properly accept or qualify a spacecraft and its components for the expected acoustic, random vibration and shock environments seen on an expendable launch vehicle. Traditionally, NASA and the U.S. Air Force have employed methods of Normal Tolerance Limits to derive these test levels based upon the amount of data available, and the probability and confidence levels desired. The Normal Tolerance Limit method contains inherent assumptions about the distribution of the data. The Bootstrap is a distribution-free statistical subsampling method which uses the measured data themselves to establish estimates of statistical measures of random sources. This is achieved through the computation of large numbers of Bootstrap replicates of a data measure of interest and the use of these replicates to derive test levels consistent with the probability and confidence desired. The comparison of the results of these two methods is illustrated via an example utilizing actual spacecraft vibroacoustic data.
Dual control vibration tests of flight hardware
A vibration retest of a spacecraft flight instrument, the Mars Observer Camera (MOC), was conducted using extremal dual control to automatically limit the shaker force and notch the shaker acceleration at resonances. This was the first application of extremal dual control with flight hardware at JPL. The retest was successful in that the environment was representative of flight plus some margin, the instrument survived without any structural or performance degradation, and the force limiting worked very well. The test set-up, force limiting procedure, and test results are described herein. It is concluded that dual control should be utilized when there is a concern about overtesting in hard-base-drive tests and the instrumentation for force measurement and control is available. Recommendations for improving the implementation of dual control are provided as a result of this first experience.
Benefits of Spacecraft Level Vibration Testing
NASA-HDBK-7008 Spacecraft Level Dynamic Environments Testing discusses the approaches, benefits, dangers, and recommended practices for spacecraft level dynamic environments testing, including vibration testing. This paper discusses in additional detail the benefits and actual experiences of vibration testing spacecraft for NASA Goddard Space Flight Center (GSFC) and Jet Propulsion Laboratory (JPL) flight projects. JPL and GSFC have both similarities and differences in their spacecraft level vibration test approach: JPL uses a random vibration input and a frequency range usually starting at 5 Hz and extending to as high as 250 Hz. GSFC uses a sine sweep vibration input and a frequency range usually starting at 5 Hz and extending only to the limits of the coupled loads analysis (typically 50 to 60 Hz). However, both JPL and GSFC use force limiting to realistically notch spacecraft resonances and response (acceleration) limiting as necessary to protect spacecraft structure and hardware from exceeding design strength capabilities. Despite GSFC and JPL differences in spacecraft level vibration test approaches, both have uncovered a significant number of spacecraft design and workmanship anomalies in vibration tests. This paper will give an overview of JPL and GSFC spacecraft vibration testing approaches and provide a detailed description of spacecraft anomalies revealed.
Tail Buffeting
An approximate theory of buffeting is here presented, based on the assumption of harmonic disturbing forces. Two cases of buffeting are considered: namely, for a tail angle of attack greater and less than the stalling angle, respectively. On the basis of the tests conducted and the results of foreign investigators, a general analysis is given of the nature of the forced vibrations the possible load limits on the tail, and the methods of elimination of buffeting.
The LDCM actuator for vibration suppression
A linear dc motor (LDCM) has been proposed as an actuator for the COFS I mast and the COFS program ground test Mini-Mast. The basic principles of operation of the LDCM as an actuator for vibration suppression in large flexible structures are reviewed. Because of force and stroke limitations, control loops are required to stabilize the actuator, which results in a non-standard actuator-plant configuration. A simulation model that includes LDCM actuator control loops and a finite element model of the Mast is described, with simulation results showing the excitation capability of the actuator.
Modifications to Marshall's Annular Seal Test (MAST) Rig and Facility for Improved Rotordynamic Coefficient Testing of Annular Seals and Fluid Film Bearings
The limits of rotordynamic stability continue to be pushed by the high power densities and rotational speeds of modern rocket engine turbomachinery. Destabilizing forces increase dramatically with rotor speed. Rotordynamic stability is lost when these destabilizing forces overwhelm the stabilizing forces. The vibration from the unstable rotor grows until it is limited by some nonlinearity. For example, a rolling element bearing with a stiffness characteristic that increases with deflection may limit the vibration amplitude. The loads and deflections resulting from this limit cycle vibration (LCV) can lead to bearing and seal damage which promotes ever increasing levels of subsynchronous vibration. Engineers combat LCV by introducing rotordynamic elements that generate increased stabilizing forces and reduced destabilizing forces. For example, replacing a labyrinth seal with a damping seal results in substantial increases in the damping and stiffness rotordynamic coefficients. Adding a swirl brake to the damping seal greatly reduces the destabilizing cross-coupled forces generated by the damping seal for even further increases in the stabilizing capacity. Marshall?s Annular Seal Test (MAST) rig is designed to experimentally measure the stabilizing capacity of new annular seal designs. The rig has been moved to a new facility and outfitted with a new slave bearing to allow increased test durations and to enable the testing of fluid film bearings. The purpose of this paper is to describe the new facility and the new bearing arrangement. Several novel seal and bearing designs will also be discussed.
An investigation of hydraulic-line resonance and its attenuation
An investigation of fluid resonance in high-pressure hydraulic lines has been made with two types of fluid dampers (or filters) installed in the line. One type involved the use of one or more closed-end tubes branching at right angles from a main line, and the other type was a fluid muffler installed in-line. These devices were evaluated in forced vibration tests with oscillatory disturbances over a 1000-Hz range applied to one end of the line and with oscillatory pressures measured at various stations along the main pipe. Limited applications of acoustic-wave theory to the branched systems are also included. Results show varying attenuations of pressure perturbations, depending on the number and location of branches and the type of muffler. Up to three branches were used in the branch-resonator study, and the largest frequency range with maximum attenuation was obtained for a three-branch configuration. The widest frequency ranges with significant attenuations were obtained with two types of fluid mufflers.
Vibrations of twisted cantilevered plates - Experimental investigation
The experimental portion of a joint government/industry/university research study on the vibrational characteristics of twisted cantilevered plates is presented. The overall purpose of the research study was to assess the capabilities and limitations of existing analytical methods in predicting the vibratory characteristics of twisted plates. Thirty cantilevered plates were precision machined at the Air Force's Aero Propulsion Laboratory. These plates, having five different degrees of twist, two thicknesses, and three aspect ratios representative of turbine engine blade geometries, were tested for their vibration mode shapes and frequencies. The resulting nondimensional frequencies and selected mode shapes are presented as a function of plate tip twist. The trends of the natural frequencies as a function of the governing geometric parameters are discussed. The effect of support compliance on the plate natural frequency and its impact on numerically modeling twisted plates is also presented.
Vibration Test With Extremal Dual Control
Report discusses use of extremal dual control to prevent overtesting. In extremal dual control, electronic test-control subsystem automatically reduces excitation supplied to shaker subsystem to keep force applied by shaker below preset force limit and to keep acceleration of shaker below preset acceleration limit.
Analysis of dual control vibration testing
Analysis of dual control vibration testing is conducted using a two-degree-of-freedom system to represent the interaction between a vibration mode of a test item and a mode of a mounting structure. The results indicate that exact dual control based on specification of the source free acceleration and blocked force is strictly valid only if phase is taken into account. However, extremal dual control without phase alleviates overtesting without risk of undertesting, when the limit acceleration and force specifications are chosen to envelope the coupled system results. Several approaches to deriving appropriate force specifications are explored. Random vibration parametric results from the literature are used to estimate the limit force between coupled oscillators with different source and load masses.
Stability Limits of a PD Controller for a Flywheel Supported on Rigid Rotor and Magnetic Bearings
Active magnetic bearings are used to provide a long-life, low-loss suspension of a high-speed flywheel rotor. This paper describes a modeling effort used to understand the stability boundaries of the PD controller used to control the active magnetic bearings on a high speed test rig. Limits of stability are described in terms of allowable stiffness and damping values which result in stable levitation of the nonrotating rig. Small signal stability limits for the system is defined as a nongrowth in vibration amplitude of a small disturbance. A simple mass-force model was analyzed. The force resulting from the magnetic bearing was linearized to include negative displacement stiffness and a current stiffness. The current stiffness was then used in a PD controller. The phase lag of the control loop was modeled by a simple time delay. The stability limits and the associated vibration frequencies were measured and compared to the theoretical values. The results show a region on stiffness versus damping plot that have the same qualitative tendencies as experimental measurements. The resulting stability model was then extended to a flywheel system. The rotor dynamics of the flywheel was modeled using a rigid rotor supported on magnetic bearings. The equations of motion were written for the center of mass and a small angle linearization of the rotations about the center of mass. The stability limits and the associated vibration frequencies were found as a function of nondimensional magnetic bearing stiffness and damping and nondimensional parameters of flywheel speed and time delay.