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A magnetic bearing control approach using flux feedback is described and test results for a laboratory model magnetic bearing actuator are presented. Test results were obtained using a magnetic bearing test fixture, which is also described. The magnetic bearing actuator consists of elements similar to those used in a laboratory test model Annular Momentum Control Device (AMCD).
In this report, a thorough analytical procedure is developed for evaluating the frequency-dependent loss characteristics and effective permittivity of microstrip lines. The technique is based on the measured reflection coefficient of microstrip resonator pairs. Experimental data, including quality factor Q, effective relative permittivity, and fringing for 50-omega lines on gallium arsenide (GaAs) from 26.5 to 40.0 GHz are presented. The effects of an imperfect open circuit, coupling losses, and loading of the resonant frequency are considered. A cosine-tapered ridge-guide text fixture is described. It was found to be well suited to the device characterization.
As a part of the redesign of the Space Shuttle Solid Rocket Motor, the field and nozzle-to-case joints were redesigned to minimize the dynamic flexure caused by internal motor pressurization during ignition. The O-ring seals and glands for the joints were designed to accommodate both structural deflections and to promote pressure assistance. A test program was conducted to determine if a fluorocarbon elastomeric O-ring could meet this criteria in the redesigned gland. Resiliency tests were used to investigate the O-ring response to gap motion while static seal tests were used to verify design criteria of pressure assistance for sealing. All tests were conducted in face seal fixtures mounted in servo-hydraulic test machines. The resiliency of the O-ring was found to be extremely sensitive to the effects of temperature. The External Tank/Solid Rocket Booster attach strut loads had a negligible affect on the ability of the O-ring to track the simulated SRB field joint deflection. In the static pressure-assisted seal tests, as long as physical contact was maintained between the O-ring and the gland sealing surface, pressure assistance induced instantaneous sealing.
Designing space-based telerobotic systems presents many problems unique to telerobotics and the space environment, but it also shares many common hardware and software design problems with Earth-based industrial robot applications. Such problems include manipulator design and placement, grapple-fixture design, and of course the development of effective and reliable control algorithms. Since first being applied to industrial robotics just a few years ago, interactive graphic simulation has proven to be a powerful tool for anticipating and solving problems in the design of Earth-based robotic systems and processes. Where similar problems are encountered in the design of space-based robotic mechanisms, the same graphic simulation tools may also be of assistance. The capabilities of PLACE, a commercially available interactive graphic system for the design and simulation of robotic systems and processes is described. A space-telerobotics application of the system is presented and discussed. Potential future enhancements are described.
Traditionally, a fixed base modal test has been performed as a means of verifying the coupled loads math model for Space Shuttle flight payloads. An alternate method, a free-free configured payload using mass loaded boundary conditions, is presented as a means of verifying the coupled loads model of the ASTRO-1 flight payload. This method allows evaluation of the influence of local load paths into the frequency range of the free-free test. The method is cost effective and does not contaminate the modal test results with fixture coupled modes or boundary condition uncertainties. This paper describes the mass additive modal test technique as applied to the Space Shuttle ASTRO-1 flight payload.
Resiliency tests have been conducted in order to evaluate O-ring sealing response in the revised Space Shuttle SRBs, giving attention to the effects of temperature and gap-opening rates. Additional testing was conducted to ascertain O-ring responses to simulated SRB field-joint deflections. All tests employed a face-seal fixture mounted on a servohydraulic apparatus. The Viton candidate O-ring material tracked the gap-opening rate better at higher temperatures and lower gap-opening rates; it was also the only material inert to the calcium grease employed. Heaters must be used to maintain the 70 F minimum temperature at which the Viton O-ring will track the required gap opening rate.
Topics discussed include extreme/hostile environment testing, establishing design allowables, and property/behavior specific testing. Papers are presented on environmental effects on the high strain rate properties of graphite/epoxy composite, the low-temperature performance of short-fiber reinforced thermoplastics, the abrasive wear behavior of unidirectional and woven graphite fiber/PEEK, test methods for determining design allowables for fiber reinforced composites, and statistical methods for calculating material allowables for MIL-HDBK-17. Attention is also given to a test method to measure the response of composite materials under reversed cyclic loads, a through-the-thickness strength specimen for composites, the use of torsion tubes to measure in-plane shear properties of filament-wound composites, the influlence of test fixture design on the Iosipescu shear test for fiber composite materials, and a method for monitoring in-plane shear modulus in fatigue testing of composites.
The residual stresses in graphite fiber reinforced aluminum (Gr/Al) composites with various thermal histories are measured using X-ray diffraction (XRD) methods. The XRD stress analysis is based on the determination of lattice strains by precise measurements of the interplanar spacings in different directions of the sample. The sample is a plate consisting of two-ply P 100 Gr/Al 6061 precursor wires and Al 6061 overlayers. Prior to XRD measurement, the 6061 overlayers are electrochemically removed. In order to calibrate the relationship between stress magnitude and lattice spacing shift, samples of Al 6061 are loaded at varying stress levels in a three-point bend fixture, while the stresses are simultaneously determined by XRD and surface-attached strain gages. The stresses determined by XRD closely match those determined by the strain gages. Using these calibrations, the longitudinal residual stresses of P 100 Gr/Al 6061 composites are measured for various heat treatments, and the results are presented.
This paper describes a method developed for precompensating the front-end (telescope) optical alignment of the Imager and Sounder radiometric instruments, which will be launched as components of the GOES I - M series of meteorological satellites. To satisfy the severe pointing accuracy requirements on these instruments, their alignments must be offset in the one - G field of the laboratory, in order that they will be correct in orbit. A method was developed to make the necessary alignment offset, using a counterweight mechanism; autocollimation returns from reference mirrors on the instrument structure and supporting fixturing provided feedback for adjusting the counterweight mechanism. A series of experiments was performed to verify that these autocollimation return measurements were a good predictor of telescope line-of-sight changes; these experiments are described and their results summarized.
Technique enables measurement of leakage areas created by small obstructions in O-ring seals. With simple fixture, gaps measured directly. Compresses piece of O-ring by amount determined by spacers. Camera aimed through clear plastic top plate records depression made in O-ring by obstruction. Faster, easier, more accurate than conventional estimation.
Mechanical fixture and electronic gauge probe surface before and after fabrication processes. Assembly of commercially available devices measures changes in dimensions of irregularly shaped part. Turbine blade clamped on rotary table touched by probe of electronic depth gauge. Positioned by micrometers of three-axis translation stage, probe just touches blade. Assembly developed specifically to measure thickness of material added to or removed from surface of turbine blade during fabrication processes.
Inexpensive, safe apparatus built to test cooling by, ignition in, and nucleate boiling to film boiling of liquid oxygen flowing around ball bearings. Provides for heating of bearing specimens, direct observations, and measurements of temperatures and temperature distributions by thermocouples and infrared sensors. Used to evaluate suitability of various materials and surface treatments for ball bearings in high-pressure liquid-oxygen turbopumps. Ball rests in fixture while liquid oxygen flows around it. Flow reversed so observer or infrared sensor can view phenomena on trailing or leading side of ball.
Graphite/aluminum plate absorbs most of light. Beam stop fits on standard optical mounting fixture. Graphite plate thick enough to absorb incident laser beam but thin enough to transfer heat quickly to heat sink. Device used for variety of blocking purposes. For example, blocks laser beam after it passes through experimental setup, or at each stage of setup so stages checked and tested in sequence. Negligible reflectance of device is valuable safety feature, protecting both users and equipment from reflections.
An investigation into the heat sink effects due to weldment irregularities and fixtures used in the variable polarity plasma arc (VPPA) process was conducted. A basic two-dimensional model was created to represent the net heat sink effect of surplus material using Duhamel's theorem to superpose the effects of an infinite number of line heat sinks of variable strength. Parameters were identified that influence the importance of heat sink effects. A characteristic length, proportional to the thermal diffusivity of the weldment material divided by the weld torch travel rate, correlated with heat sinking observations. Four tests were performed on 2219-T87 aluminum plates to which blocks of excess material were mounted in order to demonstrate heat sink effects. Although the basic model overpredicted these effects, it correctly indicated the trends shown in the experimental study and is judged worth further refinement.
Efficient robot operation requires the use of specialized end effectors or tools for tasks. In spacecraft applications, the microgravity environment precludes the use of gravitational forces to retain the tools in holding fixture. As a result of this, a retention mechanism which forms a part of the tool storage container is required. A unique approach to this problem has resulted in the development of an end effector exchange mechanism that meets the requirements for spaceflight applications while avoiding the complexity usually involved. This mechanism uses multiple latching cams both on the manipulator and in the tool storage container, combined with a system of catch rings to provide retention in both locations and the required failure tolerance. Because of the cam configuration the mechanism operates passively, requiring no electrical commands except those needed to move the manipulator into position. Similarly, it inherently provides interlocks to prevent the release of one cam before its opposite number is engaged.
Elements of the analytical/experimental program to characterize the response of silicon carbide titanium (SCS-6/Ti-15-3) composite tubes under biaxial loading are outlined. The analytical program comprises prediction of initial yielding and subsequent inelastic response of unidirectional and angle-ply silicon carbide titanium tubes using a combined micromechanics approach and laminate analysis. The micromechanics approach is based on the method of cells model and has the capability of generating the effective thermomechanical response of metal matrix composites in the linear and inelastic region in the presence of temperature and time-dependent properties of the individual constituents and imperfect bonding on the initial yield surfaces and inelastic response of (0) and (+ or - 45)sub s SCS-6/Ti-15-3 laminates loaded by different combinations of stresses. The generated analytical predictions will be compared with the experimental results. The experimental program comprises generation of initial yield surfaces, subsequent stress-strain curves and determination of failure loads of the SCS-6/Ti-15-3 tubes under selected loading conditions. The results of the analytical investigation are employed to define the actual loading paths for the experimental program. A brief overview of the experimental methodology is given. This includes the test capabilities of the Composite Mechanics Laboratory at the University of Virginia, the SCS-6/Ti-15-3 composite tubes secured from McDonnell Douglas Corporation, a text fixture specifically developed for combined axial-torsional loading, and the MTS combined axial-torsion loader that will be employed in the actual testing.
An investigation into the heat sink effects due to weldment irregularities and fixtures used in the variable polarity plasma arc (VPPA) process was conducted. A basic two-dimensional model was created to represent the net heat sink effect of surplus material using Duhamel's theorem to superpose the effects of an infinite number of line heat sinks of variable strength. Parameters were identified that influence the importance of heat sink effects. A characteristic length, proportional to the thermal diffusivity of the weldment material divided by the weld torch travel rate, correlated with heat sinking observations. Four tests were performed on 2219-T87 aluminum plates to which blocks of excess material were mounted in order to demonstrate heat sink effects. Although the basic model overpredicted these effects, it correctly indicated the trends shown in the experimental study and is judged worth further refinement.
To determine shuttle orbiter wing loads during ascent, wing load instrumentation was added to Columbia (OV-102). This instrumentation included strain gages and pressure orifices on the wing. The loads derived from wing pressure measurements taken during STS 61-C did not agree with those derived from strain gage measurements or with the loads predicted from the aerodynamic database. Anomalies in the surface immediately surrounding the pressure orifices in the thermal protection system (TPS) tiles were one possible cause of errors in the loads derived from wing pressure measurements. These surface anomalies were caused by a ceramic filler material which was installed around the pressure tubing. The filler material allowed slight movement of the TPS tile and pressure tube as the airframe flexed and bent under aerodynamic loads during ascent and descent. Postflight inspection revealed that this filler material had protruded from or receeded beneath the surface, causing the orifice to lose its flushness. Flight tests were conducted at NASA Ames Research Center Dryden Flight Research Facility to determine the effects of any anomaly in surface flushness of the orifice installation on the measured pressures at Mach numbers between 0.6 and 1.4. An F-104 aircraft with a flight test fixture mounted beneath the fuselage was used for these flights. Surface flushness anomalies typical of those on the orbiter after flight (STA 61-C) were tested. Also, cases with excessive protrusion and recession of the filler material were tested. This report shows that the anomalies in STS 61-C orifice installations adversely affected the pressure measurements. But the magnitude of the affect was not great enough to account for the discrepancies with the strain gage measurements and the aerodynamic predictions.