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Overview of Glenn Mechanical Components Branch Research

Mr. James Zakrajsek, chief of the Mechanical Components Branch, gave an overview of research conducted by the branch. Branch members perform basic research on mechanical components and systems, including gears and bearings, turbine seals, structural and thermal barrier seals, and space mechanisms. The research is focused on propulsion systems for present and advanced aerospace vehicles. For rotorcraft and conventional aircraft, we conduct research to develop technology needed to enable the design of low noise, ultra safe geared drive systems. We develop and validate analytical models for gear crack propagation, gear dynamics and noise, gear diagnostics, bearing dynamics, and thermal analyses of gear systems using experimental data from various component test rigs. In seal research we develop and test advanced turbine seal concepts to increase efficiency and durability of turbine engines. We perform experimental and analytical research to develop advanced thermal barrier seals and structural seals for current and next generation space vehicles. Our space mechanisms research involves fundamental investigation of lubricants, materials, components and mechanisms for deep space and planetary environments.

Zakrajsek, James

Mechanical Components Branch Overview

Mr. James Zakrajsek, chief of the Mechanical Components Branch, presented an overview of research conducted by the branch. Branch members perform basic research on mechanical components and systems, including gears and bearings, turbine seals, structural and thermal barrier seals, and space mechanisms. The research is focused on propulsion systems for present and advanced aerospace vehicles. For rotorcraft and conventional aircraft, we conduct research to develop technology needed to enable the design of low noise, ultra safe geared drive systems. We develop and validate analytical models for gear crack propagation, gear dynamics and noise, gear diagnostics, bearing dynamics, and thermal analyses of gear systems using experimental data from various component test rigs. In seal research we develop and test advanced turbine seal concepts to increase efficiency and durability of turbine engines. We perform experimental and analytical research to develop advanced thermal barrier seals and structural seals for current and next generation space vehicles. In space mechanisms, we conduct fundamental research on lubricants, materials, components and mechanisms subjected to deep space and planetary environments.

Source record

7th AAS/AIAA Space Flight Mechanics Meeting

TOPEX/Poseidon is a joint American/French ocean topography experiment conducted by the National Aeronautics and Space Administration (NASA) and the Centre National d'Etudes Spatiales (CNES)...Specifically, the paper first presents the present task configuration. Changes implemented after the prime mission are then discussed. Four areas of statistical performance are emhaszed and presented in detail...finally, the paper addresses problems encountered and lessons learned.

TOPEX TOPEX/POSEIDON POEs Precision Orbit Determin

Implications of privacy needs and interpersonal distancing mechanisms for space station design

Privacy needs, or the need of people to regulate their degree of contact with one another, and interpersonal distancing mechanisms, which serve to satisfy these needs, are common in all cultures. Isolation, confinement, and other conditions accociated with space flight may at once accentuate privacy needs and limit the availability of certain common interpersonal contact. Loneliness occurs when people have less contact with one another than they desire. Crowding occurs when people have more contact with one another than they desire. Crowding, which is considered the greater threat to members of isolated and confined groups, can contribute to stress, a low quality of life, and poor performance. Drawing on the general literature on privacy, personal space, and interpersonal distancing, and on specialized literature on life aboard spacecraft and in spacecraft-analogous environments, a quantitative model for understanding privacy, interpersonal distancing, loneliness, and crowding was developed and the practical implications of this model for space station design were traced.

Harrison, A. A.

A study of the feasibility of directly applying gas generator systems to space shuttle mechanical functions

This study examined the current status and potential application of pyrotechnic gas generators and energy convertors for the space shuttle program. While most pyrotechnic devices utilize some form of linear actuation, only limited use of rotary actuators has been observed. This latter form of energy conversion, using a vane-type actuator as optimum, offers considerable potential in the area of servo, as well as non-servo systems, and capitalizes on a means of providing prolonged operating times. Pyrotechnic devices can often be shown to provide the optimum means of attaining a truly redundant back-up to a primary, non-pyrotechnic system.

Lake, E. R.

Ion Implantation of Perfluoropolyether-Lubricated Surfaces for Improved Tribological Performance

For over 30 years, perfluoropolyethers (PFPE's) have been the liquid lubricants of choice for space applications because of their proven tribological performance and desirable properties, such as low vapor pressure and a wide liquid temperature range. These oils are used in such space mechanisms as gyroscopes, scanning mirrors, actuators, and filter wheels. In the past few years, there have been several incidents during which PFPE-lubricated space mechanisms have shown anomalous behavior. These anomalies are thought to be the result of PFPE degradation. Investigative research focused on understanding and modeling the degradation of PFPE lubricants has shown that PFPE's degrade and lose their desirable properties while under boundary-lubricated, sliding/rolling contacts and at elevated temperatures. These performance deficiencies are strongly dependent on the surface chemistry and reactivity of the lubricated contacts, which dictate the formation of harmful catalytic by-products. One way to inhibit tribo-induced degradation may be to use passivated surfaces that do not promote the formation of harmful by-products. Such a passivated surface would inhibit PFPE degradation and increase the lifetime of the lubricated mechanism. Ion implantation is one such passivation technique. This surface-treatment technique can modify the surface properties of materials without affecting either the properties or dimensions of the bulk material beneath the treated layer. By introducing a foreign species into a submicron surface layer, ion implantation can induce unique surface microstructures.

Shogrin, Brad

A robot end effector exchange mechanism for space applications

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.

Gorin, Barney F.

The ESA Large Space Simulator Mechanical Ground Support Equipment for Spacecraft Testing

Environmental test facilities are not suitable in any case to comply with special or complex test requirements without modifications. Dedicated upgrades of the test facility and their subsystems with respect to the test requirements and specifications are often necessary. The Flight Model of the Planck Space Telescope was tested in the Large Space Simulator (LSS) of the ESTEC Test Centre. Main goals of the test were the verification of the deformation of the Telescope during thermal vacuum conditions at different temperature levels and the validation of the Thermal Model. The deformations of the telescope have been traced by two Videogrammetry canisters. In order to provide different view positions with respect to the PLANCK Telescope it was necessary to rotate the specimen by +/- 180deg. In addition very stringent requirements for the low temperature level of the thermal environment has lead to a comprehensive test set-up which was divided in four main elements: Dedicated support structure for the Videogrammetry canisters providing several DoF for adjustment. Structure to support three Infrared panels around the specimen. MLI curtain to cover the LSS 8m auxiliary chamber opening. System providing LN2 supply for the rotating PLANCK telescope cold panel. The design, manufacturing and integration of the necessary mechanical ground support to install for instance the canisters and to ensure the 180 rotation of the telescope under cold and high vacuum conditions was an extensive and important part of the entire test program. This paper will concentrate on the design issues, the implementation and verification of the MGSE provided for the Planck Space Telescope FM Videogrammetry Test in the LSS and the troubleshooting caused by a failure during the first rotation under cold conditions.

Hagelschuer, Dirk

Development of a rotary fluid transfer coupling and support mechanism for space station

A design was developed for a rotary fluid coupling to transfer coolant fluids (primarily anhydrous ammonia) across rotating joints of the space station. Development testing using three conceptual designs yielded data which were used to establish the design of a multipass fluid coupling capable of handling three fluid circuits. In addition, a mechanism to support the fluid coupling and allow an astronaut to replace the coupling quickly and easily was designed.

Bradley, O. H., Jr.

Practical Considerations for Using Constant Force Springs in Space-Based Mechanisms

Mechanical springs are a common element in mechanism from all walks of life; cars, watches, appliances, and many others. These springs generally exhibit a linear relationship between force and deflection. In small mechanisms, deflections are small so the variation in spring force between one position and another are generally small and do not influence the design or functionality of the device. However, as the spacecraft industry drives towards larger, deployable satellites, the distances a spring or springs must function over can become considerable so much so that the structural integrity of the device may be impacted. As such, an increasingly common mechanism element is the constant force spring- one that provides a constant force regardless of deflection. These elements are commonly in the conceptual design phase to deal with system-level large deflections, but in the detailed design or integration test phase they can pose significant implementation issues. This article addresses some of the detailed issues in order for these constant force springs to be properly designed into space systems.

reliability testing

System requirements and design features of Space Station Remote Manipulator System mechanisms

The Space Station Remote Manipulator System (SSRMS) is a long robotic arm for handling large objects/payloads on the International Space Station Freedom. The mechanical components of the SSRMS include seven joints, two latching end effectors (LEEs), and two boom assemblies. The joints and LEEs are complex aerospace mechanisms. The system requirements and design features of these mechanisms are presented. All seven joints of the SSRMS have identical functional performance. The two LEES are identical. This feature allows either end of the SSRMS to be used as tip or base. As compared to the end effector of the Shuttle Remote Manipulator System, the LEE has a latch and umbilical mechanism in addition to the snare and rigidize mechanisms. The latches increase the interface preload and allow large payloads (up to 116,000 Kg) to be handled. The umbilical connectors provide power, data, and video signal transfer capability to/from the SSRMS.

Kumar, Rajnish

Drive System Research

An overview of the NASA Glenn Research Center Drive Systems Research will be presented. The primary purpose of this research is to improve performance, reliability, and integrity of aerospace drive systems and space mechanisms. The research is conducted through a combination of in-house, academia, and through contractors. Research is conducted through computer code development and validated through component and system testing. The drive system activity currently has four major thrust areas including: thermal behavior of high speed gearing, health and usage monitoring, advanced components, and space mechanisms.

Handschuh, Robert F.

Umbilical mechanism assembly for the international space station

Mechanisms for engaging and disengaging electrical and fluid line connectors are required to be operated repeatedly in hazardous or remote locations on space station, nuclear reactors, toxic chemical and undersea environments. Such mechanisms may require shields to protect the mating faces of the connectors when connectors are not engaged and move these shields out of the way during connector engagement. It is desirable to provide a force-transmitting structure to react the force required to engage or disengage the connectors. It is also desirable that the mechanism for moving the connectors and shields is reliable, simple, and the structure as lightweight as possible. With these basic requirements, an Umbilical Mechanism Assembly (UMA) was originally designed for the Space Station Freedom and now being utilized for the International Space Station.

Mandvi, A. Ali

Design and Manufacturing Considerations for Shockproof and Corrosion-Immune Superelastic Nickel-Titanium Bearings for a Space Station Application

An intermetallic nickel-titanium alloy, 60NiTi (60wt%Ni, 40wt%Ti), is a promising tribological material for space mechanisms. 60NiTi offers a broad combination of physical properties that make it unique among bearing materials. 60NiTi is hard, electrically conductive, highly corrosion resistant, readily machined prior to final heat treatment, easily lubricated and is non-magnetic. It also falls within the class of superelastic alloys and can elastically endure large strains (beyond 5 percent) making it highly resistant to excessive and unexpected (shock) loads. Key material properties and characteristics such as elastic modulus, tensile fracture sensitivity and residual stress behavior, however, differ from conventional alloys such as steel and this significantly affects bearing design and manufacturing. In this paper, the preliminary design and manufacture of ball bearings made from 60NiTi are considered for a highly corrosive, lightly loaded, low speed bearing application found inside the International Space Station s water recycling system. The information presented is expected to help guide more widespread commercialization of this new technology into space mechanism and other applications.

DellaCorte, Christopher

Tribometer for Lubrication Studies in Vacuum

The NASA Lewis Research Center has developed a new way to evaluate the liquid lubricants used in ball bearings in space mechanisms. For this evaluation, a liquid lubricant is exercised in the rolling contact vacuum tribometer shown in the photo. This tribometer, which is essentially a thrust bearing with three balls and flat races, has contact stresses similar to those in a typical preloaded, angular contact ball bearing. The rotating top plate drives the balls in an outward-winding spiral orbit instead of a circular path. Upon contact with the "guide plate," the balls are forced back to their initial smaller orbit radius; they then repeat this spiral orbit thousands of times. The orbit rate of the balls is low enough, 2 to 5 rpm, to allow the system to operate in the boundary lubrication regime that is most stressful to the liquid lubricant. This system can determine the friction coefficient, lubricant lifetime, and species evolved from the liquid lubricant by tribodegradation. The lifetime of the lubricant charge is only few micrograms, which is "used up" by degradation during rolling. The friction increases when the lubricant is exhausted. The species evolved by the degrading lubricant are determined by a quadrupole residual gas analyzer that directly views the rotating elements. The flat races (plates) and 0.5-in.-diameter balls are of a configuration and size that permit easy post-test examination by optical and electron microscopy and the full suite of modern surface and thin-film chemical analytical techniques, including infrared and Raman microspectroscopy and x-ray photoelectron spectroscopy. In addition, the simple sphere-on-a-flat-plate geometry allows an easy analysis of the contact stresses at all parts of the ball orbit and an understanding of the frictional energy losses to the lubricant. The analysis showed that when the ball contacts the guide plate, gross sliding occurs between the ball and rotating upper plate as the ball forced back to a smaller orbit radius. The friction force due to gross sliding is sensed by the piezoelectric force transducer behind the guide plate and furnishes the coefficient of friction for the system. This tribometer has been used to determine the relative lifetimes of Fomblin Z-25, a lubricant often used in space mechanisms, as a function of the material of the plates against which it was run. The balls were 440C steel in all cases; the plate materials were aluminum, chromium (Cr), 440C steel (17 wt % Cr), and 4150 steel (1 wt % Cr). As shown in the bar graph, the lifetime is greatest for the plate material with least chromium, thus implicating chromium as a tribochemically active element attacking Fomblin Z-25.

Pepper, Stephen V.