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At least 1,063 records · Page 59

Effects of Planetary Speed Reduction Ratio on Mean Service Life

Planetary gear transmissions are compact speed reductions which use parallel-load paths to transmit high power. The range of possible reduction ratios is bounded from below and above by limits on the relative size of the planet gears. For a single plane planetary transmission, the speed-reduction ratio must be greater than two for planet gears to exist. As the ratio increase, so does the size of the planets relative to the sizes of the sun and ring. Which ratio is best for a planetary reduction can be resolved by studying a series of optimal designs. In this series, each design is obtained by maximizing the service life for a spur-gear planetary with a fixed size, speed reduction ratio, input speed, power and materials. The planetary gear reduction service life is modeled as a function of the two-parameter Weibull distributed service lives of the ball bearings and spur gears in the reduction. Planet-bearing life strongly influences the optimal reduction lives which point to an optimal planetary reduction ratio in the neighborhood of four to five.

Savage, M.↗

Effects of Planetary Speed-Reduction Ratio on Mean Service Life

Planetary-gear transmissions are compact speed reductions which use parallel-load paths to transmit high power. The range of possible reduction ratios is bounded from below and above by limits on the relative size of the planet gears. For a single-plane planetary transmission, the speed-reduction ratio must be greater than two for planet gears to exist. As the ratio increases, so does the size of the planets relative to the sizes of the sun and ring. Which ratio is best for a planetary reduction can be resolved by studying a series of optimal designs. In this series, each design is obtained by maximizing the service life for a spur-gear planetary with a fixed size, speed-reduction ratio, input speed, power and materials. The planetary-gear reduction service life is modeled as a function of the two-parameter Weibull distributed service lives of the ball bearings and spur gears in the reduction. Planet-bearing life strongly influences the optimal reduction lives which point to an optimal planetary reduction ratio in the neighborhood of four to five.

Savage, M.↗

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↗

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↗

Design of Oil-Lubricated Machine for Life and Reliability

In the post-World War II era, the major technology drivers for improving the life, reliability, and performance of rolling-element bearings and gears have been the jet engine and the helicopter. By the late 1950s, most of the materials used for bearings and gears in the aerospace industry had been introduced into use. By the early 1960s, the life of most steels was increased over that experienced in the early 1940s, primarily by the introduction of vacuum degassing and vacuum melting processes in the late 1950s. The development of elastohydrodynamic (EHD) theory showed that most rolling bearings and gears have a thin film separating the contacting bodies during motion and it is that film which affects their lives. Computer programs modeling bearing and gear dynamics that incorporate probabilistic life prediction methods and EHD theory enable optimization of rotating machinery based on life and reliability. With improved manufacturing and processing, the potential improvement in bearing and gear life can be as much as 80 times that attainable in the early 1950s. The work presented summarizes the use of laboratory fatigue data for bearings and gears coupled with probabilistic life prediction and EHD theories to predict the life and reliability of a commercial turboprop gearbox. The resulting predictions are compared with field data.

Zaretsky, Erwin V.↗

Experimental Study of Wake / Flap Interaction Noise and the Reduction of Flap Side Edge Noise

The effects of the interaction of a wake with a half-span flap on radiated noise are examined. The incident wake is generated by bars of various widths and lengths or by a simplified landing gear model. Single microphone and phased array measurements are used to isolate the effects of the wake interaction on the noise radiating from the flap side edge and flap cove regions. The effects on noise of the wake generator's geometry and relative placement with respect to the flap are assessed. Placement of the wake generators upstream of the flap side edge is shown to lead to the reduction of flap side edge noise by introducing a velocity deficit and likely altering the instabilities in the flap side edge vortex system. Significant reduction in flap side edge noise is achieved with a bar positioned directly upstream of the flap side edge. The noise reduction benefit is seen to improve with increased bar width, length and proximity to the flap edge. Positioning of the landing gear model upstream of the flap side edge also leads to decreased flap side edge noise. In addition, flap cove noise levels are significantly lower than when the landing gear is positioned upstream of the flap mid-span. The impact of the local flow velocity on the noise radiating directly from the landing gear is discussed. The effects of the landing gear side-braces on flap side edge, flap cove and landing gear noise are shown.

Hutcheson, Florence V.↗

Development of Pericyclic Gearbox for Roving Application

Many aerospace mechanisms require high gear reduction ratios to reduce the high output speed of a motor to much lower speeds for precision rotation. Conventionally this actuation is performed with multiple gear stages, typically including a harmonic gearbox, and is required to be lightweight for spaceflight. One application of multiple gear stages is in rover wheel actuators intended for use on the Moon and Mars. These actuators require low total mass, high reliability, and precision actuation due to their remote operation. The pericyclic gearbox has the capability in a single stage to provide high reduction ratios equivalent to multiple conventional stages. Some benefits of utilizing pericyclic gear technology over multiple conventional stages are a compact form, fewer total parts, no reliance on flexible members (such as in harmonic drives), and lower total system mass. The goal of this work was to modify and build on existing modeling tools to determine the feasibility of utilizing the pericyclic gearbox for such an application. Critical aspects to consider were gear tooth loads, gear mesh efficiency, bearing loads, bearing efficiency, and total system mass. Developed tools were then used to examine a single stage pericyclic gearbox's trends in mass and efficiency for a Mars 2020 rover wheel actuator mechanism design case which was then compared to multistage gearbox designs.

Krantz, Timothy↗

Mars 2020 Mobility Actuator Thermal Testing and Model Correlation

This paper describes the thermal testing and model correlation of a mobility actuator planned for use on the Mars 2020 Rover. The mobility actuator is identical to those which have been successfully flown and operated on the Mars Science Laboratory (MSL) Curiosity rover since its successful landing on Mars in August of 2012. The actuator consists of a motor, brake, and encoder paired with a four stage planetary gear box. In this thermal test, the actuator was instrumented with a number of thermocouples on both the interior and exterior of the gearbox. Heaters and a cold plate were used to generate thermal gradients across the actuator in vacuum, low pressure GN2, and low pressure CO2 environments in an effort to correlate a thermal model and develop a better understanding of how heat flows through the mechanism. This testing resulted in the successful model correlation of a simplified thermal model, and yielded important insights regarding the conductance of ball bearings and gear-to-gear contact. Ball bearing thermal conductance in a low pressure environment can be estimated by using correlations for vacuum thermal conductance along with a multiplier to account for increased gas conduction, and gear-to-gear conductance can be estimated by accounting for gas and grease conduction between two gears.

Novak, Keith↗

Comparison of Orion Flywheel to Commercially Available Flywheel Device

INTRODUCTION: The chosen exercise device for the Orion Multi-purpose Crew Vehicle (MPCV) for Artemis missions is the Orion Flywheel (OFW), which was selected in 2017 from a pool of exercise devices. The Orion Flywheel is to be installed in the MPCV for its first use during the Artemis II mission and will be utilized for subsequent Artemis missions. The OFW provides the capability to perform both resistive and aerobic exercises while taking up a small volume and not requiring power. Aerobic exercise consists of rowing while resistive exercise includes the deadlift, harness squat, and deadlift high pull among others. The efficacy of the OFW as an exercise countermeasure to spaceflight deconditioning has not yet been fully evaluated. A future HRP-funded study using head-down tilt bed rest is planned to evaluate the efficacy of the OFW to mitigate aerobic and muscular deconditioning. The OFW, made by KBR, is a specialized device that poses high costs for purchase and maintenance. The aim of the study is to determine if a commercially available alternative could be used as a backup for the OFW during the bed rest study or as an alternative in other studies. This study seeks to compare the loading profile and mechanics of a commercial flywheel device (kBox Pro) with the three resistance settings of the OFW using a controlled, instrumented setup to validate its acceptability as a backup. METHODS: An experimental setup was designed to simulate human use of the OFW. Flywheel devices can have varied actuated inertial mass and strap length. The inertial mass refers to the flywheel itself or the object that spins as the result of the movement of the strap. The OFW has three gears actuated with a lever, with the low gear used for aerobic rowing and the medium and high gears used for resistance exercises. These gears correspond to increasing flywheel inertia, which corresponds to a certain number and sizes of inertial plates on a commercial flywheel. The kBox Pro has varied sizes of inertial discs that are installed to the external shaft of the device and can be configured to roughly match the inertia seen in the OFW per gear setting. The strap length can be adjusted to allow for different ranges of motion. The experimental setup allows for the simulation of rowing, harness squats, and deadlift high pulls with corresponding exercise strap lengths. All three OFW gears are to be tested, as well as multiple combinations of kBox discs. The setup was created using a system of pulleys and cables to minimize friction loss. The system is actuated through the dropping of a connected mass which, through the pulley system, pulls the strap of the exercise device upwards as if a human was exercising. A string potentiometer and tensile force transducer are used to measure strap displacement and strap force, respectively. The masses dropped are exercise chains that simulate the decrease in force observed throughout a typical exercise. As the chains are lowered to the ground, they begin to spool and therefore are no longer subjecting the exercise device’s strap to their load. This setup was designed to provide realistic loads and protect the OFW from damage, an important precaution because it’s the only available unit for research and ground operations. Data is to be collected across simulated exercises and with different strap lengths, with the same conditions collected on both the OFW and the kBox Pro. RESULTS: Data collection is ongoing for the kBox and the Orion Flywheel. CONCLUSIONS: Study results will inform if the OFW and a kBox Pro device can be deemed mechanically similar. Depending on the results, additional data collection may be required to assess the user experience between the devices. A key result of this study is a mechanical characterization of the OFW device, demonstrating the load and force profile using a repeatable test method. This data will guide next steps on potential kBox Pro modifications needed to produce a comparable exercise experience to the OFW.

Exercise↗

Results of ISO/TS 6336-22 Evaluating Full Contact Zone: Preprint

ISO/TS 6336-22 (Calculation of load capacity of spur and helical gears — Part 22: Calculation of micropitting load capacity) is the ISO technical specification containing a proposal for calculations of the risk of micropitting in gear sets. Micropitting is a Hertzian fatigue phenomenon that appears as ultra-fine cracking and pitting on the flanks of gear teeth. Since progressive micropitting can lead to macropitting and flank damage, critical applications such as wind turbines, marine drives, and high-speed gear drives seek to accurately predict whether their designs are susceptible to this damage. ISO/TS 6336-22 assesses micropitting risk through a safety factor which is calculated as the minimum specific film thickness in the contact zone divided by a permissible specific film thickness. In the previous paper, the calculations were performed using the simplified method (Method B) that evaluates points on the path of contact. This was done for three gear sets that experienced micropitting in operation. The minimum specific film thickness for the two field cases was very high, which indicates that the gears were operating in the full elastohydrodynamic lubrication (EHL) regime. A more accurate calculation for these cases (Method A) calculates the specific film thickness across the entire contact zone. This paper applies this Method to the case study from the previous paper. The results are compared to micropitting observed in operation. Results are also compared to the results of the previous paper. Conclusions are made regarding the accuracy of both Methods compared to the field cases and relative to each other.

gearbox↗

Results of ISO/TS 6336-22 Evaluating Full Contact Zone

ISO/TS 6336-22 (Calculation of load capacity of spur and helical gears - Part 22: Calculation of micropitting load capacity) is the ISO technical specification containing a proposal for calculations of the risk of micropitting in gear sets. Micropitting is a Hertzian fatigue phenomenon that appears as ultra-fine cracking and pitting on the flanks of gear teeth. Since progressive micropitting can lead to macropitting and flank damage, critical applications such as wind turbines, marine drives, and high-speed gear drives seek to accurately predict whether their designs are susceptible to this damage. ISO/TS 6336-22 assesses micropitting risk through a safety factor which is calculated as the minimum specific film thickness in the contact zone divided by a permissible specific film thickness. In the previous paper, the calculations were performed using the simplified method (Method B) that evaluates points on the path of contact. This was done for three gear sets that experienced micropitting in operation. The minimum specific film thickness for the two field cases was very high, which indicates that the gears were operating in the full elastohydrodynamic lubrication (EHL) regime. A more accurate calculation for these cases (Method A) calculates the specific film thickness across the entire contact zone. This paper applies this Method to the case study from the previous paper. The results are compared to micropitting observed in operation. Results are also compared to the results of the previous paper. Conclusions are made regarding the accuracy of both Methods compared to the field cases and relative to each other.

gearbox↗

Focal Fisheries Requirements for Floating Offshore Wind Co-Design in the Gulf of Maine and the Mid-Atlantic Bight

Floating offshore wind is an emerging renewable energy technology in U.S. waters and globally. Floating offshore wind technology is more complex than fixed-bottom installations, requiring platforms, moorings, and power cables that take up a larger footprint, both in the water column and along the seafloor. This complexity affects opportunities for compatibility between floating offshore wind and other ocean users, particularly fishermen, whose fishing gear also takes up space in the water column and along the seafloor. This report describes the results of semi-structured interviews with key fishing informants from two focal fisheries: (1) Gulf of Maine lobster (fixed gear) and (2) Mid-Atlantic Bight pelagic longline and recreational tuna (mobile gear). A total of six fishermen were interviewed: four from the Gulf of Maine and two from the Mid-Atlantic Bight. The interviews were designed to elicit information and opinions on the co-design of marine space for particular fishing gear and floating offshore wind infrastructure. Here, we provide an overview of participant fishing experience, the spatial requirements of specific gear types, self-reported comfort levels in different fishing scenarios, and concerns about accessing and operating within floating offshore wind arrays. This summary of fishermen s concerns around floating offshore wind infrastructure can guide future co-existence conversations.

17 WIND ENERGY↗

A rotary actuator for space missions

A new rotary actuator is reported that consists of a motor functionally integrated with the transmission of a ring gear in a single element which is driven by the rotating magnetic vector in the stator. Because the number of teeth on the ring gear is different from that on the fixed ground gear, the ring gear rotates at a fraction of a revolution and simultaneously rotates the output gear in one eccentric cycle in the opposite direction. The advantages of the design are that only two bearings are required on a low speed output shaft.

Devine, E. J.↗

Power control for hot gas engines

A hot gas engine in which the expander piston of the engine is connected to an expander crankshaft. A displacer piston of the engine is connected to a separate displacer crankshaft which may or may not be coaxial with the expander crankshaft. A phase angle control mechanism used as a power control for changing the phase angle between the expander and displacer crankshaft is located between the two crankshafts. The phase angle control mechanism comprises a differential type mechanism comprised of a pair of gears, as for example, bevel gears, one of which is connected to one end of the expander crankshaft and the other of which is connected to the opposite end of the displacer crankshaft. A mating bevel gear is disposed in meshing engagement with the first two level gears to provide a phase angle control between the two crankshafts. Other forms of differential mechanisms may be used including conventional spur gears connected in a differential type arrangement.

Macglashan, W. F.↗

System life and reliability modeling for helicopter transmissions

A computer program which simulates life and reliability of helicopter transmissions is presented. The helicopter transmissions may be composed of spiral bevel gear units and planetary gear units - alone, in series or in parallel. The spiral bevel gear units may have either single or dual input pinions, which are identical. The planetary gear units may be stepped or unstepped and the number of planet gears carried by the planet arm may be varied. The reliability analysis used in the program is based on the Weibull distribution lives of the transmission components. The computer calculates the system lives and dynamic capacities of the transmission components and the transmission. The system life is defined as the life of the component or transmission at an output torque at which the probability of survival is 90 percent. The dynamic capacity of a component or transmission is defined as the output torque which can be applied for one million output shaft cycles for a probability of survival of 90 percent. A complete summary of the life and dynamic capacity results is produced by the program.

Savage, M.↗

Angular-Momentum-Compensating Servomechanism

Servomechanism for rotating an instrumentation platform isolates supporting vehicle or stationary platform from reaction torques producedby rotations. Prevents aiming of instrument from disturbing vehicle or other instrument platforms. Rotating oppositely to instrument platform, reaction wheel, motor, and gear 1 have angular momentum equal and opposite to gear 2, output shaft, and platform. External torque reaction to rotation of platform canceled. Although spur gears appear in schematic diagram, gear train made of spline gears.

Marchetto, Carl A.↗

Effect of advanced component technology on helicopter transmissions

Experimental tests were performed on the NASA/Bell Helicopter Textron (BHT) 500 hp advanced technology transmission (ATT) at the NASA Lewis Research Center. The ATT was a retrofit of the OH-58C helicopter 236 kW (317 hp) main rotor transmission, upgraded to 373 kW (500 hp), with a design goal of retaining long life with a minimum increase in cost, weight, and size. Vibration, strain, efficiency, deflection, and temperature experiments were performed and the results were compared to previous experiments on the OH-58A, OH-58C, and UH-60A transmissions. The high-contact-ratio gears and the cantilevered-mounted, flexible ring gear of the ATT reduced vibration compared to that of the OH-58C. The ATT flexible ring gear improved planetary load sharing compared to that of the rigid ring gear of the UH-60A transmission. The ATT mechanical efficiency was lower than that of the OH-58A transmission, probably due to the high-contact-ratio planetary gears.

Lewicki, David G.↗

Effect of advanced component technology on helicopter transmissions

Experimental tests were performed on the NASA/Bell Helicopter Textron (BHT) 500 hp advanced technology transmission (ATT) at the NASA Lewis Research Center. The ATT was a retrofit of the OH-58C helicopter 236 kW (317 hp) main rotor transmission, upgraded to 373 kW (500 hp), with a design goal of retaining long life with a minimum increase in cost, weight, and size. Vibration, strain, efficiency, deflection, and temperature experiments were performed and the results were compared to previous experiments on the OH-58A, OH-58C, and UH-60A transmissions. The high-contact-ratio gears and the cantilevered-mounted, flexible ring gear of the ATT reduced vibration compared to that of the OH-58C. The ATT flexible ring gear improved planetary load sharing compared to that of the rigid ring gear of the UH-60A transmission. The ATT mechanical efficiency was lower than that of the OH-58A transmission, probably due to the high-contact-ratio planetary gears.

Lewicki, D. G.↗