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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 1,135 records · Page 63

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NASA NTRS1992

Elastomeric load sharing device

An elastomeric load sharing device, interposed in combination between a driven gear and a central drive shaft to facilitate balanced torque distribution in split power transmission systems, includes a cylindrical elastomeric bearing and a plurality of elastomeric bearing pads. The elastomeric bearing and bearing pads comprise one or more layers, each layer including an elastomer having a metal backing strip secured thereto. The elastomeric bearing is configured to have a high radial stiffness and a low torsional stiffness and is operative to radially center the driven gear and to minimize torque transfer through the elastomeric bearing. The bearing pads are configured to have a low radial and torsional stiffness and a high axial stiffness and are operative to compressively transmit torque from the driven gear to the drive shaft. The elastomeric load sharing device has spring rates that compensate for mechanical deviations in the gear train assembly to provide balanced torque distribution between complementary load paths of split power transmission systems.

Isabelle, Charles J.↗

NASA NTRS2009

Linear Actuator Has Long Stroke and High Resolution

The term precision linear actuator, direct drive ( PLADD ) refers to a robust linear actuator designed to be capable of repeatedly performing, over a lifetime of the order of 5 to 10 years, positioning maneuvers that include, variously, submicron increments or slews of the order of a centimeter. The PLADD is capable of both long stroke (120 mm) and high resolution (repeatable increments of 20 nm). Unlike precise linear actuators of prior design, the PLADD contains no gears, levers, or hydraulic converters. The PLADD, now at the prototype stage of development, is intended for original use as a coarse-positioning actuator in a spaceborne interferometer. The PLADD could also be adapted to terrestrial applications in which there are requirements for long stroke and high resolution: potential applications include medical imaging and fabrication of semiconductor devices. The PLADD (see figure) includes a commercially available ball-screw actuator driven directly by a commercially available three-phase brushless DC motor. The ball-screw actuator comprises a spring-preloaded ball nut on a ball screw that is restrained against rotation as described below. The motor is coupled directly (that is, without an intervening gear train) to a drive link that, in turn, is coupled to the ball nut. By eliminating the gear train, the direct-drive design eliminates the complexity, backlash, and potential for misalignment associated with a gear train. To prevent inadvertent movement, there is a brake that includes flexured levers compressed against the drive link by preload springs. This is a power-off brake: There are also piezoelectric stacks that can be activated to oppose the springs and push the levers away from the drive link. Hence, power must be applied to the piezoelectric stacks to release the drive link from braking. To help ensure long operational life, all of the mechanical drive components are immersed in an oil bath within hermetically sealed bellows. The outer end of the bellows holds the outer end of the ball screw, thereby preventing rotation of the ball screw. Positioning is controlled by an electronic control system that includes digital and analog subsystems that interact with the motor and brake and with two sensor/encoder units: a Hall-effect-sensor rotation encoder and a linear glass-scale encoder. This system implements a proportional + integral + derivative control algorithm that results in variation of voltage commands to each of the three pairs of windings of the brushless DC motor. In one of two alternative control modes, the voltages are applied to the windings in a trapezoidal commutation scheme on the basis of timing signals obtained from the Hall-effect sensors; this scheme yields relatively coarse positioning - 24 steps per motor revolution. The second control mode involves a sinusoidal commutation scheme in which the output of the linear glass-scale encoder is transposed to rotational increments to yield much finer position feedback - more than 400,000 steps per revolution.

Cook, Brant T.↗

NASA NTRS2010

Rotorcraft Transmission Noise Path Model, Including Distributed Fluid Film Bearing Impedance Modeling

A computational approach for simulating the effects of rolling element and journal bearings on the vibration and sound transmission through gearboxes has been demonstrated. The approach, using ARL/Penn State s CHAMP methodology, uses Component Mode Synthesis of housing and shafting modes computed using Finite Element (FE) models to allow for rapid adjustment of bearing impedances in gearbox models. The approach has been demonstrated on NASA GRC s test gearbox with three different bearing configurations: in the first condition, traditional rolling element (ball and roller) bearings were installed, and in the second and third conditions, the traditional bearings were replaced with journal and wave bearings (wave bearings are journal bearings with a multi-lobed wave pattern on the bearing surface). A methodology for computing the stiffnesses and damping in journal and wave bearings has been presented, and demonstrated for the journal and wave bearings used in the NASA GRC test gearbox. The FE model of the gearbox, along with the rolling element bearing coupling impedances, was analyzed to compute dynamic transfer functions between forces applied to the meshing gears and accelerations on the gearbox housing, including several locations near the bearings. A Boundary Element (BE) acoustic model was used to compute the sound radiated by the gearbox. Measurements of the Gear Mesh Frequency (GMF) tones were made by NASA GRC at several operational speeds for the rolling element and journal bearing gearbox configurations. Both the measurements and the CHAMP numerical model indicate that the journal bearings reduce vibration and noise for the second harmonic of the gear meshing tones, but show no clear benefit to using journal bearings to reduce the amplitudes of the fundamental gear meshing tones. Also, the numerical model shows that the gearbox vibrations and radiated sound are similar for journal and wave bearing configurations.

Hambric, Stephen A.↗

NASA NTRS2010

Deployment of a Curved Truss

Structures capable of deployment into complex, three-dimensional trusses have well known space technology applications such as the support of spacecraft payloads, communications antennas, radar reflectors, and solar concentrators. Such deployable trusses could also be useful in terrestrial applications such as the rapid establishment of structures in military and emergency service situations, in particular with regard to the deployment of enclosures for habitat or storage. To minimize the time required to deploy such an enclosure, a single arch-shaped truss is preferable to multiple straight trusses arranged vertically and horizontally. To further minimize the time required to deploy such an enclosure, a synchronous deployment with a single degree of freedom is also preferable. One method of synchronizing deployment of a truss is the use of a series of gears; this makes the deployment sequence predictable and testable, allows the truss to have a minimal stowage volume, and the deployed structure exhibits the excellent stiffness-to-mass and strength-to-mass ratios characteristic of a truss. A concept for using gears with varying ratios to deploy a truss into a curved shape has been developed and appears to be compatible with both space technology applications as well as potential use in terrestrial applications such as enclosure deployment. As is the case with other deployable trusses, this truss is formed using rigid elements (e.g., composite tubes) along the edges, one set of diagonal elements composed of either cables or folding/hinged rigid members, and the other set of diagonal elements formed by a continuous cable that is tightened by a motor or hand crank in order to deploy the truss. Gears of varying ratios are used to constrain the deployment to a single degree of freedom, making the deployment synchronous, predictable, and repeatable. The relative sizes of the gears and the relative dimensions of the diagonal elements determine the deployed geometry (e.g. curvature) of the truss.

Giersch, Louis R.↗

NASA NTRS2011

Anti-Rotation Device Releasable by Insertion of a Tool

A drive mechanism enables a socket-type wrench to rotate a shaft and prevents accidental rotation of the shaft when the wrench is not coupled to the shaft. In the original intended application, the shaft would be part of an attachment mechanism on a spacecraft, and the purpose to be served by the drive is to prevent back-driving of the shaft by launch vibrations while enabling an astronaut equipped with the appropriate wrench to actuate the shaft while in orbit. The design could also be adapted to terrestrial applications in which it is necessary to prevent rotational back-driving. The mechanism includes a gear near the tip of the shaft, and a drive nut that constitutes the tip of the shaft. The gear and drive nut are positioned in a recess in a housing. The recess is sized to receive the wrench socket that mates with the drive nut. Also contained in the housing are four linkages that include pins that are spring-loaded into engagement with the gear to prevent rotation of the shaft. When the wrench socket is inserted in the recess, it pushes on the linkages in such a manner as to disengage the pins from the gear.

Warden, Harry K.↗

NASA NTRS2011

Diagonal-Axes Stage for Pointing an Optical Communications Transceiver

Traditional azimuth-elevation ("az-el") stages are used to point a variety of devices ranging from large optical telescopes to tank guns. Such a stage typically has an elevation stage having a horizontal axis mounted on an azimuth stage with a vertical axis. Both stages are often motorized. Optical communications transceivers often require two-axis motorized control, as when the communications link is between a ground station and an aircraft or satellite. In such applications, the traditional azimuth-elevation stage has two important drawbacks: a gimbal lock exclusion zone at zenith and susceptibility to pointing errors caused by backlash. Az-el stages in which the azimuth stage cannot rotate a full 360deg have the additional drawback of an azimuth exclusion zone. The diagonal-axes stage described here mitigates or eliminates all of these problems. Instead of one vertical axis and one horizontal axis, a diagonal-axes stage has two horizontal axes, both oriented at 45 to the trajectory of the target. For example, a ground station located on the equator tracking a satellite with an equatorial orbit would have one axis parallel to northeast and southwest, and the other axis parallel to northwest and southeast. The diagonal-axes stage is considerably less vulnerable to backlash. If it is correctly oriented, its axes rotate in only one direction during an overhead pass by a satellite. As a result, the effects of backlash may be inherently eliminated. If the gravity-induced torque on either axis changes during the pass, then backlash may become important during the part of the pass where the gravity torque, instead of opposing the motion of the stage, pushes the stage in the direction of motion. This can result in the loss of gear-to-gear contact in one or more stages of the gear reduction mechanism. In this case, a preload spring used to eliminate backlash need only be sufficiently strong to overcome the gravity torque, i.e. it need not overcome friction in the gear train. The diagonal-axes stage is not backlash-free for arbitrary target trajectories such as an aircraft might execute. If properly oriented for any particular satellite, however, it is backlash-free for all passes of that satellite, which will trace out parallel paths on the sky, and for all passes of any other satellite that are perpendicular to the first. It will also be backlash-free for some fraction of other satellite trajectories.

Regehr, Martin W.↗

NASA NTRS2009

CFD Technology for Rotorcraft Gearbox Windage Aerodynamics Simulation

A computational fluid dynamics (CFD) method is adapted, validated and applied to spinning gear systems with emphasis on predicting windage losses. Several spur gears and a disc are studied. The CFD simulations return good agreement with measured windage power loss. Turbulence modeling choices, the relative importance of viscous and pressure torques with gear speed and the physics of the complex 3-D unsteady flow field in the vicinity of the gear teeth are studied.

Handschuh, Robert↗

NASA NTRS2014

Towards Full Aircraft Airframe Noise Prediction: Lattice Boltzmann Simulations

Computational results for an 18%-scale, semi-span Gulfstream aircraft model are presented. Exa Corporation's lattice Boltzmann PowerFLOW(trademark) solver was used to perform time-dependent simulations of the flow field associated with this high-fidelity aircraft model. The simulations were obtained for free-air at a Mach number of 0.2 with the flap deflected at 39 deg (landing configuration). We focused on accurately predicting the prominent noise sources at the flap tips and main landing gear for the two baseline configurations, namely, landing flap setting without and with gear deployed. Capitalizing on the inherently transient nature of the lattice Boltzmann formulation, the complex time-dependent flow features associated with the flap were resolved very accurately and efficiently. To properly simulate the noise sources over a broad frequency range, the tailored grid was very dense near the flap inboard and outboard tips. Extensive comparison of the computed time-averaged and unsteady surface pressures with wind tunnel measurements showed excellent agreement for the global aerodynamic characteristics and the local flow field at the flap inboard and outboard tips and the main landing gear. In particular, the computed fluctuating surface pressure field for the flap agreed well with the measurements in both amplitude and frequency content, indicating that the prominent airframe noise sources at the tips were captured successfully. Gear-flap interaction effects were remarkably well predicted and were shown to affect only the inboard flap tip, altering the steady and unsteady pressure fields in that region. The simulated farfield noise spectra for both baseline configurations, obtained using a Ffowcs-Williams and Hawkings acoustic analogy approach, were shown to be in close agreement with measured values.

Khorrami, Mehdi R.↗

NASA NTRS2014

Towards Full Aircraft Airframe Noise Prediction: Detached Eddy Simulations

Results from a computational study on the aeroacoustic characteristics of an 18%-scale, semi-span Gulf-stream aircraft model are presented in this paper. NASA's FUN3D unstructured compressible Navier-Stokes solver was used to perform steady and unsteady simulations of the flow field associated with this high-fidelity aircraft model. Solutions were obtained for free-air at a Mach number of 0.2 with the flap deflected at 39 deg, with the main gear off and on (the two baseline configurations). Initially, the study focused on accurately predicting the prominent noise sources at both flap tips for the baseline configuration with deployed flap only. Building upon the experience gained from this initial effort, subsequent work involved the full landing configuration with both flap and main landing gear deployed. For the unsteady computations, we capitalized on the Detached Eddy Simulation capability of FUN3D to capture the complex time-dependent flow features associated with the flap and main gear. To resolve the noise sources over a broad frequency range, the tailored grid was very dense near the flap inboard and outboard tips and the region surrounding the gear. Extensive comparison of the computed steady and unsteady surface pressures with wind tunnel measurements showed good agreement for the global aerodynamic characteristics and the local flow field at the flap inboard tip. However, the computed pressure coefficients indicated that a zone of separated flow that forms in the vicinity of the outboard tip is larger in extent along the flap span and chord than measurements suggest. Computed farfield acoustic characteristics from a FW-H integral approach that used the simulated pressures on the model solid surface were in excellent agreement with corresponding measurements.

Khorrami, Mehdi R.↗

NASA NTRS2015

Space Shuttle Rudder Speed Brake Actuator-A Case Study Probabilistic Fatigue Life and Reliability Analysis

The U.S. Space Shuttle fleet was originally intended to have a life of 100 flights for each vehicle, lasting over a 10-year period, with minimal scheduled maintenance or inspection. The first space shuttle flight was that of the Space Shuttle Columbia (OV-102), launched April 12, 1981. The disaster that destroyed Columbia occurred on its 28th flight, February 1, 2003, nearly 22 years after its first launch. In order to minimize risk of losing another Space Shuttle, a probabilistic life and reliability analysis was conducted for the Space Shuttle rudder/speed brake actuators to determine the number of flights the actuators could sustain. A life and reliability assessment of the actuator gears was performed in two stages: a contact stress fatigue model and a gear tooth bending fatigue model. For the contact stress analysis, the Lundberg-Palmgren bearing life theory was expanded to include gear-surface pitting for the actuator as a system. The mission spectrum of the Space Shuttle rudder/speed brake actuator was combined into equivalent effective hinge moment loads including an actuator input preload for the contact stress fatigue and tooth bending fatigue models. Gear system reliabilities are reported for both models and their combination. Reliability of the actuator bearings was analyzed separately, based on data provided by the actuator manufacturer. As a result of the analysis, the reliability of one half of a single actuator was calculated to be 98.6 percent for 12 flights. Accordingly, each actuator was subsequently limited to 12 flights before removal from service in the Space Shuttle.

Rudder↗

NASA NTRS2016

Airframe Noise from a Hybrid Wing Body Aircraft Configuration

A high fidelity aeroacoustic test was conducted in the NASA Langley 14- by 22-Foot Subsonic Tunnel to establish a detailed database of component noise for a 5.8% scale HWB aircraft configuration. The model has a modular design, which includes a drooped and a stowed wing leading edge, deflectable elevons, twin verticals, and a landing gear system with geometrically scaled wheel-wells. The model is mounted inverted in the test section and noise measurements are acquired at different streamwise stations from an overhead microphone phased array and from overhead and sideline microphones. Noise source distribution maps and component noise spectra are presented for airframe configurations representing two different approach flight conditions. Array measurements performed along the aircraft flyover line show the main landing gear to be the dominant contributor to the total airframe noise, followed by the nose gear, the inboard side-edges of the LE droop, the wing tip/LE droop outboard side-edges, and the side-edges of deployed elevons. Velocity dependence and flyover directivity are presented for the main noise components. Decorrelation effects from turbulence scattering on spectral levels measured with the microphone phased array are discussed. Finally, noise directivity maps obtained from the overhead and sideline microphone measurements for the landing gear system are provided for a broad range of observer locations.

Hutcheson, Florence V.↗

DOE OSTI2022

Linear differential

Apparatuses and methods of operating a linear differential (100, 600) are described herein. The linear differential (100, 600) contains a slide portion (102) with parallel right-hand and left-hand threaded rods (112, 114). Threaded onto the right-hand and left-hand threaded rods (112, 114) and attached to the slide portion (102) are right-hand and left-hand gears (116, 118). Meshed between the right-hand and left-hand gears (116, 118) and also attached to the slide portion (102) is a driven gear (200). An end effector (104) is attached to the driven gear (200) and is configured to translate along a translation axis (110) and rotate around a rotation axis (120).

Crawford, Anthony↗

DOE OSTI2020

Oil miscible phosphonium-phosphate ionic liquid as novel antiwear and antipitting additive for low-viscosity rear axle lubricants

Here we explored the feasibility of using a phosphonium phosphate ionic liquid as a candidate anti-wear and anti-pitting additive for rear axle lubricant. This particular IL was first added to a VHVI8 base oil at 2–3% concentration and demonstrated effective surface protection for wear and micro-cracking under rolling-sliding contacts. The promising results directed to a step further to produce a series of IL-containing low-viscosity (about a half of SAE 75W-90) fully formulated gear oils. Selected IL-containing experimental oils showed superior mitigation of rolling contact fatigue to a commercial SAE 75W-90 gear oil in bench-scale rolling-sliding tests. Full-scale hub dynamometer tests were then conducted and demonstrated more than 3% power output and torque generation for an IL-containing low-viscosity gear oil benchmarked against commercial baselines.

36 MATERIALS SCIENCE↗

NASA NTRS2016

A Review of Noise and Vibration Control Technologies for Rotorcraft Transmissions

An expanded commercial use of rotorcraft can alleviate runway congestion and improve the accessibility of routine air travel. To date, commercial use has been hindered by excessive cabin noise. The primary noise source is structure-borne vibration originating from the main rotor gearbox. Despite significant advancements in gear design, the gear mesh tones generated often exceed 100 dB. This paper summarizes the findings of a literature survey of vibration control technologies that serve to attenuate this vibration near the source, before it spreads into the airframe and produces noise. The scope is thus limited to vibration control treatments and modifications of the gears, driveline, housing structures, and the strut connections to the airframe. The findings of the literature are summarized and persistent and unresolved issues are identified. An emphasis is placed on components and systems that have been demonstrated in flight vehicles. Then, a discussion is presented of emerging technologies that have the potential to make significant advancements over the state of the art.

cabin noise↗

NASA NTRS2016

A Review of Noise and Vibration Control Technologies for Rotorcraft Transmissions

cabin noise↗

NASA NTRS2018

Design Space Exploration of Pericyclic Transmission

The pericyclic transmission provides the opportunity to vastly impact transmission design in rotorcraft due to its ability to provide exceedingly high reduction ratios in a single stage that would normally require multiple gear stages to produce. This could lead to lighter transmissions with fewer components, increased range, reliability, efficiency, speed and decreased cost to maintain. While many previous studies have focused upon the gearing within the pericyclic transmission, this work focused on what influences pericyclic geometry, and how changes in geometry impacts bearing loads. Specifically the loading of bearings that must deliver power from the input shaft to the nutating and rotating gears of the system were of primary concern. A comprehensive look at dynamic loads generated by nutating bodies was performed. Methods to address these dynamic loads via application of counterbalances and deviation from conventional pericyclic transmission designs were utilized to negate the dynamic moment of concern. Finally a static solver was used to determine the bearing loads with updated component geometries and mass moment of inertias that included the required counterbalances.

Nutational Gearing↗

DOE OSTI2020

Case Study of ISO/TS 6336-22 Micropitting Method: 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 a method to calculate the risk of micropitting in gear sets. It 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. A sliding parameter is used to adjust the film thickness in the contact zone to the region of highest sliding, which is where micropitting has been observed. The permissible specific film thickness is best determined through experience or testing, but there is an option to estimate it based on the lubricant’s failure load stage in FZG testing. This paper is a case study of how the method behaves when applied to several gear sets and applications that have experienced micropitting in the field.

gears↗

DOE OSTI2020

Case Study of ISO/TS 6336-22 Micropitting Calculation

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 a method to calculate the risk of micropitting in gear sets. It 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. A sliding parameter is used to adjust the film thickness in the contact zone to the region of highest sliding, which is where micropitting has been observed. The permissible specific film thickness is best determined through experience or testing, but there is an option to estimate it based on the lubricant’s failure load stage in FZG testing. This paper is a case study of how the method behaves when applied to several gear sets and applications that have experienced micropitting in the field.

ENGINEERING,WIND ENERGY↗