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Direct drive electromechanical system is composed of brushless dc torque motor, offset-tooth magnetic sensor that derives position and rate information directly from output shaft, and rotary power transformer that transfers electrical power from external source to proper load. System has high servo loop stiffness and minimum power consumption.
In the Subsonics Rotary Wing (SRW) Project being funded for propulsion work at NASA Glenn Research Center, performance of the propulsion system is of high importance. In current rotorcraft drive systems many gearing components operate at high rotational speed (pitch line velocity > 24000 ft/ min). In our testing of high speed helical gear trains at NASA Glenn we have found that the work done on the air - oil mist within the gearbox can become a significant part of the power loss of the system. This loss mechanism is referred to as windage. The effort described in this presentation is to try to understand the variables that affect windage, develop a good experimental data base to validate, the analytical project being conducted at Penn State University by Dr. Rob Kunz under a NASA SRW NRA. The presentation provides an update to the status of these efforts.
Helicopters present many advantages over fixed-wing aircraft: they can take off from and land in tight spots, they can move in any direction with relative ease, and they can hover in one area for extended periods of time. But that maneuverability comes with costs. For example, one persistent issue in helicopter maintenance and operation is that their components are subject to high amounts of wear compared to fixed-wing aircraft. In particular, the rotor drive system that makes flight possible undergoes heavy vibration during routine performance, slowly degrading components in a way that can cause failures if left unmonitored. The level of attention required to ensure flight safety makes helicopters very expensive to maintain. As a part of NASA s Fundamental Aeronautics Program, the Subsonic Rotary Wing Project seeks to advance knowledge about and improve prediction capabilities for rotorcraft, with the aim of developing technology that will meet future civilian requirements like higher efficiency and lower noise flights. One of the program s goals is to improve technology to detect and assess the health of critical components in rotorcraft drive systems.
Innovation uses solid-state Hall-effect sensor to turn electrical circuit on or off. Though normally held off by a small bias magnet, Hall device turns on when strong actuating magnet comes into proximity. Drive magnet moves actuating magnet against restraint of detent magnet.
Two versions of bioreactor vessel provide steady supplies of oxygen and nutrients with little turbulence. Suspends cells in environment needed for sustenance and growth, while inflicting less damage from agitation and bubbling than do propeller-stirred reactors. Gentle environments in new reactors well suited to delicate mammalian cells. One reactor kept human kidney cells alive for as long as 11 days. Cells grow on carrier beads suspended in liquid culture medium that fills cylindrical housing. Rotating vanes - inside vessel but outside filter - gently circulates nutrient medium. Vessel stationary; magnetic clutch drives filter cylinder and vanes. Another reactor creates even less turbulence. Oxygen-permeable tubing wrapped around rod extending along central axis. Small external pump feeds oxygen to tubing through rotary coupling, and oxygen diffuses into liquid medium.
The results of the Independent Orbiter Assessment (IOA) of the Failure Modes and Effects Analysis (FMEA) and Critical Items List (CIL) are presented. The IOA approach features a top-down analysis of the hardware to determine failure modes, criticality, and potential critical items. To preserve independence, this analysis was accomplished without reliance upon the results contained within the NASA FMEA/CIL documentation. The independent analysis results for the Orbiter Rudder/Speedbrake Actuation Mechanism is documented. The function of the Rudder/Speedbrake (RSB) is to provide directional control and to provide a means of energy control during entry. The system consists of two panels on a vertical hinge mounted on the aft part of the vertical stabilizer. These two panels move together to form a rudder but split apart to make a speedbrake. The Rudder/Speedbrake Actuation Mechanism consists of the following elements: (1) Power Drive Unit (PDU) which is composed of hydraulic valve module and a hydraulic motor-powered gearbox which contains differentials and mixer gears to provide PDU torque output; (2) four geared rotary actuators which apply the PDU generated torque to the rudder/speedbrake panels; and (3) ten torque shafts which join the PDU to the rotary actuators and interconnect the four rotary actuators. Each level of hardware was evaluated and analyzed for possible failures and causes. Criticality was assigned based upon the severity of the effect for each failure mode. Critical RSB failures which result in potential loss of vehicle control were mainly due to loss of hydraulic fluid, fluid contaminators, and mechanical failures in gears and shafts.
A 17 axis anthropomorphic manipulator, providing coordinated control of two seven degree of freedom arms mounted on a three degree of freedom torso-waist assembly, is presented. This massively redundant telerobot, designated the Robotics Research K/B-2017 Dexterous Manipulator, employs a modular mechanism design with joint-mounted actuators based on brushless motors and harmonic drive gear reducers. Direct joint torque control at the servo level causes these high-output joint drives to behave like direct-drive actuators, facilitating the implementation of an effective impedance control scheme. The redundant, but conservative motion control system models the manipulator as a spring-loaded linkage with viscous damping and rotary inertia at each joint. This approach allows for real time, sensor-driven control of manipulator pose using a hierarchy of competing rules, or objective functions, to avoid unplanned collisions with objects in the workplace, to produce energy-efficient, graceful motion, to increase leverage, to control effective impedance at the tool or to favor overloaded joints.
With the increasing demands placed on extravehicular activity (EVA) for the International Space Station (ISS) assembly and maintenance, along with planned lunar and Martian missions, the need for increased human productivity and capability becomes ever more critical. This is most readily achieved by reduction in space suit weight and volume, and increased hardware reliability, durability, and operating lifetime. Considerable progress has been made with each successive generation of space suit design; from the Apollo A7L suit, to the current Shuttle Extravehicular Mobile Unit (EMU) suit, and the next generation Constellation Space Suit Element (CSSE). However, one area of space suit design which has continued to lag is the fluid pump used to drive the water cooling loop of the Primary Life Support System (PLSS). The two main types of fluid pumps typically used in space applications are rotodynamic pumps (pumping is achieved through a rotary vaned impeller) and displacement pumps (which includes rotary and diaphragm pumps). The rotating and moving parts found in the pumps and electric motor add significantly to the susceptibility to wear and friction, thermal mismatch, and complexity of the pumps. Electric motor-driven pumps capable of achieving high operational reliability are necessarily large, heavy, and energy inefficient. This report describes a development effort conducted for NASA by Lynntech, Inc., who recently demonstrated the feasibility of an electrochemically-driven fluid cooling pump. With no electric motor and minimal lightweight components, an electrochemically-driven pump is expected to be significantly smaller, lighter and achieve a longer life time than conventional rotodynamic and displacement pumps. By employing sulfonated polystyrene-based proton exchange membranes, rather than conventional Nafion membranes, a significant reduction in the actuator power consumption was demonstrated. It was also demonstrated that these membranes possess the necessary mechanical strength, durability, and temperature range for long life space operation. The preliminary design for a Phase II prototype pump compares very favorably to the fluid cooling pumps currently used in space suit portable life support systems (PLSS). Characteristics of the electrochemically-driven pump are described and the benefits of the technology as a replacement for electric motor pumps in mechanically pumped single-phase fluid loops (MPFLs) is discussed.
A hydraulic valve controller that uses an existing pressure differential as some or all of the power source for valve operation. In a high pressure environment, such as downhole in an oil or gas well, the pressure differential between the inside of a pipe and the outside of the pipe may be adequately large to drive a linear slide valve. The valve is operated hydraulically by a piston in a bore. When a higher pressure is applied to one end of the bore and a lower pressure to the other end, the piston moves in response to the pressure differential and drives a valve attached to it. If the pressure differential is too small to drive the piston at a sufficiently high speed, a pump is provided to generate a larger pressure differential to be applied. The apparatus is conveniently constructed using multiport valves, which can be rotary valves.
Transmission consisting of corrugated metal tube that can bend along its axis can transmit torques in range of 100 to 1000 pound-inches at corner angles as great as 180 deg. Possible uses include submerged mechanisms and food processing machinery where sealed drive line without contaminating lubricants is required.
Depth profiles of Na-22 and Al-26 in the upper portions of five lunar cores are analyzed. From the analyses, it is concluded that the natural gardening processes on the lunar surface result in mixing of the regolith to a depth of 2-3 cm over a time period which is short compared with the half-life of Al-26 (0.73 m.y.). It is also concluded that the rotary drill processes which were used to obtain the deep drill samples generally resulted in loss and/or mixing of the upper portions of the cores. In contrast, the near-surface regions of the drive tube cores appear to have a well-preserved stratigraphy. Analysis of Mn-53 in samples of six lunar rocks helps substantiate the accuracy of age date estimates by other means, and provides definite information that the total lunar surface exposure of two of these rocks has occurred during a single surface event which continued to their collection.
Gas turbine engines for military/commercial fixed-wing and rotary wing aircraft use thermal barrier coatings in the high-temperature sections of the engine for improved efficiency and power. The desire to further make improvements in gas turbine engine efficiency and high power-density is driving the research and development of thermal barrier coatings and the effort of improving their tolerance to fine foreign particulates that may be contained in the intake air. Both commercial and military aircraft engines often are required to operate over sandy regions such as in the Middle-East nations, as well as over volcanic zones. For rotorcraft gas turbine engines, the sand ingestion is adverse during take-off, hovering near ground, and landing conditions. Although, most of the rotorcraft gas turbine engines are fitted with inlet particle separators, they are not 100 percent efficient in filtering fine sand particles of size 75 microns or below. The presence of these fine solid particles in the working fluid medium has an adverse effect on the durability of turbine blade thermal barrier coatings and overall performance of the engine. Typical turbine blade damages include blade coating wear, sand glazing, Calcia-Magnesia-Alumina-Silicate (CMAS) attack, oxidation, plugged cooling holes, all of which can cause rapid performance deterioration including loss of aircraft. The objective of this research is to understand the fine particle interactions with typical ceramic coatings of turbine blades at the microstructure level. A finite-element based microstructure modeling and analysis has been performed to investigate particle-surface interactions, and restitution characteristics. Experimentally, a set of tailored thermal barrier coatings and surface treatments were down-selected through hot burner rig tests and then applied to first stage nozzle vanes of the Gas Generator Turbine of a typical rotorcraft gas turbine engine. Laser Doppler velocity measurements were performed during hot burner rig testing to determine sand particle incoming velocities and their rebound characteristics upon impact on coated material targets. Further, engine sand ingestion tests were carried out to test the CMAS tolerance of the coated nozzle vanes. The findings from this on-going collaborative research to develop the next-gen sand tolerant coatings for turbine blades are presented in this paper.
A hyperspectral imaging system of high spectral and spatial resolution that incorporates several innovative features has been developed to incorporate a focal plane scanner (U.S. Patent 6,166,373). This feature enables the system to be used for both airborne/spaceborne and laboratory hyperspectral imaging with or without relative movement of the imaging system, and it can be used to scan a target of any size as long as the target can be imaged at the focal plane; for example, automated inspection of food items and identification of single-celled organisms. The spectral resolution of this system is greater than that of prior terrestrial multispectral imaging systems. Moreover, unlike prior high-spectral resolution airborne and spaceborne hyperspectral imaging systems, this system does not rely on relative movement of the target and the imaging system to sweep an imaging line across a scene. This compact system (see figure) consists of a front objective mounted at a translation stage with a motorized actuator, and a line-slit imaging spectrograph mounted within a rotary assembly with a rear adaptor to a charged-coupled-device (CCD) camera. Push-broom scanning is carried out by the motorized actuator which can be controlled either manually by an operator or automatically by a computer to drive the line-slit across an image at a focal plane of the front objective. To reduce the cost, the system has been designed to integrate as many as possible off-the-shelf components including the CCD camera and spectrograph. The system has achieved high spectral and spatial resolutions by using a high-quality CCD camera, spectrograph, and front objective lens. Fixtures for attachment of the system to a microscope (U.S. Patent 6,495,818 B1) make it possible to acquire multispectral images of single cells and other microscopic objects.
Developing technologies that would enable future NASA exploration missions to penetrate deeper into the subsurface of planetary bodies for sample collection is of great importance. Performing these tasks while using minimal mass/volume systems and with low energy consumption is another set of requirements imposed on such technologies. A deep drill, called Auto-Gopher II, is currently being developed as a joint effort between JPL’s NDEAA laboratory and Honeybee Robotics Corp. The Auto-Gopher II is a wireline rotary-hammer drill that combines formation breaking by hammering using an ultrasonic actuator and cuttings removal by rotating a fluted auger bit. The hammering mechanism is based on the Ultrasonic/Sonic Drill/Corer (USDC) mechanism that has been developed as an adaptable tool for many drilling and coring applications. The USDC uses an intermediate free-flying mass to transform high frequency vibrations of a piezoelectric transducer horn tip into sonic hammering of the drill bit. The USDC concept was used in a previous task to develop an Ultrasonic/Sonic Ice Gopher and then integrated into a rotary hammer device to develop the Auto-Gopher-I. The lessons learned from these developments are being integrated into the development of the Auto-Gopher-II, an autonomous deep wireline drill with integrated cuttings and sample management and drive electronics. Subsystems of the wireline drill are being developed in parallel at JPL and Honeybee Robotics Ltd. This paper presents the development efforts of the piezoelectric actuator, cuttings removal and retention flutes and drive electronics.
An important challenge of exploring the solar system is the ability to penetrate at great depths the subsurface of planetary bodies for sample collection. The requirements of the drilling system are minimal mass, volume and energy consumption. To address this challenge, a deep drill, called the Auto-Gopher II, is currently being developed as a joint effort between JPL’s NDEAA laboratory and Honeybee Robotics Corp. The Auto-Gopher II is a wireline rotaryhammer drill that combines breaking formations by hammering using a piezoelectric actuator and removing the cuttings by rotating a fluted bit. The hammering is produced by the Ultrasonic/Sonic Drill/Corer (USDC) mechanism that has been developed by the JPL team as an adaptable tool for many drilling and coring applications. The USDC uses an intermediate free-flying mass to convert high frequency vibrations of a piezoelectric transducer horn tip into sonic hammering of the drill bit. The USDC concept was used in a previous task to develop an Ultrasonic/Sonic Ice Gopher and then integrated into a rotary hammer device to develop the Auto-Gopher-I. The lessons learned from these developments are being integrated into the development of the Auto-Gopher-II, an autonomous deep wireline drill with integrated cuttings and sample management and drive electronics. In this paper the latest development will be reviewed including the piezoelectric actuator, cuttings removal and retention flutes and drive electronics.
The goal of this project is to design, fabricate, and test a hermetically sealed 50 kilowatt (kW) multistage magnetically geared generator (MGG). This project will benefit MHK device developers by providing an MHK PTO that overcomes the reliability concerns of the mechanical gears and the sizing constraints of the direct-drive generators. Experimental Testing Data for a 6.66:1 gear ratio dual-stack magnetic gear with a measured peak torque of 1391 N-m
This is an overview presentation of research being performed in the Advanced Materials Task within the NASA Subsonic Rotary Wing Project. This research is focused on technology areas that address both national goals and project goals for advanced rotorcraft. Specific technology areas discussed are: (1) high temperature materials for advanced turbines in turboshaft engines; (2) polymer matrix composites for lightweight drive system components; (3) lightweight structure approaches for noise and vibration control; and (4) an advanced metal alloy for lighter weight bearings and more reliable mechanical components. An overview of the technology in each area is discussed, and recent accomplishments are presented.
An apparatus that passes vibrational energy across a mechanical structure lacking a perforation. The disclosed apparatus and method provide the ability to transfer work (rotary or linear motion) across pressure or thermal barriers or in a sterile environment without generating contaminants; the presence of reflectors in the solid barrier to enhance the efficiency of the energy/power transmission, and the ability to produce a bi-directional driving mechanism using a plurality of different mode resonances, such as a fundamental frequency resonance and a higher frequency resonance. In some instances, a plane within the mechanical structure lacking a perforation is a nodal plane of the vibrational energy field.