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A critical missile component required operational verification while subjected to combined environments within and beyond flight parameters. The testing schedule necessitated the design and fabrication of a test facility in order to provide the specified temperatures combined with humidity, altitude and vibration.
The achievement of the combustion research under microgravity depends substantially on the availability of diagnostic systems. The non-intrusive diagnostic systems are potentially applicable for providing the accurate, realistic and detailed information on momentum, mass and energy transport, complex gas phase chemistry, and phase change in the combustion field under microgravity. The non-intrusive nature of optical instruments is essential to the measurement of combustion process under microgravity which is very nervous to any perturbation. However, the implementation of the non-intrusive combustion diagnostic systems under microgravity is accompanied by several constraints. Usually, a very limited space is only available for constructing a highly sophisticated system which is so sensitive that it is easily affected by the magnitude of the gravitational force, vibration and heterogeneous field of temperature and density of the environments. The system should be properly adjusted prior to the experiment. Generally, it is quite difficult to tune the instruments during measurements. The programmed sequence of operation should also be provided. Extensive effort has been toward the development of non-intrusive diagnostic systems available for the combustion experiments under microgravity. This paper aims to describe the current art and the future strategy on the non-intrusive diagnostic systems potentially applicable to the combustion experiments under microgravity in Japan.
This paper discusses the recommissioning of the Annular Suspension and Pointing System (ASPS), originally developed in the mid 1970's for pointing and vibration isolation of space experiments. The hardware was developed for NASA Langley Research Center by Sperry Flight Systems (now Honeywell Satellite Systems), was delivered to NASA in 1983. Recently, the hardware was loaned to Old Dominion University (ODU). The ASPS includes coarse gimbal assemblies and a Vernier Pointing Assembly (VPA) that utilize magnetic suspension to provide noncontacting vibration isolation and vernier pointing of the payload. The VPA is the main focus of this research. At ODU, the system has been modified such that it can now be operated in a l-g environment without a gravity offload. Suspension of the annular iron rotor in five degrees-of-freedom has been achieved with the use of modern switching power amplifiers and a digital controller implemented on a 486-class PC.
The Crew Exploration Vehicle (CEV) that will travel to the moon and Mars, and all future Exploration vehicles and habitats will be highly computerized, necessitating an accurate method of interaction with the computers. The design of a cursor control device will have to take into consideration g-forces, vibration, gloved operations, and the specific types of tasks to be performed. The study described here is being undertaken to begin identifying characteristics of cursor control devices that will work well for the unique Exploration mission environments. The objective of the study is not to identify a particular device, but to begin identifying design characteristics that are usable and desirable for space missions. Most cursor control devices have strengths and weaknesses; they are more appropriate for some tasks and less suitable for others. The purpose of this study is to collect some initial usability data on a large number of commercially available and proprietary cursor control devices. A software test battery was developed for this purpose. Once data has been collected using these low-level, basic point/click/drag tasks, higher fidelity, scenario-driven evaluations will be conducted with a reduced set of devices. The standard tasks used for testing cursor control devices are based on a model of human movement known as Fitts law. Fitts law predicts that the time to acquire a target is logarithmically related to the distance over the target size. To gather data for analysis with this law, fundamental, low-level tasks are used such as dragging or pointing at various targets of different sizes from various distances. The first four core tasks for the study were based on the ISO 9241-9:(2000) document from the International Organization for Standardization that contains the requirements for non-keyboard input devices. These include two pointing tasks, one dragging and one tracking task. The fifth task from ISO 9241-9, the circular tracking task was not used because it is a movement that is not applicable to most of the applications used on aviation displays. Additionally, we opted to add a multi-size and multi-distance pointing task, and two ecologically more valid tasks which included text selection, and interaction with drop down menus, sliders, and checkboxes. The Visual Basic test battery tracks the task and trial numbers, measures the pointing, tracking or dragging time, as well as the number and types of errors. The testing session includes a practice set for each input device, then the randomized 7 tasks, and finally a questionnaire about the device. This is repeated for all the devices tested within a session. The experiment is a within-subjects design, with participants returning for multiple sessions to test additional devices. The input devices will be compared based on objective performance data from the tasks, as well as subjective feedback and ratings on the questionnaire.
A Two-Axis Thruster Gimbal was developed for a two degree-of-freedom tip-tilt gimbal application. This light weight gimbal mechanism is equipped with flexible xenon propellant lines and features numerous thermal control features for all its critical components. Unique thermal profiles and operating environments have been the key design drivers for this mechanism which is fully tolerant of extreme space environmental conditions. Providing thermal controls that are compatible with flexible components and are also capable of surviving launch vibration within this gimbal mechanism has proven to be especially demanding, requiring creativity and significant development effort. Some of these features, design drivers, and lessons learned will be examined herein.
The Space Launch System (SLS) Core Stage Thrust Vector Control (TVC) system is comprised of eight mechanical feedback Shuttle heritage Type III TVC actuators that vector the four Shuttle heritage RS-25 engines about a Shuttle heritage gimbal block/bearing. The MSFC Controls community has long regarded gimbal friction to be a negligible effect on the overall control of gimbaled RS-25 engines. This is corroborated by Space Shuttle test and flight data that does not appear to show degraded effects, nor limit cycling at the end of the shuttle flight. For this reason, friction was not expected to be a driving factor of performance and control of the reused RS-25 engines aboard the SLS. However, after test data showed a large shift in frequency behavior and a highly damped step-response in the time series, there was further investigation into what could have caused this behavior. Heritage friction models used in previous gimbal and ball bearings were evaluated such as Coulomb, Dahl and LuGre, but the single degree of freedom friction models alone were not enough to explain the behavior and shifts seen in the test data. This paper presents the additional findings and modeling efforts regarding friction on the RS-25 engines. Using the Two Actuator Operational Simulation (TAOS), the difference from modeling separate friction degrees of freedom to coupled degrees of freedom was investigated to deduce the effects of one axis’s movement on the other. Next, due to the vibration environment, a modified LuGre model has been proposed that adds an additional term to decrease the friction coefficient at low engine velocity amplitudes. Lastly, the addition of the stiffness in each half of the gimbal bearing has increased modeling fidelity by also adding the effect on the gimbal bearing bending in compliance to both the friction torque on the surface of the gimbal bearing and the actuator force that is forcing the engine in a specified direction. Through these effects, the time and frequency domain behavior seen in test can be characterized accurately.
The Space Launch System (SLS) Core Stage Thrust Vector Control (TVC) system is comprised of eight mechanical feedback Shuttle heritage Type III TVC actuators that vector the four Shuttle heritage RS-25 engines about a Shuttle heritage gimbal block/bearing. The MSFC Controls community has long regarded gimbal friction to be a negligible effect on the overall control of gimbaled RS-25 engines. This is corroborated by Space Shuttle test and flight data that does not appear to show degraded effects, nor limit cycling at the end of the shuttle flight. For this reason, friction was not expected to be a driving factor of performance and control of the reused RS-25 engines aboard the SLS. However, after test data showed a large shift in frequency behavior and a highly damped step-response in the time series, there was further investigation into what could have caused this behavior. Heritage friction models used in previous gimbal and ball bearings were evaluated such as Coulomb, Dahl and LuGre, but the single degree of freedom friction models alone were not enough to explain the behavior and shifts seen in the test data. This paper presents the additional findings and modeling efforts regarding friction on the RS-25 engines. Using the Two Actuator Operational Simulation (TAOS), the difference from modeling separate friction degrees of freedom to coupled degrees of freedom was investigated to deduce the effects of one axis’s movement on the other. Next, due to the vibration environment, a modified LuGre model has been proposed that adds an additional term to decrease the friction coefficient at low engine velocity amplitudes. Lastly, the addition of the stiffness in each half of the gimbal bearing has increased modeling fidelity by also adding the effect on the gimbal bearing bending in compliance to both the friction torque on the surface of the gimbal bearing and the actuator force that is forcing the engine in a specified direction. Through these effects, the time and frequency domain behavior seen in test can be characterized accurately.
Control Moment Gyroscopes (CMGs) are used for non-propulsive attitude control of satellites and space stations, including the International Space Station (ISS). CMGs could be essential for future long duration space missions due to the fact that they help to save propellant. CMGs were successfully tested on the ground for many years, and have been successfully used on satellites. However, operations have shown that the CMG service life on the ISS is significantly shorter than predicted. Since the dynamic environment of the ISS differs greatly from the nominal environment of satellites, it was important to analyze how operations specific to the station (dockings and undockings, huge solar array motion, crew exercising, robotic operations, etc) can affect the CMG performance. This task became even more important since the first CMG failure onboard the ISS. The CMG failure resulted in the limitation of the attitude control capabilities, more propellant consumption, and additional operational issues. Therefore, the goal of this work was to find out how the vibrations of a space vehicle structure, caused by a variety of onboard operations, can affect the CMG dynamics and performance. The equations of CMG motion were derived and analyzed for the case when the gyro foundation can vibrate in any direction. The analysis was performed for unbalanced CMG gimbals to match the CMG configuration on ISS. The analysis showed that vehicle structure vibrations can amplify and significantly change the CMG motion if the gyro gimbals are unbalanced in flight. The resonance frequencies were found. It was shown that the resonance effect depends on the magnitude of gimbal imbalance, on the direction of a structure vibration, and on gimbal bearing friction. Computer modeling results of CMG dynamics affected by the external vibration are presented. The results can explain some of the CMG vibration telemetry observed on ISS. This work shows that balancing the CMG gimbals decreases the effect of vehicle structure vibration on CMGs. Additionally, the effect of external vibrations may also be decreased by increasing the gimbal bearing friction. With the suggested modifications there may be no need to lower the gimbal rates below the nominal design requirements as it is currently done on ISS. The conclusions of this work
It has been proposed to incorporate piezoelectric vibrational actuators into the structural supports of solar photovoltaic panels, for the purpose of occasionally inducing vibrations in the panels in order to loosen accumulated dust. Provided that the panels were tilted, the loosened dust would slide off under its own weight. Originally aimed at preventing obscuration of photovoltaic cells by dust accumulating in the Martian environment, the proposal may also offer an option for the design of solar photovoltaic panels for unattended operation at remote locations on Earth. The figure depicts a typical lightweight solar photovoltaic panel comprising a backside grid of structural spars that support a thin face sheet that, in turn, supports an array of photovoltaic cells on the front side. The backside structure includes node points where several spars intersect. According to the proposal, piezoelectric buzzers would be attached to the node points. The process of designing the panel would be an iterative one that would include computational simulation of the vibrations by use of finite- element analysis to guide the selection of the vibrational frequency of the actuators and the cross sections of the spars to maximize the agitation of dust.
Power generation schemes that could be used downhole in an oil well to produce about 1 Watt average power with long-life (decades) are actively being developed. A variety of proposed energy harvesting schemes could be used to extract energy from this environment but each of these has their own limitations that limit their practical use. Since vibrating piezoelectric structures are solid state and can be driven below their fatigue limit, harvesters based on these structures are capable of operating for very long lifetimes (decades); thereby, possibly overcoming a principle limitation of existing technology based on rotating turbo-machinery. An initial survey identified that spline nozzle configurations can be used to excite a vibrating piezoelectric structure in such a way as to convert the abundant flow energy into useful amounts of electrical power. This paper presents current flow energy harvesting designs and experimental results of specific spline nozzle/ bimorph design configurations which have generated suitable power per nozzle at or above well production analogous flow rates. Theoretical models for non-dimensional analysis and constitutive electromechanical model are also presented in this paper to optimize the flow harvesting system.
When designing vehicle vibration monitoring systems for aerospace devices, it is common to use well-established models of vibration features to determine whether failures or defects exist. Most of the algorithms used for failure detection rely on these models to detect significant changes in a flight environment. In actual practice, however, most vehicle vibration monitoring systems are corrupted by high rates of false alarms and missed detections. This crucial roadblock makes their implementation in real vehicles (e.g., helicopter transmissions and aircraft engines) difficult, making their operation costly and unreliable. Research conducted at the NASA Ames Research Center has determined that a major reason for the high rates of false alarms and missed detections is the numerous sources of statistical variations that are not taken into account in the modeling assumptions. In this paper, we address one such source of variations, namely, those caused during the design and manufacturing of rotating machinery components that make up aerospace systems. We present a novel way of modeling the vibration response by including design variations via probabilistic methods. Using such models, we develop a methodology to account for design and manufacturing variations, and explore the changes in the vibration response to determine its stochastic nature. We explore the potential of the methodology using a nonlinear cam-follower model, where the spring stiffness values are assumed to follow a normal distribution. The results demonstrate initial feasibility of the method, showing great promise in developing a general methodology for designing more accurate aerospace vehicle monitoring systems.
The results of a space flight qualification test program for a low-voltage, quartz tungsten-halogen light are presented. The test program was designed to qualify a halogen light for use in the Pool Boiling Experiment, a Get Away Special (GAS) payload that will be flown in the space shuttle payload bay. Vibration and thermal vacuum tests were performed. The test results indicated that the halogen light will survive the launch and ascent loads, and that the convection-free environment associated with the GAS payload system will not detrimentally affect the operation of the halogen light.
The need for measurements of the velocity flow field about spinner propeller nacelle configurations at Mach numbers to 0.8 was met by a specially developed laser velocimeter system. This system, which uses an argon ion laser and 4 beam 2 color optics, was required to operate in the hostile environment associated with the operation of a large transonic wind tunnel. To overcome the conditions present in locating the sensitive optics in close proximity to the wind tunnel, an isolation system was developed. The system protects the velocimeter from the high vibrations, elevated temperatures, destructive acoustic pressures and low atmospheric pressures attendant with the operation of the wind tunnel. The system was utilized to map the flow field in front of, behind and in between the rotating blades of an advanced swept blade propeller model at a Mach number of 0.8. The data collected by the system will be used to correlate and verify computer analyses of propeller nacelle flow fields and propeller performance.
The main thrust of these studies has resulted in an active inertial feedforward/feedback isolation system. This prototype magnetic suspension system has been demonstrated in a laboratory setting in six degrees-of-freedom and has been preliminarily characterized in its isolation performance with favorable results. This isolation system consists of a closed loop digital control system referencing a platform around six relative and six inertial sensors. These sensors control the isolated mass through nine attractive electromagnetic actuators with a system capability of +/- three-tenths of an inch travel in three dimensions. The development of a prototype system from design to fabrication leads directly into the demonstration phase of the project which will attempt a low gravity environmental demonstration of engineering hardware for the isolation of a scientific payload. The demonstration phase of the project will use an aircraft low gravity maneuver to establish a research testbed for the study of isolation hardware and control strategies in an off-loaded environment. In developing this demonstration capability the Lewis Learjet aircraft has been characterized through its parabolic flight maneuvers and a trunnioned experimental volume has been designed for the test of both active and passive isolation packages. This vibration isolation testbed is operational and has two data acquisition systems available for both autonomous and interactive operation, with a combined input capability of 32 channels.
As part of a JPL-funded effort to develop lightweight telescope technology suitable for far-infrared astronomy, COI designed and fabricated a spherical, f/1, 2-meter aperture prototype primary mirror using solely graphite/resin composite materials. To assess the performance of this technology, optical metrology of the mirror surface was performed from ambient to an intended operational temperature for IR-telescopes of 70K. Testing was performed horizontally in a cryogenic vacuum chamber at Arnold AFB, Tennessee. The test design had to accommodate requirements for rapid and uniform cooling across the optic, passivation of the ambient vibrational environment, and de-coupling of the mirror from the thermal strain of the test stand. An IR-wavelength phase shifting interferometer (PSI) was the primary instrument used to measure the mirror surface. From an initial surface figure of 2.1 microns RMS at ambient, a modest 3.9 microns of additional RMS surface error was induced at 70K. The thermally induced error was dominated by low-order deformations, of the type that could easily be corrected with secondary or tertiary optics. In addition to exceptional thermal stability, the mirror exhibited no measurable hysteresis between both ambient and cryo measurements.
Switched reluctance motors typically consist of pairs of poles protruding outward from a central rotor, surrounded by pairs of coils protruding inward from a stator. The pairs of coils, positioned a short distance from opposing sides of the rotor, are connected in series. A current runs through the coils, generating a magnetic flux between the coils. This attracts the protruding poles on the rotor, and just as the poles on the rotor approach the coils, the current to the coils is inverted, repelling the rotor s poles as they pass the coils. This current switching, back and forth, provides a continuous rotational torque to the rotor. reliability, durability, low cost, and operation in adverse environments such as high temperatures, extreme temperature variations, and high rotational speeds. However, because rotors are often manufactured with minute flaws due to imperfections in the machining process, traditional switched reluctance motors often suffer from substantial amounts of vibration. In addition, the current in the coils imparts a strong radial magnetic force on the rotor; the continuous alternating of the direction of this force also causes vibration. As a result, switched reluctance motors require bearings that, run at high speeds, can require lubrication apparatus and are subject to problems with heat and wear. My mentor s recent invention, the "Bearingless" Switched Reluctance Motor, actually uses magnetic bearings instead of traditional physical bearings. Sensors are used to continuously determine the position of the rotor. A computer reads the position sensor input, performs calculations, and outputs a current to a set of extra coils (in addition to the coils rotating the rotor). This current provides a magnetic force that counters and damps the vibration. The sense-calculate-update loop iterates more than thirty thousand times per second. For now, our goal is to have the rotor rotate at about 6000 rprn, and at that speed, the magnetic bearing is adjusting the rotor s position more than 300 times per rotation. and vibration-suppression capacity for the switched reluctance motor. Traditional switched reluctance motors possess many positive traits, including It is hoped that this new invention will increase load-carrying capacity, stiffness, and vibration-suppression capacity for the switched reluctance motor.
The NEXT propulsion system is an advanced ion propulsion system presently under development that is oriented towards robotic exploration of the solar system using solar electric power. The subsystem includes an ion engine, power processing unit, feed system components, and thruster gimbal. The Prototype Model engine PM1 was subjected to qualification-level environmental testing in 2006 to demonstrate compatibility with environments representative of anticipated mission requirements. Although the testing was largely successful, several issues were identified including the fragmentation of potting cement on the discharge and neutralizer cathode heater terminations during vibration which led to abbreviated thermal testing, and generation of particulate contamination from manufacturing processes and engine materials. The engine was reworked to address most of these findings, renamed PM1R, and the environmental test sequence was repeated. Thruster functional testing was performed before and after the vibration and thermal-vacuum tests. Random vibration testing, conducted with the thruster mated to the breadboard gimbal, was executed at 10.0 Grms for 2 min in each of three axes. Thermal-vacuum testing included three thermal cycles from 120 to 215 C with hot engine re-starts. Thruster performance was nominal throughout the test program, with minor variations in a few engine operating parameters likely caused by facility effects. There were no significant changes in engine performance as characterized by engine operating parameters, ion optics performance measurements, and beam current density measurements, indicating no significant changes to the hardware as a result of the environmental testing. The NEXT PM1R engine and the breadboard gimbal were found to be well-designed against environmental requirements based on the results reported herein. The redesigned cathode heater terminations successfully survived the vibration environments. Based on the results of this test program and confidence in the engineering solutions available for the remaining findings of the first test program, specifically the particulate contamination, the hardware environmental qualification program can proceed with confidence
A communication link for the transfer of data between the crew cabin and payload bay of the Shuttle is proposed. The configuration of the system, which is to transmit data optically through the Shuttle cabin window, is described. The effects of temperature cycling and cosmic radiation on optical fibers, the cable, connectors, and lenses, and of vibrations during a mission on the alignment of collimating lenses at the window are investigated. Consideration is given to determining the optimum design for the optical fiber and the optimum system operation wavelength for transmission through the aft Orbiter window and the payload environment.