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Results from an intensive FBW advanced development effort indicate significant improvements in overall flight control system performance, reliability, safety and maintainability. Additionally, the strong and credible FBW technology base developed as a result paved the way for further exploitation through the application of advanced concepts such as control configured vehicles and multi-mode controls.
Development of reliable power-by-wire actuation systems for both aeronautical and space applications has been sought recently to eliminate hydraulic systems from aircraft and spacecraft and thus improve safety, efficiency, reliability, and maintainability. The Electrically Powered Actuation Design (EPAD) program was a joint effort between the Air Force, Navy, and NASA to develop and fly a series of actuators validating power-by-wire actuation technology on a primary flight control surface of a tactical aircraft. To achieve this goal, each of the EPAD actuators was installed in place of the standard hydraulic actuator on the left aileron of the NASA F/A-18B Systems Research Aircraft (SRA) and flown throughout the SRA flight envelope. Numerous parameters were recorded, and overall actuator performance was compared with the performance of the standard hydraulic actuator on the opposite wing. This paper discusses the integration and testing of the EPAD electromechanical actuator (EMA) on the SRA. The architecture of the EMA system is discussed, as well as its integration with the F/A-18 Flight Control System. The flight test program is described, and actuator performance is shown to be very close to that of the standard hydraulic actuator it replaced. Lessons learned during this program are presented and discussed, as well as suggestions for future research.
Development of reliable power-by-wire actuation systems for both aeronautical and space applications has been sought recently to eliminate hydraulic systems from aircraft and spacecraft and thus improve safety, efficiency, reliability, and maintainability. The Electrically Powered Actuation Design (EPAD) program was a joint effort between the Air Force, Navy, and NASA to develop and fly a series of actuators validating power-by-wire actuation technology on a primary flight control surface of a tactical aircraft. To achieve this goal, each of the EPAD actuators was installed in place of the standard hydraulic actuator on the left aileron of the NASA F/A-18B Systems Research Aircraft (SRA) and flown throughout the SRA flight envelope. Numerous parameters were recorded, and overall actuator performance was compared with the performance of the standard hydraulic actuator on the opposite wing. This paper discusses the integration and testing of the EPAD electromechanical actuator (EMA) on the SRA. The architecture of the EMA system is discussed, as well as its integration with the F/A-18 Flight Control System. The flight test program is described, and actuator performance is shown to be very close to that of the standard hydraulic actuator it replaced. Lessons learned during this program are presented and discussed, as well as suggestions for future research.
Design, equipment specifications, and operating characteristics for cross wire resistance microwelding system
Systems to provide improved tactile feedback to aircraft pilots are being developed to help the pilots maintain harmony between their control actions and the positions of aircraft control surfaces, thereby helping to prevent loss of control. A system of this type, denoted a loss-of-control-inhibitor system (LOCIS) can be implemented as a relatively simple addition to almost any pre-existing flight-control system. The LOCIS concept offers at least a partial solution to the problem of (1) keeping a pilot aware of the state of the control system and the aircraft and (2) maintaining sufficient control under conditions that, as described below, have been known to lead to loss of control. Current commercial aircraft exhibit uneven responses of primary flight-control surfaces to aggressive pilot control commands, leading to deterioration of pilots ability to control their aircraft. In severe cases, this phenomenon can result in loss of control and consequent loss of aircraft. For an older aircraft equipped with a purely mechanical control system, the loss of harmony between a pilot s command action and the control- surface response can be attributed to compliance in the control system (caused, for example, by stretching of control cables, flexing of push rods, or servo-valve distortion). In a newer aircraft equipped with a fly-by-wire control system, the major contributions to loss of harmony between the pilot and the control surfaces are delays attributable to computer cycle time, control shaping, filtering, aliasing, servo-valve distortion, and actuator rate limiting. In addition, a fly-by-wire control system provides no tactile feedback that would enable the pilot to sense such features of the control state as surface flutter, surface jam, position limiting, actuator rate limiting, and control limiting imposed by the aircraft operational envelope. Hence, for example, when a pilot is involved in aggressive closed-loop maneuvering, as when encountering a wake-vortex upset on final landing approach, the control-surface delay can lead to loss of control. Aggressive piloting can be triggered and exacerbated by control-system anomalies, which the pilot cannot diagnose because of the lack of symptoms caused by the absence of feedback through the controls. The purpose served by a LOCIS is to counteract these adverse effects by providing real-time feedback that notifies the pilot that the aircraft is tending to lag the pilot s commands. A LOCIS (see figure) includes cockpit control input-position sensors, control-surface output-position sensors, variable dampers (for example, shock absorbers containing magneto-rheological fluids such that the damping forces can be varied within times of the order of milliseconds by varying applied magnetic fields) attached to the cockpit control levers, electromagnet coils to apply the magnetic fields, and feedback control circuits to drive the electromagnet coils. The feedback control gains are chosen so that the current applied to each electromagnet coil results in a damping force that increases in a suitable nonlinear manner (e.g., exponentially) with the difference between the actual and commanded positions of the affected control surface. The increasing damping force both alerts the pilot to the onset of a potentially dangerous situation and resists the pilot s effort to command a control surface to change position at an excessive rate
An open rotor was considered as a process for converting an unsteady velocity inflow into sound radiation. With the aid of crude assumptions, aero-acoustic transfer functions were defined theoretically for both discrete frequency and broad band noise. A study of the validity of these transfer functions yielded results which show good agreement at discrete frequencies though slightly less good for broad band noise. Agreement in both cases holds over three or more decades of the relevant parameters. A rotating hot wire anemometry system consisting of a single hot wire probe mounted in the nose cone of the rotor was used to quantify fluctuations in the airflow onto a single rotor blade for the transfer function results. Further theoretical analysis revealed that the sound field can be expressed in terms of blade-to-blade correlations in the airflow, and results from two probes rotating simultaneously were modelled mathematically and inserted in the theory. Preliminary results snow encouraging agreement with experimental data.
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We studied the functionality of the IFA300 Hot Wire Anemometry system and its feasibility for the calibration of Direct Estimator Velocimetry (DEV) using Laser Induced Florescence (LIF). The experimental setup consisted of a single-wire hot wire probe measuring one component of velocity, the anemometry computational hardware and software, an HP oscilloscope, and a table fan to produce a simple flow with fluctuations. Measurements were taken at several points in the stream wise and transverse directions in the flow and various parameters recorded such as mean velocities temperature, turbulence intensities, skewness coefficients and flatness coefficients. The IFA300 software also allowed us to perform statistical manipulations such as spectrum analysis on velocities samples and correlation. Utilization of data files, also produced by the anemometry software, and post analysis were performed to produce graphical representations of turbulent intensity versus probe position and a flow field velocity profile. We concluded that the IFA300 Hot Wire Anemometry system is a reliable and functional method for calibration of DEV using LIF. Our future intentions are to set up a test chamber such that both velocity measurement techniques can be applied simultaneously, thus the calibration.
Work is progressing as outlined in the proposal for this contract. A working planning and scheduling system has been documented and packaged and made available to the WIRE Small Explorer group at JPL, the FUSE group at JHU, the NASA/GSFC Laboratory for Astronomy and Solar Physics and the Advanced Planning and Scheduling Branch at STScI. The package is running successfully on the WIRE computer system. It is expected that the WIRE will reuse significant portions of the SWAS code in its system. This scheduling system itself was tested successfully against the spacecraft hardware in December 1995. A fully automatic scheduling module has been developed and is being added to the toolkit. In order to maximize reuse, the code is being reorganized during the current build into object-oriented class libraries. A paper describing the toolkit has been written and is included in the software distribution. We have experienced interference between the export and production versions of the toolkit. We will be requesting permission to reprogram funds in order to purchase a standalone PC onto which to offload the export version.
The National Aeronautics and Space Administration (NASA) Glenn Research Center (GRC) Plum Brook Station (PBS) Spacecraft Propulsion Research Facility, commonly referred to as B-2, is NASA s third largest thermal-vacuum facility with propellant systems capability. B-2 has completed a modernization effort of its facility legacy data, video and control systems infrastructure to accommodate modern integrated testing and Information Technology (IT) Security requirements. Integrated systems tests have been conducted to demonstrate the new data, video and control systems functionality and capability. Discrete analog signal conditioners have been replaced by new programmable, signal processing hardware that is integrated with the data system. This integration supports automated calibration and verification of the analog subsystem. Modern measurement systems analysis (MSA) tools are being developed to help verify system health and measurement integrity. Legacy hard wired digital data systems have been replaced by distributed Fibre Channel (FC) network connected digitizers where high speed sampling rates have increased to 256,000 samples per second. Several analog video cameras have been replaced by digital image and storage systems. Hard-wired analog control systems have been replaced by Programmable Logic Controllers (PLC), fiber optic networks (FON) infrastructure and human machine interface (HMI) operator screens. New modern IT Security procedures and schemes have been employed to control data access and process control flows. Due to the nature of testing possible at B-2, flexibility and configurability of systems has been central to the architecture during modernization.
The National Aeronautics and Space Administration (NASA) Glenn Research Center (GRC) Plum Brook Station (PBS) Spacecraft Propulsion Research Facility, commonly referred to as B-2, is NASA's third largest thermal-vacuum facility with propellant systems capability. B-2 has completed a modernization effort of its facility legacy data, video and control systems infrastructure to accommodate modern integrated testing and Information Technology (IT) Security requirements. Integrated systems tests have been conducted to demonstrate the new data, video and control systems functionality and capability. Discrete analog signal conditioners have been replaced by new programmable, signal processing hardware that is integrated with the data system. This integration supports automated calibration and verification of the analog subsystem. Modern measurement systems analysis (MSA) tools are being developed to help verify system health and measurement integrity. Legacy hard wired digital data systems have been replaced by distributed Fibre Channel (FC) network connected digitizers where high speed sampling rates have increased to 256,000 samples per second. Several analog video cameras have been replaced by digital image and storage systems. Hard-wired analog control systems have been replaced by Programmable Logic Controllers (PLC), fiber optic networks (FON) infrastructure and human machine interface (HMI) operator screens. New modern IT Security procedures and schemes have been employed to control data access and process control flows. Due to the nature of testing possible at B-2, flexibility and configurability of systems has been central to the architecture during modernization.
In this study, an optimized Litz wire and polyphase coil winding design is proposed for high-power wireless charging systems operating at 85 kHz frequency. Litz wire in a wireless charging system contributes to more than half of the losses of the system, making it a critical design component. Here, the Litz wire is optimized through Finite Element Analysis (FEA) considering electrical and mechanical design aspects and the design was validated through experimental tests on different Litz wires with various strand-diameters, twisting ratio, and number of strands. The proposed optimal Litz wire maximizes the system efficiency considering the tradeoff between coil resistance and mutual inductance. The optimal Litz wire shows that Litz wire constructed with the 63µm strands significantly outperform the traditionally used Litz wire with 100µm strand diameter. Additionally, the coil with optimal Litz wire design shows 60% reduction in the copper volume for the same loss, and at the same time increase the coil-to-coil efficiency by more than 2% by increasing the mutual inductance and reducing coil current. The optimized Litz wire was implemented in a 22-kW wireless charging system achieving 94.7% efficiency.
The effect of using multiword addressing with laminated ferrite arrays was made. Both a reduction in the number of components, and a reduction in power consumption was obtained for memory capacities between one million bits and one million words. An investigation into the effect of variations in the processing steps resulted in a number of process modifications that improved the quality of the arrays. A feasibility model laminated ferrite memory system was constructed by modifying a commercial plated wire memory system to operate with laminated ferrite arrays. To provide flexibility for the testing of the laminated ferrite memory, an exerciser has been constructed to automatically control the loading and recirculation of arbitrary size checkerboard patterns of one's and zero's and to display the patterns of stored information on a CRT screen.
A digital fly-by-wire flight control system has been installed in an F-8C test airplane and has undergone extensive ground and flight testing as part of an overall program to develop digital fly-by-wire technology. This is the first airplane to fly with a digital fly-by-wire system as its primary means of control and with no mechanical reversion capability. Forty-two test flights were made for a total flight time of 57 hours. Six pilots participated in the evaluation. This paper presents an overview of the digital fly-by-wire program and discusses some of the flight-test results.
A fly by wire flight control system architecture designed for high reliability includes spare sensor and computer elements to permit safe dispatch with failed elements, thereby reducing unscheduled maintenance. A methodology capable of demonstrating that the architecture does achieve the predicted performance characteristics consists of a hierarchy of activities ranging from analytical calculations of system reliability and formal methods of software verification to iron bird testing followed by flight evaluation. Interfacing this architecture to the Lockheed S-3A aircraft for flight test is discussed. This testbed vehicle can be expanded to support flight experiments in advanced aerodynamics, electromechanical actuators, secondary power systems, flight management, new displays, and air traffic control concepts.
The program at NASA Lewis Research Center to develop a high temperature static strain gage system for the hypersonic vehicle and turbine engine research has emphasized a palladium- 13wt%chromium (PdCr) alloy. Gages made from this alloy are being developed in both fine wire and thin film form. The wire gage system had platinum wire as a temperature compensator and was coated with a special alumina and zirconia mixture overcoat. This PdCr compensated wire gage responded linearly to the imposed strain to at least i000 microstrain. The strain sensitivity of the gage did not vary much with temperature. The apparent strain of this compensated gage was significantly lower than that of the other gages. It varied within 300 microstrain from room temperature to 800 deg. C with a reproducibility within 50 microstrain between thermal cycles to 800 deg. C. This is a significant advance over the 400 deg. C barrier of previous techniques for resistance static strain gages. The sputtered thin film PdCr strain gage, whose size was 8x8 mm and 10 micron thick, has demonstrated the possibility of extending the use of the PdCr strain gage to a temperature of approximately 1000 deg. C.
The results of extensive testing (mechanical, electrical, chemical, environmental, thermal, and analytical) are reported for a flat conductor cable baseboard system for residential and commercial wiring. In all of the tests, Underwriters Laboratories (UL) Standards, UL Tentative Test Programs, or Accepted Engineering Practices were followed during test selection, test setup, and test accomplishment.
The program at NASA Lewis Research Center to develop a high temperature static strain gage system for the hypersonic vehicle and turbine engine research has emphasized a palladium-13 wt pct chromium (PdCr) alloy. Gages made from this alloy are being developed in both fine wire and thin film form. The wire gage system had platinum wire as a temperature compensator and was coated with a special alumina and zirconia mixture overcoat. This PdCr compensated wire gage responded linearly to the imposed strain to at least 1000 microstrain. The apparent strain varied within 300 microstrain from room temperature to 800 C with a reproducibility within 50 microstrain between thermal cycles to 800 C. The sputtered thin film PdCr strain gage, whose size was 8 x 8 mm and 10 microns thick, has demonstrated the possibility of extending the use of the PdCr strain gage to a temperature of approximately 1000 C.