The NACA Balanced-diaphragm Dynamometer-torque Indicator
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VALVES, PILOT-SPOOL↗
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Effects of potassium titanate fiber on the wear of automotive brake linings
Asbestos reinforcing fiber in an automotive friction material was replaced by an experimental ingredient having better thermal stability, and the effects on wear and friction were studied. A friction materials test machine (SAE J661a) was used to determine friction and wear, under constant energy output conditions, as a function of temperature between 121 and 343 C (250 and 650 F). When potassium titanate fiber replaced one half of the asbestos in a standard commercial lining, with a 40 percent upward adjustment of phenolic resin content, wear above 204 C (400 F) was improved by 40% and friction by 30%. Tests on a full-scale inertial dynamometer supported the findings of the sample dynamometer tests. It was demonstrated that the potassium titanate fiber contributes directly to the improvement in wear and friction.
Halberstadt, M. L.↗
Small Hydro Power Plants with Integrated BESS for Enhance Resiliency
Battery energy storage systems (BESS) are an important asset for power systems with high integration levels of renewable energy, and they can be controlled to provide various services to the grid. This paper presents the hardware demonstration and characterization of using a utility-scale BESS with grid-following (GFL) and grid-forming (GFM) controls and a run-of-river (ROR) hydropower plant to perform a bottom-up power system black start that enhances power systems' resiliency. ROR hydropower plants are generally not used for power system restoration due to their frequency instability during islanded operation; however, BESS with droop control can provide critical damping to convert a ROR hydropower generator into a black start- capable unit. To demonstrate this, we carry out hardware experiments at the megawatt-scale integrating a synchronous generator driven by a dynamometer, an actual GFL/GFM BESS, a medium-voltage impedance network, and a load bank. The demonstration shows the different roles of BESS with GFL and GFM control in power system restoration. GFL BESS can suffer from high-frequency oscillations, even instability, depending on the droop control gain and loading condition. The results provide further insights for system operators on how GFL- or GFM controlled BESS can enhance grid stability and how hydro-BESS hybrids can operate as a black-start-capable unit. The presented experimental results are also a valuable resource to understand the different stability characteristics of real-world BESS with different control modes.
24 POWER TRANSMISSION AND DISTRIBUTION↗
Demonstration of Power System Black Start with Hydropower Generator and Battery Energy Storage: Preprint
Battery energy storage systems (BESS) are an important asset for power systems with high integration levels of renewable energy, and they can be controlled to provide various services to the grid. This paper presents the hardware demonstration and characterization of using a utility-scale BESS with grid-following (GFL) and grid-forming (GFM) controls and a run-of-river (ROR) hydropower plant to perform a bottom-up power system black start that enhances power systems' resiliency. ROR hydropower plants are generally not used for power system restoration due to their frequency instability during islanded operation; however, BESS with droop control can provide critical damping to convert a ROR hydropower generator into a blackstart- capable unit. To demonstrate this, we carry out hardware experiments at the megawatt-scale integrating a synchronous generator driven by a dynamometer, an actual GFL/GFM BESS, a medium-voltage impedance network, and a load bank. The demonstration shows the different roles of BESS with GFL and GFM control in power system restoration. GFL BESS can suffer from high-frequency oscillations, even instability, depending on the droop control gain and loading condition. The results provide further insights for system operators on how GFL- or GFMcontrolled BESS can enhance grid stability and how hydro-BESS hybrids can operate as a black-start-capable unit. The presented experimental results are also a valuable resource to understand the different stability characteristics of real-world BESS with different control modes.
24 POWER TRANSMISSION AND DISTRIBUTION↗
Modeling and Power-Hardware-in-the-Loop Validation of Synchronous Machine Governor
This paper introduces the development of a high-fidelity gas turbine governor model using a programmable logic controller for power-hardware-in-the-loop (PHIL) validation. The governor model is integrated with the National Renewable Energy Laboratory's (NREL) PHIL test bed, featuring a 2-MVA synchronous machine and a 2.5-MW variable-speed drive, to emulate NG-driven HRSGs and CTs under various operational scenarios. The primary objective of this research is to study the grid-connected and islanding operations of conventional generation sources, with representative startup sequences including turbine purge, ignition, speed ramp-up, synchronization, and breaker closure. Preliminary results of the generator governor model on NREL PHIL platform, particularly using the 2.5-MW dynamometer system, offered significant insights into the modeling techniques, hardware integration, scaling, and real-world simulation dynamics.
24 POWER TRANSMISSION AND DISTRIBUTION↗
An Investigation of the Effect of the WADC 30,000-Horsepower Whirl Rig Upon the Static Characteristics of a Propeller
Tests have been made at the Langley Aeronautical Laboratory on a 6000-horsepower propeller dynamometer installed at a ground test facility to determine the effect of a half-scale model of the Wright Aeronautical Development Center 30,000-horsepower whirl rig upon the aerodynamic characteristics of a three-blade NACA 10-(3)(062)-045 propeller. The model of the whirl rig was mounted in front of the 6000-horsepower propeller dynamometer. Static propeller tests were made for 0deg, 5deg, 10deg, 15deg, and 20deg blade angles over a range of rotational speeds from 600 to 2200 rpm in 100-rpm increments. Measurements were made of propeller thrust and torque, stresses in the propeller blades, and static and total pressures over the surface of the model. Propeller thrust and torque were increased up to 33 percent by the presence of the model of the whirl rig, but the average increase was from 5 to 10 percent. Blade vibratory stresses were small.
Salters, Leland B., Jr.↗
A comparison of some static and dynamic mechanical properties of 18 x 5.5 and 49 x 17 type 7 aircraft tires as measured by three test facilities
The properties were measured during static, slow rolling, and high-speed tests, and comparisons were made between data as acquired on indoor drum dynamometers and on an outdoor test track. In addition, mechanical properties were also obtained from scale model tires and compared with corresponding properties from full-size tires. While the tests covered a wide range of tire properties, results seem to indicate that speed effects are not large, scale models may be used for obtaining some but not all tire properties, and that predictive equations developed in NASA TR R-64 are still useful in estimating most mechanical properties.
Dodge, R. N.↗
Friction Stir Welding Development
The research of this summer was a continuation of work started during the previous summer faculty fellowship period. The Friction Stir Welding process (FSW) patented by The Welding Institute (TWI), in Great Britain, has become a popular topic at the Marshall Space Flight Center over the past year. Last year it was considered a novel approach to welding but few people took it very seriously as a near term solution. However, due to continued problems with cracks in the new aluminum-lithium space shuttle external tank (ET), the friction stir process is being mobilized at full speed in an effort to mature this process for the potential manufacture of flight hardware. It is now the goal of NASA and Lockheed-Martin Corporation (LMC) to demonstrate a full-scale friction stir welding system capable of welding ET size barrel sections. The objectives this summer were: (1) Implementation and validation of the rotating dynamometer on the MSFC FSW system; (2) Collection of data for FSW process modeling efforts; (3) Specification development for FSW implementation on the vertical weld tool; (4) Controls and user interface development for the adjustable pin tool; and (5) Development of an instrumentation system for the planishing process. The projects started this summer will lead to a full scale friction stir welding system that is expected to produce a friction stir welded shuttle external tank type barrel section. The success of this could lead to the implementation of the friction stir process for manufacturing future shuttle external tanks.
Romine, Peter L.↗
The development of experimental techniques for the study of helicopter rotor noise
The features of existing wind tunnels involved in noise studies are discussed. The acoustic characteristics of the MIT low noise open jet wind tunnel are obtained by employing calibration techniques: one technique is to measure the decay of sound pressure with distance in the far field; the other technique is to utilize a speaker, which was calibrated, as a sound source. The sound pressure level versus frequency was obtained in the wind tunnel chamber and compared with the corresponding calibrated values. Fiberglas board-block units were installed on the chamber interior. The free field was increased significantly after this treatment and the chamber cut-off frequency was reduced to 160 Hz from the original designed 250 Hz. The flow field characteristics of the rotor-tunnel configuration were studied by using flow visualization techniques. The influence of open-jet shear layer on the sound transmission was studied by using an Aeolian tone as the sound source. A dynamometer system was designed to measure the steady and low harmonics of the rotor thrust. A theoretical Mach number scaling formula was developed to scale the rotational noise and blade slap noise data of model rotors to full scale helicopter rotors.
Widnall, S. E.↗
A Wind-Tunnel Investigation of the Aerodynamic Characteristics of a Full-Scale Supersonic-Type Three-blade Propeller at Mach Numbers to 0.96
An investigation of the characteristics of a full-scale supersonic-type propeller has been made in the Langley 16-foot transonic tunnel with the 6000-horsepower propeller dynamometer. The tests covered a range of blade angles from 20.2 degrees to 60.2 degrees at forward Mach numbers up to 0.96. The results showed that envelope efficiency at an advance ratio of 2.8 decreased from 86 percent to 72 percent when the forward Mach number was increased from 0.70 to 0.96. A comparison of the experimental results with calculated results showed that maximum propeller efficiency can be calculated with good accuracy by using ordinary subsonic strip theory when the blade-section speeds are supersonic. The investigation also showed favorable power-absorption properties of the supersonic-type propeller at high speeds.
Evans, Albert J↗
Aerodynamic Characteristics at High Speeds of Full-Scale Propellers having Different Shank Designs
Tests of two 10-foot-diameter two-blade propellers which differed only in shank design have been made in the Langley 16-foot high-speed tunnel. The propellers are designated by their blade design numbers, NACA 10-(5)(08)-03, which had aerodynamically efficient airfoil shank sections, and NACA l0-(5)(08)-03R which had thick cylindrical shank sections typical of conventiona1 blades, The propellers mere tested on a 2000-horsepower dynamometer through a range of blade-angles from 20deg to 55deg at various rotational speeds and at airspeeds up to 496 miles per hour. The resultant tip speeds obtained simulate actual flight conditions, and the variation of air-stream Mach number with advance ratio is within the range of full-scale constant-speed propeller operation. Both propellers were very efficient, the maximum envelope efficiency being approximately 0,95 for the NACA 10-(5)(08)-03 propeller and about 5 percent less for the NACA 10-(5)(08)-03R propeller. Based on constant power and rotational speed, the efficiency of the NACA 10-(05)(08)-03 propeller was from 2.8 to 12 percent higher than that of the NACA 10-(5)(08)-03R propeller over a range of airspeeds from 225 to 450 miles per hour. The loss in maximum efficiency at the design blade angle for the NACA 10-(5)(08)-03 and 10-(5)(08)-03R propellers vas about 22 and 25 percent, respectively, for an increase in helical tip Mach number from 0.70 to 1.14.
Maynard, Julian D.↗
Improved transistorized AC motor controller for battery powered urban electric passenger vehicles
An ac motor controller for an induction motor electric vehicle drive system was designed, fabricated, tested, evaluated, and cost analyzed. A vehicle performance analysis was done to establish the vehicle tractive effort-speed requirements. These requirements were then converted into a set of ac motor and ac controller requirements. The power inverter is a three-phase bridge using power Darlington transistors. The induction motor was optimized for use with an inverter power source. The drive system has a constant torque output to base motor speed and a constant horsepower output to maximum speed. A gear shifting transmission is not required. The ac controller was scaled from the base 20 hp (41 hp peak) at 108 volts dec to an expanded horsepower and battery voltage range. Motor reversal was accomplished by electronic reversal of the inverter phase sequence. The ac controller can also be used as a boost chopper battery charger. The drive system was tested on a dynamometer and results are presented. The current-controlled pulse width modulation control scheme yielded improved motor current waveforms. The ac controller favors a higher system voltage.
Peak, S. C.↗
Development of a precision, six-axis laboratory dynamometer
This paper describes the design, fabrication, test, and operation of a unique six axis force/torque dynamometer The specimen table used to hold components under test is supported in a full six axis kinematic mount. Support struts fabricated from high strength steel with special integral two axis flexures link the specimen table to the load cell transducers. Realtime force/torque coordinate transform, root mean squared calculation, and data averaging, and color six axis display with controllable scaling are provided by a specially programmed desktop computer. The extensive structural analysis and design optimization required to obtain a stiff, well damped, lightweight structure is described in detail. Geometric optimization of the kinematic mount and fabrication details of the struts are also described.
P. J. Champagne↗
Validation and Calibration of Energy Models with Real Vehicle Data from Chassis Dynamometer Experiments
Accurate estimation of vehicle fuel consumption typically requires detailed modeling of complex internal powertrain dynamics, often resulting in computationally intensive simulations. However, many transportation applications-such as traffic flow modeling, optimization, and control-require simplified models that are fast, interpretable, and easy to implement, while still maintaining fidelity to physical energy behavior. This work builds upon a recently developed model reduction pipeline that derives physics-like energy models from high-fidelity Autonomie vehicle simulations. These reduced models preserve essential vehicle dynamics, enabling realistic fuel consumption estimation with minimal computational overhead. While the reduced models have demonstrated strong agreement with their Autonomie counterparts, previous validation efforts have been confined to simulation environments. This study extends the validation by comparing the reduced energy model's outputs against real-world vehicle data. Focusing on the MidSUV category, we tune the baseline Autonomie model to closely replicate the characteristics of a Toyota RAV4. We then assess the accuracy of the resulting reduced model in estimating fuel consumption under actual drive conditions. Our findings suggest that, when the reference Autonomie model is properly calibrated, the simplified model produced by the reduction pipeline can provide reliable, semi-principled fuel rate estimates suitable for large-scale transportation applications.
42 ENGINEERING↗