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NASA NTRS2018

Auto-Gopher-II – A wireline rotary-hammer ultrasonic drill that operates autonomously

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.

Paulsen, Gale L.↗
NASA NTRS2018

Auto-Gopher-2 – An Autonomous Wireline Rotary Piezo-Percussive Deep Drilling Mechanism

Drilling deep into the subsurface of planetary bodies in the Solar System for samples acquisition enables critical capabilities for future NASA exploration missions in its quest to understand the origins of the Solar System and potentially the search for life. Such planetary bodies as Mars and Europa are key targets for potential missions that would require reaching great depths. Performing drilling while using minimal mass/volume systems and with low energy consumption are the main requirements that are imposed on such technologies. A wireline deep drill, called Auto-Gopher-2, is currently being developed as a joint effort between JPL and Honeybee Robotics Ltd. The Auto-Gopher II is a wireline rotary piezo-percussive deep drilling mechanism that combines formation breaking by rotating and piezoelectric actuator hammering and cuttings removal by rotating a fluted 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 ball-shape free-mass to transform high frequency vibrations of a piezoelectric transducer horn tip into sonic hammering of the drill bit. The lessons learned from the previous studies are being implemented 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. Issues related to the bit and its ability to retain the cuttings for caching and removal are currently being addressed. This paper presents the development efforts of the piezoelectric actuator, cuttings removal and retention flutes and drive electronics.

Bar-Cohen, Yoseph↗
NASA NTRS2017

Auto-Gopher-II – An Autonomous Wireline Rotary-Hammer Ultrasonic Drill

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.

Badescu, Mircea↗
NASA NTRS2011

Auto-Gopher: A Wire-Line Rotary-Hammer Ultrasonic Drill

Developing technologies that would enable NASA to sample rock, soil, and ice by coring, drilling or abrading at a significant depth is of great importance for a large number of in-situ exploration missions as well as for earth applications. Proven techniques to sample Mars subsurface will be critical for future NASA astrobiology missions that will search for records of past and present life on the planet, as well as, the search for water and other resources. A deep corer, called Auto-Gopher, is currently being developed as a joint effort of the JPL's NDEAA laboratory and Honeybee Robotics Corp. The Auto-Gopher is a wire-line rotary-hammer drill that combines rock breaking by hammering using an ultrasonic actuator and cuttings removal by rotating a fluted bit. The hammering mechanism is based on the Ultrasonic/Sonic Drill/Corer (USDC) that has been developed as an adaptable tool for many of drilling and coring applications. The USDC uses an intermediate free-flying mass to transform the high frequency vibrations of the horn tip into a sonic hammering of a drill bit. The USDC concept was used in a previous task to develop an Ultrasonic/Sonic Ice Gopher. The lessons learned from testing the ice gopher were implemented into the design of the Auto-Gopher by inducing a rotary motion onto the fluted coring bit. A wire-line version of such a system would allow penetration of significant depth without a large increase in mass. A laboratory version of the corer was developed in the NDEAA lab to determine the design and drive parameters of the integrated system. The design configuration lab version of the design and fabrication and preliminary testing results are presented in this paper

life dectection↗
NASA NTRS2012

Single Piezo-Actuator Rotary-Hammering (SPaRH) Drill

The search for present or past life in the Universe is one of the most important objectives of NASA's exploration missions. Drills for subsurface sampling of rocks, ice and permafrost are an essential tool for astrobiology studies on other planets. Increasingly, it is recognized that drilling via a combination of rotation and hammering offers an efficient and effective rapid penetration mechanism. The rotation provides an intrinsic method for removal of cuttings from the borehole while the impact and shear forces aids in the fracturing of the penetrated medium. Conventional drills that use a single actuator are based on a complex mechanism with many parts and their use in future mission involves greater risk of failure and/or may require lubrication that can introduce contamination. In this paper, a compact drill is reported that uses a single piezoelectric actuator to produce hammering and rotation of the bit. A horn with asymmetric grooves was design to impart a longitudinal (hammering) and transverse force (rotation) to a keyed free mass. The drill requires low axial pre-load since the hammering-impacts fracture the rock under the bit kerf and rotate the bit to remove the powdered cuttings while augmenting the rock fracture via shear forces. The vibrations 'fluidize' the powdered cuttings inside the flutes reducing the friction with the auger surface. This action reduces the consumed power and heating of the drilled medium helping to preserve the pristine content of the acquired samples. The drill consists of an actuator that simultaneously impacts and rotates the bit by applying force and torque via a single piezoelectric stack actuator without the need for a gearbox or lever mechanism. This can reduce the development/fabrication cost and complexity. In this paper, the drill mechanism will be described and the test results will be reported and discussed.

ultrasonic impacts↗
NASA NTRS2012

Free-Mass and Interface Configurations of Hammering Mechanisms

A series of free-mass designs for the ultrasonic/ sonic driller/corer (USDC) has been developed to maximize the transfer of energy from the piezoelectric transducer through the horn to the bit, as well as to minimize potential jamming. A systematic development was made producing novel designs of free-mass configurations where the impact force is spread across a minimal area maximizing the impact on the bit. The designed free masses were made to operate at high temperatures (500 C) as on Venus, and they can be made to operate at extremely low temperature, too. In normal operation, the free mass bounces between the horn and the bit, impacting both repeatedly. The impact stress profile, maximum stress, contact time duration, and the required yielding stress for the materials of the free mass, bit, and horn are all affected by the contact area. A larger contact area results in lower stress in the contact region, and avoids yielding of the materials. However, before the excitation voltage is applied to the transducer, the horn, free mass, and the bit are pressed together. Larger contact area results in a stronger coupling of the bit to the horn transducer, which greatly changes the vibration characteristics of the transducer, and makes the USDC difficult to start. To obtain optimum performance, a catalog of free-mass designs is required, allowing maximum flexibility during trade-off for these conflicting contact area requirements. For this purpose, seven different designs were conceived: point contacts, circular contacts, point/circular contacts, line contacts, ring contacts, line/ring contacts, and dashed line contacts. Besides point/circular and line/ring contacts, the free mass can be designed as any of the above shapes. Depending on the ratio of the diameter to the height, and the free-mass retention method used (the cup or rod), the free mass can be configured with one or more sliding surfaces on the outside or inside diameter surface or both. Matching horn tips and free mass may also offer some utility in maximizing the stress pulse.

Bao, Xiaoqi↗
NASA NTRS2010

Ultrasonic/Sonic Rotary-Hammer Drills

Ultrasonic/sonic rotary-hammer drill (USRoHD) is a recent addition to the collection of apparatuses based on ultrasonic/sonic drill corer (USDC). As described below, the USRoHD has several features, not present in a basic USDC, that increase efficiency and provide some redundancy against partial failure. USDCs and related apparatuses were conceived for boring into, and/or acquiring samples of, rock or other hard, brittle materials of geological interest. They have been described in numerous previous NASA Tech Briefs articles. To recapitulate: A USDC can be characterized as a lightweight, lowpower, piezoelectrically driven jackhammer in which ultrasonic and sonic vibrations are generated and coupled to a tool bit. A basic USDC includes a piezoelectric stack, an ultrasonic transducer horn connected to the stack, a free mass ( free in the sense that it can bounce axially a short distance between hard stops on the horn and the bit), and a tool bit. The piezoelectric stack creates ultrasonic vibrations that are mechanically amplified by the horn. The bouncing of the free mass between the hard stops generates the sonic vibrations. The combination of ultrasonic and sonic vibrations gives rise to a hammering action (and a resulting chiseling action at the tip of the tool bit) that is more effective for drilling than is the microhammering action of ultrasonic vibrations alone. The hammering and chiseling actions are so effective that unlike in conventional twist drilling, little applied axial force is needed to make the apparatus advance into the material of interest. There are numerous potential applications for USDCs and related apparatuses in geological exploration on Earth and on remote planets. In early USDC experiments, it was observed that accumulation of cuttings in a drilled hole causes the rate of penetration of the USDC to decrease steeply with depth, and that the rate of penetration can be increased by removing the cuttings. The USRoHD concept provides for removal of cuttings in the same manner as that of a twist drill: An USRoHD includes a USDC and a motor with gearhead (see figure). The USDC provides the bit hammering and the motor provides the bit rotation. Like a twist drill bit, the shank of the tool bit of the USRoHD is fluted. As in the operation of a twist drill, the rotation of the fluted drill bit removes cuttings from the drilled hole. The USRoHD tool bit is tipped with a replaceable crown having cutting teeth on its front surface. The teeth are shaped to promote fracturing of the rock face through a combination of hammering and rotation of the tool bit. Helical channels on the outer cylindrical surface of the crown serve as a continuation of the fluted surface of the shank, helping to remove cuttings. In the event of a failure of the USDC, the USRoHD can continue to operate with reduced efficiency as a twist drill. Similarly, in the event of a failure of the gearmotor, the USRoHD can continue to operate with reduced efficiency as a USDC.

Badescu, Mircea↗
NASA NTRS2009

Micro-Horn Arrays for Ultrasonic Impedance Matching

Thin-layered structures containing arrays of micromachined horns, denoted solid micro-horn arrays (SMIHAs), have been conceived as improved means of matching acoustic impedances between ultrasonic transducers and the media with which the transducers are required to exchange acoustic energy. Typically, ultrasonic transducers (e.g., those used in medical imaging) are piezoelectric or similar devices, which produce small displacements at large stresses. However, larger displacements at smaller stresses are required in the target media (e.g., human tissues) with which acoustic energy is to be exchanged. Heretofore, efficiencies in transmission of acoustic energy between ultrasonic transducers and target media have been severely limited because substantial mismatches of acoustic impedances have remained, even when coupling material layers have been interposed between the transducers and the target media. In contrast, SMIHAs can, in principle, be designed to effect more nearly complete acoustic impedance matching, leading to power transmission efficiencies of 90 percent or even greater. The SMIHA concept is based on extension, into the higher-frequency/ lower-wavelength ultrasonic range, of the use of horns to match acoustic impedances in the audible and lower-frequency ultrasonic ranges. In matching acoustic impedance in transmission from a higher-impedance acoustic source (e.g., a piezoelectric transducer) and a lowerimpedance target medium (e.g., air or human tissue), a horn acts as a mechanical amplifier. The shape and size of the horn can be optimized for matching acoustic impedance in a specified frequency range. A typical SMIHA would consist of a base plate, a face plate, and an array of horns that would constitute pillars that connect the two plates (see figure). In use, the base plate would be connected to an ultrasonic transducer and the face plate would be placed in contact with the target medium. As at lower frequencies, the sizes and shapes of the pillars could be tailored for impedance matching in a specified ultrasonic frequency range. In a design that would be simplest to implement by micromachining, the horns would have constant cross-sectional areas as shown in the upper part of the figure. In this case, the dimensions of the horns could be chosen on the basis of a Mason equivalent-circuit model (a simplified model, well-known in the piezoelectric-transducer art, in which the electrical and mechanical dynamics, including electromechanical couplings, are expressed as electrical circuit elements that can include inductors, capacitors, and lumped-parameter complex impedances.) In a more complex, more nearly optimum design, the cross-sectional area of each horn would be either stepped or made to vary as a continuous function of through-the thickness position, as shown in the lower part of the figure.

Rao, Shanti↗
NASA NTRS2008

Solid Micro Horn Array (SMIHA) for Acoustic Matching

Transduction of electrical signals to mechanical signals and vice-versa in piezoelectric materials is controlled by the material coupling coefficient. In general in a loss-less material the ratio of energy conversion per cycle is proportional to the square of the coupling coefficient. In practical transduction however the impedance mismatch between the piezoelectric material and the electrical drive circuitry or the mechanical structure can have a significant impact on the power transfer. This paper looks at novel methods of matching the acoustic impedance of structures to the piezoelectric material in an effort to increase power transmission and efficiency. In typical methods the density and acoustic velocity of the matching layer is adjusted to give good matching between the transducer and the load. The approach discussed in this paper utilizes solid micro horn arrays in the matching layer which channel the stress and increase the strain in the layer. This approach is found to have potential applications in energy harvesting, medical ultrasound and in liquid and gas coupled transducers.

power transmission↗
NASA NTRS2009

NASA Tech Briefs, September 2009

opics covered include: Filtering Water by Use of Ultrasonically Vibrated Nanotubes; Computer Code for Nanostructure Simulation; Functionalizing CNTs for Making Epoxy/CNT Composites; Improvements in Production of Single-Walled Carbon Nanotubes; Progress Toward Sequestering Carbon Nanotubes in PmPV; Two-Stage Variable Sample-Rate Conversion System; Estimating Transmitted-Signal Phase Variations for Uplink Array Antennas; Board Saver for Use with Developmental FPGAs; Circuit for Driving Piezoelectric Transducers; Digital Synchronizer without Metastability; Compact, Low-Overhead, MIL-STD-1553B Controller; Parallel-Processing CMOS Circuitry for M-QAM and 8PSK TCM; Differential InP HEMT MMIC Amplifiers Embedded in Waveguides; Improved Aerogel Vacuum Thermal Insulation; Fluoroester Co-Solvents for Low-Temperature Li+ Cells; Using Volcanic Ash to Remove Dissolved Uranium and Lead; High-Efficiency Artificial Photosynthesis Using a Novel Alkaline Membrane Cell; Silicon Wafer-Scale Substrate for Microshutters and Detector Arrays; Micro-Horn Arrays for Ultrasonic Impedance Matching; Improved Controller for a Three-Axis Piezoelectric Stage; Nano-Pervaporation Membrane with Heat Exchanger Generates Medical-Grade Water; Micro-Organ Devices; Nonlinear Thermal Compensators for WGM Resonators; Dynamic Self-Locking of an OEO Containing a VCSEL; Internal Water Vapor Photoacoustic Calibration; Mid-Infrared Reflectance Imaging of Thermal-Barrier Coatings; Improving the Visible and Infrared Contrast Ratio of Microshutter Arrays; Improved Scanners for Microscopic Hyperspectral Imaging; Rate-Compatible LDPC Codes with Linear Minimum Distance; PrimeSupplier Cross-Program Impact Analysis and Supplier Stability Indicator Simulation Model; Integrated Planning for Telepresence With Time Delays; Minimizing Input-to-Output Latency in Virtual Environment; Battery Cell Voltage Sensing and Balancing Using Addressable Transformers; Gaussian and Lognormal Models of Hurricane Gust Factors; Simulation of Attitude and Trajectory Dynamics and Control of Multiple Spacecraft; Integrated Modeling of Spacecraft Touch-and-Go Sampling; Spacecraft Station-Keeping Trajectory and Mission Design Tools; Efficient Model-Based Diagnosis Engine; and DSN Simulator.

Source record↗
NASA NTRS2012

Actuation Using Piezoelectric Materials: Application in Augmenters, Energy Harvesters, and Motors

Piezoelectric actuators are used in many manipulation, movement, and mobility applications as well as transducers and sensors. When used at the resonance frequencies of the piezoelectric stack, the actuator performs at its maximum actuation capability. In this Space Grant internship, three applications of piezoelectric actuators were investigated including hammering augmenters of rotary drills, energy harvesters, and piezo-motors. The augmenter shows improved drill performance over rotation only. The energy harvesters rely on moving fluid to convert mechanical energy into electrical power. Specific designs allow the harvesters more freedom to move, which creates more power. The motor uses the linear movement of the actuator with a horn applied to the side of a rotor to create rotational motion. Friction inhibits this motion and is to be minimized for best performance. Tests and measurements were made during this internship to determine the requirements for optimal performance of the studied mechanisms and devices.

drills↗
NASA NTRS2001

Characterization of Transducers and Resonators under High Drive Levels

In many applications, piezoelectric transducers are driven at AC voltage levels well beyond the level for which the material was nominally characterized. In this paper we describe an experimental setup that allows for the determination of the main transducer or resonator properties under large AC drive. A sinusoidal voltage from a waveform generator is amplified and applied across the transducer/resonator in series with a known high power resistor. The amplitude of applied voltage and the amplitude and the relative phase of the current through the resistor are monitored on a digital scope. The frequency of the applied signal is swept through resonance and the voltage/current signals are recorded. After corrections for the series resistance and parasitic elements the technique allows for the determination of the complex impedance spectra of the sample as a function of frequency. In addition, access to the current signal allows for the direct investigation of non-linear effects through the application of Fourier transform techniques on the current signal. Our results indicate that care is required when interpreting impedance data at high drive level due to the frequency dependence of the dissipated power. Although the transducer/resonator at a single frequency and after many cycles may reach thermal equilibrium, the spectra as a whole cannot be considered an isothermal measurement due to the temperature change with frequency. Methods to correct for this effect will be discussed. Results determined from resonators of both soft and hard PZT and a ultrasonic horn transducer are presented.

transducers↗