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At least 19 records
All sourcesNASA NTRSDOE OSTI
NASA NTRSDate not supplied

Analysis of Pull Force Test Results for Crimped Connections

Crimped electrical contacts are reliable when strict process controls are followed during manufacturing and accompanied by continuous process verification through pull force testing. Cable and wire harness assemblies’ standards are developed and refined over time to provide the minimum pull force that a crimp contact must meet before it breaks from the wire. However, in practice the failures occur at a much higher tensile strength than the minimum required. The first section of this paper reviewed 780 pull force test results provided by NASA Centers were collected and analyzed to determine how the data compares to NASA’s pre-existing requirements from the cable/harness standards NASA-STD-8739.4 and IPC/WHMA-A-620B-S. The measured tensile strength of most of the contact/conductor pairs (i.e. Contact/Wires or C/W) exceeded the minimum pull force values of NASA-STD-8739.4 and IPC/WHMA-A-620 standards by at least 100 %. The tensile strength samples of the C/W pairs values followed a normal distribution with an average tensile strength value that was at least 182 % of the minimum requirement, and all the samples analyzed passed the pull force testing. In addition, the 95 % confidence interval of the average tensile strength distributions for several C/W pairs was determined and plotted as error bars to show that there is good likelihood to observe C/W pair normal distribution with a 95 % confidence interval that will meet and surpass the standard requirements. The frequency of pull force testing can be problematic for projects because of the cost and availability of spare contacts for the destructive test. It could be possible to reduce the frequency of pull force testing if at the beginning of the production run, the conditions of the crimp tool and materials are verified, and the settings of the tool remain unchanged throughout the process. However, the project must evaluate the impact to risk from reducing the frequency of testing.

Crimped connections↗
NASA NTRSDate not supplied

Analysis of Pull Force Test Results for Crimped Connections

Crimped electrical contacts are reliable when strict process controls are followed during manufacturing and accompanied by continuous process verification through pull force testing. Cable and wire harness assemblies’ standards are developed and refined over time to provide the minimum pull force that a crimp contact must meet before it breaks from the wire. However, in practice the failures occur at a much higher tensile strength than the minimum required. The first section of this paper reviewed 780 pull force test results provided by NASA Centers that were collected and analyzed to determine how the data compare to NASA’s pre-existing requirements from the cable/harness standards NASA-STD-8739.4 and IPC/WHMA-A-620B-S. The measured tensile strength of most of the contact/conductor pairs (i.e., Contact/Wires or C/W) exceeded the minimum pull force values of NASA-STD-8739.4 and IPC/WHMA-A-620 standards by at least 100%. The C/W pair samples’ tensile strength values followed a normal distribution with an average tensile strength value that was at least 182% of the minimum requirement, and all the samples analyzed passed the pull force testing. In addition, the 95% confidence interval of the average tensile strength distributions for several C/W pairs was determined and plotted as error bars to show that the C/W pairs will meet and surpass the requirements. The frequency of pull force testing can be problematic for projects because of the cost and availability of spare contacts for the destructive test. It is possible to reduce the frequency of pull force testing if at the beginning of the production run, the conditions of the crimp tool and materials are verified, and the settings of the tool remain unchanged throughout the process. However, the project needs to understand and evaluate the impact to risk from reducing the frequency of testing prior to implementing process changes.

Alejandra Constante↗
NASA NTRS1946

Flight Measurements to Determine Effect of a Spring-Loaded Tab on Longitudinal Stability of an Airplane

In conjunction with a program of research on the general problem of stability of airplanes in the climbing condition, tests have been made of a spring-loaded tb which. is referred to as a ?springy tab,? installed on the elevator of a low-wing scout bomber. The tab was arranged to deflect upward with decrease in speed which caused an increase in the pull force required to trim at low speeds and thereby increased the stick-free static longitudinal stability of the airplane. It was found that the springy tab would increase the stick-free stability in all flight conditions, would reduce the danger of inadvertent stalling because of the definite pull force required to stall the airplane with power on, would reduce the effect of center-of-gravity position on stick-free static stability, and would have little effect on the elevator stick forces in accelerated f11ght. Another advantage of the springy tab is that it might be used to provide almost any desired variation of elevator stick force with speed by adjusting the tab hinge-moment characteristics and the variation of spring moment with tab deflection. Unlike the bungee and the bobweight, the springy tab would provide stick-free static stability without requiring a pull force to hold the stick back while taxying. A device similar to the springy tab may be used on the rudder or ailerons to eliminate undesirable trim-force variations with speed.

TABS, ELEVATOR↗
NASA NTRS2000

Ergonomic Evaluation of Space Shuttle Light-Weight Seat Lever Position and Operation

During a Shuttle flight in the early part of 1999, one of the crewmembers was unable to operate the backrest lever for the light-weight seat in microgravity. It is essential that the crewmembers are able to adjust this back-rest lever, which is titled forward 2 degrees from vertical during launch and then moved backwards to 10 degrees aft of vertical upon reaching orbit. This adjustment is needed to cushion the crewmembers during an inadvertent crash landing situation. The original Shuttle seats, which had seat controls located on the front left and right sides of the seat, were replaced recently with the new light-weight seats. The controls for these new, seats were moved to the night side with one control at the front and the other at the back. While it was uncertain whether the problem encountered was unique to that crewmember or not it was clear to the personnel responsible for maintaining the Shuttle seats that not knowing the cause of the problem posed a safety concern for NASA. Hence the Anthropometry and Biomechanics Facility (ABF) of the Johnson Space Center was requested to perform an evaluation of the seat controls and provide NASA with appropriate recommendations on whether the seat lever positions and operations should be modified. The ABF designed an experiment to investigate the amount of pull force exerted by subjects, wearing an unpressurized or pressurized crew launch escape suit, when controls were placed in the front and back (on the right side) of the light-weight seat. Single-axis load cells were attached to the seat levers, which measured the maximum static pull forces that were exerted by the subjects. Twelve subjects, six male and six female, participated in this study. Each subject was asked to perform the pull test at least three times for each combination of lever position and suit pressure conditions. The results from this study showed that as a whole (or in general), the subjects were able to pull on the lever at the back position with only about half the amount of force that they were able to exert on the lever at the front position. In addition, the results also showed that subjects wearing the pressurized suit were unable to reach the seat lever when it was located at the back. Furthermore, the pull forces on the front lever diminished about 50 % when subjects wore the pressurized suits. Based on these results from this study, it was recommended to NASA that the levers should not be located in the back position. In addition, further investigation is needed on whether the levers at the front of the seat could be modified or adjusted to increase the leverage for crew members wearing pressurized launch/escape suits.

Maida, J.↗
NASA NTRS1979

Nondestructive pull tester

Quality control of welded electric wires is improved with easy-to-use tool applying small constant pull force to weldment (typically less than one-twentieth force required to pull weld apart).

Levy, A.↗
NASA NTRS1978

Finite element modeling of stress in the Nazca plate - Driving forces and plate boundary earthquakes

The state of stress within the Nazca plate due to plate driving forces and large plate boundary earthquakes has been analyzed by applying a finite element method using the wave front solution technique to models of the intraplate stress field in a single plate using a refined grid. Although only static elastic models have been explicitly calculated, certain limiting cases of an elastic plate over a viscous asthenosphere were also treated. A state of nearly east-west compression inferred from the source mechanism of thrust earthquakes in the interior of the plate requires ridge pushing forces. The net pulling force on the oceanic plate by the subducted slab has a maximum value comparable to pushing forces. The estimated horizontal deviatoric stress in intraplate regions, based on potential forces associated with the ridge, is on the order of a few hundred bars. The intraplate stress field in the region of the 1960 earthquake may change by a few tens of bars at most once the asthenosphere has relaxed, with changes on the order of one bar occurring at greater distances into the plate. The changes in the intraplate stress field are probably not noticeable unless the lithosphere is near failure.

Richardson, R. M.↗
NASA NTRS1999

Lightweight Seat Lever Operation Characteristics

In 1999, a Shuttle crew member was unable to operate the backrest lever for the lightweight seat in microgravity. It is essential that crew members can adjust this backrest lever, which is titled forward during launch and then moved backward upon reaching orbit. This adjustment is needed to cushion the crew members during an inadvertent crash landing situation. JSCs Anthropometry and Biomechanics Facility (ABF) performed an evaluation of the seat controls and provided recommendations on whether the seat lever positions and operations should be modified. The original Shuttle seats were replaced with new lightweight seats whose controls were moved, with one control at the front and the other at the back. The ABF designed a 12-person experiment to investigate the amount of pull force exerted by suited subjects, when controls were placed in the front and back of the lightweight seat. Each subject was asked to perform the pull test at least three times for each combination of lever position and suit pressure conditions. The results showed that, in general, the subjects were able to pull on the lever at the back position with only about half the amount of force that they were able to exert on the lever at the front position. In addition, the results also showed that subjects wearing the pressurized suit were unable to reach the seat lever when it was located at the back. The pull forces on the front lever diminished about 50% when subjects wore pressurized suits. Based on these results from this study, it was recommended that the levers should not be located in the back position. Further investigation is needed to determine whether the levers at the front of the seat could be modified or adjusted to increase the leverage for crew members wearing pressurized launch/escape suits.

Rajulu, Sudhakar↗
NASA NTRS1985

Cryogenic insulation strength and bond tester

A method and apparatus for testing the tensile strength and bonding strength of sprayed-on foam insulation attached to metal cryogenic fuel tanks is described. A circular cutter is used to cut the insulation down to the surface of the metal tank to form plugs of the insulation for testing in situ on the tank. The apparatus comprises an electromechanical pulling device powered by a belt battery pack. The pulling device comprises a motor driving a mechanical pulling structure comprising a horizontal shaft connected to two bell cracks which are connected to a central member. When the lower end of member is attached to a fitting, which in turn is bonded to a plug, a pulling force is exerted on the plug sufficient to rupture it. The force necessary to rupture the plug or pull it loose is displayed as a digital read-out.

Schuerer, P. H.↗
NASA NTRS1985

Hand-Held Power Clamp

Tool furnishes large pushing or pulling forces. Device includes two clamping blocks, two clamping plates, and a motor-driven linear actuator with selflocking screw shaft. Power clamp exerts opening or closing force at push of switch. Tool approximately 1 m long. Originally designed to secure payload aboard Space Shuttle, operated with one hand to apply opening or closing force of up to 1,000 lb (4,400 N). Clamp has potential applications as end effector for industrial robots and in rescue work to push or pull wreckage with great force.

Clancy, J. P.↗
NASA NTRS1988

Linear force device

The object of the invention is to provide a mechanical force actuator which is lightweight and manipulatable and utilizes linear motion for push or pull forces while maintaining a constant overall length. The mechanical force producing mechanism comprises a linear actuator mechanism and a linear motion shaft mounted parallel to one another. The linear motion shaft is connected to a stationary or fixed housing and to a movable housing where the movable housing is mechanically actuated through actuator mechanism by either manual means or motor means. The housings are adapted to releasably receive a variety of jaw or pulling elements adapted for clamping or prying action. The stationary housing is adapted to be pivotally mounted to permit an angular position of the housing to allow the tool to adapt to skewed interfaces. The actuator mechanisms is operated by a gear train to obtain linear motion of the actuator mechanism.

Clancy, John P.↗
NASA NTRS1985

True polar wander and plate-driving forces

The nature of net torques applied to the lithosphere by ridge and trench forces as implied by the absence of recent true polar wander is explored. The 'ridge push' and 'trench pull' forces and the potential net torques on the global lithosphere contributed by each of these forces are discussed. It is shown that the relative magnitudes of the net torques contributed by ridge and trench forces are constrained by the absence of true polar wander during the Cenozoic and by the magnitudes of basal shear stresses on the faster moving plates. It is suggested that the lack of recent true polar wander may be due at least in part to the coincidence of a near cancellation of net torques contributed by ridge and trench forces.

Davis, D. M.↗
NASA NTRS2012

SRMS Assisted Docking and Undocking for the Orbiter Repair Maneuver

As part of the Orbiter Repair Maneuver (ORM) planned for Return to Flight (RTF) operations, the Shuttle Remote Manipulator System (SRMS) must undock the Orbiter, maneuver it through a complex trajectory at extremely low rates, present it to an EVA crewman at the end of the Space Station Remote Manipulator System to perform the Thermal Protection System (TPS) repair, and then retrace back through the trajectory to dock the Orbiter with the Orbiter Docking System (ODS). The initial and final segments of this operation involve the interaction between the SRMS, ISS, Orbiter and ODS. Previously, a technique entitled "SRMS assisted docking" for installation of a payload to the ODS had been developed and was utilized for the Russian provided Docking Module on STS-74 during Shuttle-Mir missions and both the Node 1 and FGB elements on STS-88/Flight 2A. This procedure consisted of the SRMS grappling the respective payload, maneuvering it to a pre-install position inches above the ODS Androgynous Peripheral Attachment System (APAS) ring, commanding the SRMS into Test mode (which allows brakes-off motion of the joints), and then down-firing Primary Reaction Control System (PRCS) jets in order to effect a capture of the APAS latches. Once a successful capture had been achieved, then the AP AS was operated through its nominal retraction sequence to complete the mating sequence. While this technique can once again be used for the tail end docking portion of the ORM, the initial undocking of the orbiter and ISS vehicles with the assistance of the SRMS has yet to be attempted on orbit. The objective here is to determine the most efficient means to separate or extract the vehicles. Two techniques were analyzed in support of RTF: (1) the 'nominal' demating from the mated interface, and (2) the SRMS performing the operation (either in an active or passive fashion). In the first operation, the demating process would replicate standard undocking operations, with the exception that the SRMS is allowed to arrest the resulting motion. The second operation would be to extend the APAS ring to a ready to dock position, open the capture latches, and then detach the vehicles using the SRMS either actively or passively. In the active case, the APAS ring is extended and latched, and the SRMS is commanded to pull the two interfaces apart (assuming that the effective pull force of the SRMS can overcome the spec values of the combined latch resistance). In the passive case, the SRMS brakes are engaged and the AP AS mechanism is commanded to retract, pulling the two interfaces apart. Since the emphasis of both STS-74 and STS-88 had solely been on the installation operation, as opposed to the separation operation, two new models required development and incorporation within simulation tools designed to analyze those scenarios. These enhancements included: (1) a detailed demating dynamics model to characterize the pusher spring characteristics during undocking, and (2) contact and mechanical system modeling of the back side of the latches to represent unlatching dynamics. This paper first provides an overview of the Monte-Carlo screening analysis for the installation (both nominal and contingency), including the variation of separation distance, misalignment conditions, SRMS joint/brake parameter characteristics, and PRCS jet combinations and corresponding thrust durations. The resulting 'optimum' solution is presented based on trade studies between predicted capture success and integrated system loads. This paper then discusses the upgrades to the APAS math model associated with the new SRMS assisted undocking technique and reviews simulation results for various options investigated for either the active and passive separation of the ISS from the Orbiter.

Space Station Remote Manipulator System↗
NASA NTRS2011

HEXPANDO Expanding Head for Fastener-Retention Hexagonal Wrench

The HEXPANDO is an expanding-head hexagonal wrench designed to retain fasteners and keep them from being dislodged from the tool. The tool is intended to remove or install socket-head cap screws (SHCSs) in remote, hard-to-reach locations or in circumstances when a dropped fastener could cause damage to delicate or sensitive hardware. It is not intended for application of torque. This tool is made of two assembled portions. The first portion of the tool comprises tubing, or a hollow shaft, at a length that gives the user adequate reach to the intended location. At one end of the tubing is the expanding hexagonal head fitting with six radial slits cut into it (one at each of the points of the hexagonal shape), and a small hole drilled axially through the center and the end opposite the hex is internally and externally threaded. This fitting is threaded into the shaft (via external threads) and staked or bonded so that it will not loosen. At the other end of the tubing is a knurled collar with a through hole into which the tubing is threaded. This knob is secured in place by a stop nut. The second assembled portion of the tool comprises a length of all thread or solid rod that is slightly longer than the steel tubing. One end has a slightly larger knurled collar affixed while the other end is tapered/pointed and threaded. When the two portions are assembled, the all thread/rod portion feeds through the tubing and is threaded into the expanding hex head fitting. The tapered point allows it to be driven into the through hole of the hex fitting. While holding the smaller collar on the shaft, the user turns the larger collar, and as the threads feed into the fitting, the hex head expands and grips the SHCS, thus providing a safe way to install and remove fasteners. The clamping force retaining the SHCS varies depending on how far the tapered end is inserted into the tool head. Initial tests of the prototype tool, designed for a 5 mm or # 10SHCS have resulted in up to 8 lb (.35.6 N) of pull force to dislodge the SHCS from the tool. The tool is designed with a lead-in angle from the diameter of the tubing to a diameter the same as the fastener head, to prevent the fastener head from catching on any obstructions encountered that could dislodge the fastener during retrieval.

Bishop, John↗
NASA NTRS1973

Modeling and measuring limb fine-motor unsteadiness

Fine-motor unsteadiness its properties, conceptual and analytical models, and experimental measurements is examined. Based on a data review, the tentative model derived includes: neuromuscular system, grip interface, and control system dynamic elements. The properties of this model change with muscle tension and match a wide group of extant data. A simple experiment was performed to investigate the amplitude/force relationships of the tremor mode. As the finger-pull force increased from 5 to 20 Newtons, the tremor mode frequency for a given individual stayed within roughly + or - 1 Hz over a range from 9-12 Hz, while the average magnitude of the rms tremor acceleration increased tenfold. A standardized test for making such measurements is given and applications in the fields of psychophysiological stress and strain measurements are mentioned.

Magdaleno, R. E.↗
NASA NTRS1984

Adaptive triangular mesh generation

A general adaptive grid algorithm is developed on triangular grids. The adaptivity is provided by a combination of node addition, dynamic node connectivity and a simple node movement strategy. While the local restructuring process and the node addition mechanism take place in the physical plane, the nodes are displaced on a monitor surface, constructed from the salient features of the physical problem. An approximation to mean curvature detects changes in the direction of the monitor surface, and provides the pulling force on the nodes. Solutions to the axisymmetric Grad-Shafranov equation demonstrate the capturing, by triangles, of the plasma-vacuum interface in a free-boundary equilibrium configuration.

Erlebacher, G.↗
NASA NTRS1993

Analysis of pultrusion processing for long fiber reinforced thermoplastic composite system

Pultrusion is one of the composite processing technology, commonly recognized as a simple and cost-effective means for the manufacturing of fiber-reinforced, resin matrix composite parts with different regular geometries. Previously, because the majority of the pultruded composite parts were made of thermosetting resin matrix, emphasis of the analysis on the process has been on the conservation of energy from various sources, such as heat conduction and the curing kinetics of the resin system. Analysis on the flow aspect of the process was almost absent in the literature for thermosetting process. With the increasing uses of thermoplastic materials, it is desirable to obtain the detailed velocity and pressure profiles inside the pultrusion die. Using a modified Darcy's law for flow through porous media, closed form analytical solutions for the velocity and pressure distributions inside the pultrusion die are obtained for the first time. This enables us to estimate the magnitude of viscous dissipation and it's effects on the pultruded parts. Pulling forces refined in the pultrusion processing are also analyzed. The analytical model derived in this study can be used to advance our knowledge and control of the pultrusion process for fiber reinforced thermoplastic composite parts.

Tso, W.↗
NASA NTRS1992

Composite flight-control actuator development

The composite actuator is 'jam resistant', satisfying a survivability requirement for the Navy. Typically, the push-pull force needed to drive through the wound area of the composite actuator is 73 percent less than that of an all-metal actuator. In addition to improving the aircraft's combat survivability, significant weight savings were realized. The current design of the survivable, composite actuator cylinder is 36 percent lighter than that of the production steel cylinder, which equates to a 15 percent overall actuator weight savings.

Bott, Richard↗
NASA NTRS1995

Powder-Coated Towpreg: Avenues to Near Net Shape Fabrication of High Performance Composites

Near net shape parts were fabricated from powder-coated preforms. Key issues including powder loss during weaving and tow/tow friction during braiding were addressed, respectively, by fusing the powder to the fiber prior to weaving and applying a water-based gel to the towpreg prior to braiding. A 4:1 debulking of a complex 3-D woven powder-coated preform was achieved in a single step utilizing expansion rubber molding. Also, a process was developed for using powder-coated towpreg to fabricate consolidated ribbon having good dimensional integrity and low voids. Such ribbon will be required for in situ fabrication of structural components via heated head advanced tow placement. To implement process control and ensure high quality ribbon, the ribbonizer heat transfer and pulling force were modeled from fundamental principles. Most of the new ribbons were fabricated from dry polyarylene ether and polymide powders.

Johnston, N. J.↗