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Computerized method of analysis predicts bearing loads, shaft deflections, and critical speeds for shafts coupled by rolling contact bearings to the machine housing. The bearing nonlinearities, casing as well as rotor dynamics, and rotor-imbalance forcing functions are all included in the system dynamics analysis.
High-speed and heavily loaded gearing are commonplace in the rotorcraft systems employed in helicopter and tiltrotor transmissions. The components are expected to deliver high power from the gas turbine engines to the high-torque, low-speed rotor, reducing the shaft rotational speed in the range of 25:1 to 100:1. These components are designed for high power-to-weight ratios, thus the components are fabricated as light as possible with the best materials and processing to transmit the required torque and carry the resultant loads without compromising the reliability of the drive system. This is a difficult task that is meticulously analyzed and thoroughly tested experimentally prior to being applied on a new or redesigned aircraft.
A 12-state lumped-element model is presented for a flexible rotor supported by two attractive force electromagnetic journal bearings. The rotor is modeled as a rigid disk with radial mass unbalance mounted on a flexible, massless shaft with internal damping (Jeffcott rotor). The disk is offset axially from the midspan of the shaft. Bearing dynamics in each radial direction are modeled as a parallel combination of a negative (unstable) spring and a linear current-to-force actuator. The model includes translation and rotation of the rigid mass and the first and second bending models of the flexible shaft, and it simultaneously includes internal shaft damping, gyroscopic effects, and the unstable nature of the attractive force magnetic bearings. The model is used to analyze the dependence of the system transmission zeros and open-loop poles on system parameters. The dominant open-loop poles occur in stable/unstable pairs with bandwidth dependent on the ratios of bearing (unstable) stiffnesses to rotor mass and damping dependent on the shaft spin rate. The zeros occur in complex conjugate pairs with bandwidth dependent on the ratios of shaft stiffness to rotor mass and damping dependent on the shaft spin rate. Some of the transmission zeros are non-minimum phase when the spin rate exceeds the shaft critical speed. The transmission zeros and open-loop poles impact the design of magnetic bearing control systems. The minimum loop cross-over frequency of the closed-loop system is the speed of the unstable open-loop poles. For the supercritical shaft spin rates, the presence of non-minimum phase zeros limits the distribution rejection achievable at frequencies near or above the shaft critical speed. Since non-minimum phase transmission zeros can only be changed by changing the system inputs and/or outputs, closed-loop performance is limited for supercritical spin rates unless additional force or torque actuators are added.
A stability test program was conducted to determine the effects of airspeed, collective pitch, rotor speed and shaft angle on stability and loads at speeds beyond that attained in the BMR/BO-105 flight test program. Loads and performance data were gathered at forward speeds up to 165 knots. The effect of cyclic pitch perturbations on rotor response was investigated at simulated level flight conditions. Two configuration variations were tested for their effect on stability. One variable was the control system stiffness. An axially softer pitch link was installed in place of the standard BO-105 pitch link. The second variation was the addition of elastomeric damper strips to increase the structural damping. The BMR was stable at all conditions tested. At fixed collective pitch, shaft angle and rotor speed, damping generally increased between hover and 60 knots, remained relatively constant from 60 to 90 knots, then decreased above 90 knots. Analytical predictions are in good agreement with test data up to 90 knots, but the trend of decreasing damping above 90 knots is contrary to the theory.
Coupling, developed for rotor of lift/cruise aircraft, employs two clutches for smooth transmission of power from gas-turbine engine to rotor. Prior to ascent, coupling applies friction-type transition clutch that accelerates rotor shaft to speeds matching those of engine shaft. Once shafts synchronized, spline coupling engaged and friction clutch released to provide positive mechanical drive.
Design analysis, fabrication, and experimental evaluation were performed on three self-acting facetype LOX seal designs and one circumferential-type helium deal design. The LOX seals featured Rayleigh step lift pad and spiral groove geometry for lift augmentation. Machined metal bellows and piston ring secondary seal designs were tested. The helium purge seal featured floating rings with Rayleigh step lift pads. The Rayleigh step pad piston ring and the spiral groove LOX seals were successfully tested for approximately 10 hours in liquid oxygen. The helium seal was successfully tested for 24 hours. The shrouded Rayleigh step hydrodynamic lift pad LOX seal is feasible for advanced, small, high-speed oxygen turbopumps.
Shaft riding circumferential seal is used with turbine engines under high pressure conditions. Construction of seal is discussed and schematic diagram to show operations is provided.
The experimental X-29A forward swept-wing aircraft has many unique and critical systems that require constant monitoring during ground or flight operation. One such system is the power takeoff shaft, which is the mechanical link between the engine and the aircraft-mounted accessory drive. The X-29A power takeoff shaft opertes in a range between 0 and 16,810 rpm, is longer than most jet engine power takeoff shafts, and is made of graphite epoxy material. Since the X-29A aircraft operates on a single engine, failure of the shaft during flight could lead to loss of the aircraft. The monitoring techniques and test methods used during power takeoff shaft ground and flight operations are discussed. Test data are presented in two case studies where monitoring and testing of the shaft dynamics proved instrumental in discovering and isolating X-29A power takeoff shaft problems. The first study concerns the installation of an unbalanced shaft. The effect of the unbalance on the shaft vibration data and the procedure used to correct the problem are discussed. The second study deals with the shaft exceeding the established vibration limits during flight. This case study found that the vibration of connected rotating machinery unbalances contributed to the excessive vibration level of the shaft. The procedures used to identify the contributions of other rotating machinery unbalances to the power takeoff shaft unbalance are discussed.
Concentrating Solar Power (CSP) plants with Thermal Energy Storage (TES), require compressors capable of circulating supercritical carbon dioxide (sCO2) heat transfer fluids (HTFs) at temperatures from 500 to 700+°C and pressures from 8 to 25 MPa (80 to 250 Bar or 1160 to 3626 psia) in order to achieve thermal-to-electric efficiencies >50%. A review of papers relating to SCO2 compressors reveals that in almost every case the conditions being considered either allow for cooling of the SCO2 working fluid or are considering operating conditions close to the critical point at a temperature and pressure of approximately 31°C and 1070 psi). While the technology reported in these papers is relevant to most turbomachinery, the current CSP gas pathway circulator operating pressures are well above the CO2 critical point and do not allow for cooling of the main HTF flow. The purpose of this paper was to describe the key system issues affecting the design of a HTF circulator that could be scaled from a small size research and proof of concept circulator compressor to sizes supporting power plants producint upwards of 100 to 300 Mega Watts of electrical power. Due to the high temperatures and pressures the research scale HTF circulator was designed to be hermetically sealed to prevent leakage of the super critical carbon dioxide to the environment. In order to achieve hermetic sealing the drive motor and centrifugal impeller were fully integrated in a single shaft system configuration. From a preliminary assessment of compression power as a function of operating speed and impeller diameter it was determined that a smaller, higher speed impeller would result in a more efficient circulator. However, due to the high pressure and corresponding density of the sCO2 coupled with high operating speeds, large windage losses (i.e., viscous drag on the high speed rotating shaft) would occur which could result in a substantial reduction in efficiency of the system. Therefore tradoff studies were complerted to identify the operating speeds and system component sizes to achieve high efficiency. Based on the trade studies, the final design was a 55 mm diamter compressor impeller operating at speeds to 85,000 rpm. The unit will be built and tested in the future. Key Words: Super Critical Carbon Dioxide, Heat Transfer Fluid, Turbomachinery, Compressor, Circulator, Critical Point, Concentrating Solar Power, Solar Energy
A seal assembly is provided for reducing the escape of fluids from between a housing and a shaft rotably mounted in the housing. The seal assembly comprises a pair of seal rings resiliently connected to each other and disposed in side-by-side relationship. In each seal ring, both the internal bore surface and the radial face which faces away from the other seal ring are provided with a plurality of equi-spaced recesses. The seal faces referred to are located adjacent a seating surface of the housing. Under normal operating conditions, the seal assembly is stationary with respect to the housing, and the recesses generate life, keep the assembly spaced from the rotating shaft and allow slip therebetween. The seal assembly can seize on the shaft, and slip will then occur between the radial faces and the housing.
Three self acting lift pad liquid oxygen face seals and two self acting gaseous helium circumferential seals for high speed liquid oxygen turbopump were evaluated. The development of a technology for reliable, 10 hour life, multiple start seals for use in high speed liquid oxygen turbopumps is discussed.
The NASA Lewis Research Center has developed and implemented a time-efficient methodology for dynamically balancing turbomachinery shafting. This methodology minimizes costly facility downtime by using a balancing arbor (mandrel) that simulates the turbomachinery (rig) shafting. The need for precision dynamic balancing of turbomachinery shafting and for a dynamic balancing methodology is discussed in detail. Additionally, the inherent problems (and their causes and effects) associated with unbalanced turbomachinery shafting as a function of increasing shaft rotational speeds are discussed. Included are the design criteria concerning rotor weight differentials for rotors made of different materials that have similar parameters and shafting. The balancing methodology for applications where rotor replaceability is a requirement is also covered. This report is intended for use as a reference when designing, fabricating, and troubleshooting turbomachinery shafting.
Optimization is applied to the design of a spiral bevel gear reduction for maximum life at a given size. A modified feasible directions search algorithm permits a wide variety of inequality constraints and exact design requirements to be met with low sensitivity to initial values. Gear tooth bending strength and minimum contact ratio under load are included in the active constraints. The optimal design of the spiral bevel gear reduction includes the selection of bearing and shaft proportions in addition to gear mesh parameters. System life is maximized subject to a fixed backcone distance of the spiral bevel gear set for a specified speed reduction, shaft angle, input torque, and power. Design examples show the influence of the bearing lives on the gear parameters in the optimal configurations. For a fixed back-cone distance, optimal designs with larger shaft angles have larger service lives.
Optimization is applied to the design of a spiral bevel gear reduction for maximum life at a given size. A modified feasible directions search algorithm permits a wide variety of inequality constraints and exact design requirements to be met with low sensitivity to initial values. Gear tooth bending strength and minimum contact ratio under load are included in the active constraints. The optimal design of the spiral bevel gear reduction includes the selection of bearing and shaft proportions in addition to gear mesh parameters. System life is maximized subject to a fixed back-cone distance of the spiral bevel gear set for a specified speed ratio, shaft angle, input torque, and power. Significant parameters in the design are: the spiral angle, the pressure angle, the numbers of teeth on the pinion and gear, and the location and size of the four support bearings. Interpolated polynomials expand the discrete bearing properties and proportions into continuous variables for gradient optimization. After finding the continuous optimum, a designer can analyze near optimal designs for comparison and selection. Design examples show the influence of the bearing lives on the gear parameters in the optimal configurations. For a fixed back-cone distance, optimal designs with larger shaft angles have larger service lives.
Proposed fiber-optic sensor monitors axial position of shaft or bearing in turbomachine. Device senses position of non-magnetic as well as magnetic material and calibrates before assembly in machine. More compact. Concept extends to measure rotational speed of shaft.
A new test rig has been developed for simulating high-speed turbomachinery shafting using Oil-Free foil air bearing technology. Foil air journal bearings are self-acting hydrodynamic bearings with a flexible inner sleeve surface using air as the lubricant. These bearings have been used in turbomachinery, primarily air cycle machines, for the past four decades to eliminate the need for oil lubrication. More recently, interest has been growing in applying foil bearings to aircraft gas turbine engines. They offer potential improvements in efficiency and power density, decreased maintenance costs, and other secondary benefits. The goal of applying foil air bearings to aircraft gas turbine engines prompted the fabrication of this test rig. The facility enables bearing designers to test potential bearing designs with shafts that simulate the rotating components of a target engine without the high cost of building actual flight hardware. The data collected from this rig can be used to make changes to the shaft and bearings in subsequent design iterations. The rest of this article describes the new test rig and demonstrates some of its capabilities with an initial simulated shaft system. The test rig has two support structures, each housing a foil air journal bearing. The structures are designed to accept any size foil journal bearing smaller than 63 mm (2.5 in.) in diameter. The bearing support structures are mounted to a 91- by 152-cm (3- by 5-ft) table and can be separated by as much as 122 cm (4 ft) and as little as 20 cm (8 in.) to accommodate a wide range of shaft sizes. In the initial configuration, a 9.5-cm (3.75-in.) impulse air turbine drives the test shaft. The impulse turbine, as well as virtually any number of "dummy" compressor and turbine disks, can be mounted on the shaft inboard or outboard of the bearings. This flexibility allows researchers to simulate various engine shaft configurations. The bearing support structures include a unique bearing mounting fixture that rotates to accommodate a laserbased alignment system. This can measure the misalignment of the bearing centers in each of 2 translational degrees of freedom and 2 rotational degrees of freedom. In the initial configuration, with roughly a 30.5-cm- (12-in.-) long shaft, two simulated aerocomponent disks, and two 50.8-cm (2-in.) foil journal bearings, the rig can operate at 65,000 rpm at room temperature. The test facility can measure shaft displacements in both the vertical and horizontal directions at each bearing location. Horizontal and vertical structural vibrations are monitored using accelerometers mounted on the bearing support structures. This information is used to determine system rotordynamic response, including critical speeds, mode shapes, orbit size and shape, and potentially the onset of instabilities. Bearing torque can be monitored as well to predict the power loss in the foil bearings. All of this information is fed back and forth between NASA and the foil bearing designers in an iterative fashion to converge on a final bearing and shaft design for a given engine application. In addition to its application development capabilities, the test rig offers several unique capabilities for basic bearing research. Using the laser alignment system mentioned earlier, the facility will be used to map foil air journal bearing performance. A known misalignment of increasing severity will be induced to determine the sensitivity of foil bearings to misalignment. Other future plans include oil-free integral starter generator testing and development, and dynamic load testing of foil journal bearings.
A high pressure, high-temperature turbine test facility constructed for use in turbine cooling research is described. Several recently developed temperature and pressure measuring techniques are used in this facility. The measurement techniques, their status, previous applications and some results are discussed. Noncontact surface temperature measurements are made by optical methods. Radiation pyrometry principles combined with photoelectric scanning are used for rotating components and infrared photography for stationary components. Contact (direct) temperature and pressure measurements on rotating components are expected to be handled with an 80 channel rotary data package which mounts on and rotates with the turbine shaft at speeds up to 17,500 rpm. The data channels are time-division multiplexed and converted to digital words in the data package. A rotary transformer couples power and digital data to and from the shaft.
A high pressure, high-temperature turbine test facility is being constructed at the NASA Lewis Research Center for use in turbine cooling research. Several recently developed temperature and pressure measuring techniques will be used in this facility. This paper describes these measurement techniques, their status, previous applications and some results. Noncontact surface temperature measurements will be made by optical methods. Radiation pyrometry principles combined with photoelectric scanning will be used for rotating components and infrared photography for stationary components. Contact (direct) temperature and pressure measurements on rotating components will be handled with an 80-channel rotary data package which mounts on and rotates with the turbine shaft at speeds up to 17,500 rpm. The data channels are time-division multiplexed and converted to digital words in the data package. A rotary transformer couples power and digital data to and from the shaft.