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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 253 records · Page 14
All sourcesNASA NTRSDOE OSTI
NASA NTRS2013

Study and Sub-System Optimization of Propulsion and Drive Systems for the Large Civil TiltRotor (LCTR2) Rotorcraft

In a series of study tasks conducted as a part of NASA's Fundamental Aeronautics Program, Rotary Wing Project, Boeing and Rolls-Royce explored propulsion, drive, and rotor system options for the NASA Large Civil Tilt Rotor (LCTR2) concept vehicle. The original objective of this study was to identify engine and drive system configurations to reduce rotor tip speed during cruise conditions and quantify the associated benefits. Previous NASA studies concluded that reducing rotor speed (from 650 fps hover tip speed) during cruise would reduce vehicle gross weight and fuel burn. Initially, rotor cruise speed ratios of 54% of the hover tip speed were of most interest during operation at cruise air speed of 310 ktas. Interim results were previously reported1 for cruise tip speed ratios of 100%, 77%, and 54% of the hover tip speed using engine and/or gearbox features to achieve the reduction. Technology levels from commercial off-the-shelf (COTS), through entry-in-service (EIS) dates of 2025 and 2035 were considered to assess the benefits of advanced technology on vehicle gross weight and fuel burn. This technical paper presents the final study results in terms of vehicle sizing and fuel burn as well as Operational and Support (O&S) costs. New vehicle sizing at rotor tip speed reduced to 65% of hover is presented for engine performance with an EIS 2035 fixed geometry variable speed power turbine. LCTR2 is also evaluated for missions range cases of 400, 600, 800, 1000, and 1200 nautical miles and cruise air speeds of 310, 350 and 375 ktas.

Robuck, Mark↗
NASA NTRS2014

Engine Power Turbine and Propulsion Pod Arrangement Study

A study has been conducted for NASA Glenn Research Center under contract NNC10BA05B, Task NNC11TA80T to identify beneficial arrangements of the turboshaft engine, transmissions and related systems within the propulsion pod nacelle of NASA's Large Civil Tilt-Rotor 2nd iteration (LCTR2) vehicle. Propulsion pod layouts were used to investigate potential advantages, disadvantages, as well as constraints of various arrangements assuming front or aft shafted engines. Results from previous NASA LCTR2 propulsion system studies and tasks performed by Boeing under NASA contracts are used as the basis for this study. This configuration consists of two Fixed Geometry Variable Speed Power Turbine Engines and related drive and rotor systems (per nacelle) arranged in tilting nacelles near the wing tip. Entry-into-service (EIS) 2035 technology is assumed for both the engine and drive systems. The variable speed rotor system changes from 100 percent speed for hover to 54 percent speed for cruise by the means of a two speed gearbox concept developed under previous NASA contracts. Propulsion and drive system configurations that resulted in minimum vehicle gross weight were identified in previous work and used here. Results reported in this study illustrate that a forward shafted engine has a slight weight benefit over an aft shafted engine for the LCTR2 vehicle. Although the aft shafted engines provide a more controlled and centered CG (between hover and cruise), the length of the long rotor shaft and complicated engine exhaust arrangement outweighed the potential benefits. A Multi-Disciplinary Analysis and Optimization (MDAO) approach for transmission sizing was also explored for this study. This tool offers quick analysis of gear loads, bearing lives, efficiencies, etc., through use of commercially available RomaxDESIGNER software. The goal was to create quick methods to explore various concept models. The output results from RomaxDESIGNER have been successfully linked to Boeing spreadsheets that generate gear tooth geometry in Catia 3D environment. Another initial goal was to link information from RomaxDESIGNER (such as hp, rpm, gear ratio) to populate Boeing's parametric weight spreadsheet and create an automated method to estimate drive system weight. This was only partially achieved due to the variety of weight models, number of manual inputs, and qualitative assessments required. A simplified weight spreadsheet was used with data inputs from RomaxDESIGNER along with manual inputs to perform rough weight calculations.

Robuck, Mark↗
NASA NTRS2014

Aerodynamic Limits on Large Civil Tiltrotor Sizing and Efficiency

The NASA Large Civil Tiltrotor (2nd generation, or LCTR2) has been the reference design for avariety of NASA studies of design optimization, engine and gearbox technology, handling qualities, andother areas, with contributions from NASA Ames, Glenn and Langley Centers, plus academic and industrystudies. Ongoing work includes airfoil design, 3D blade optimization, engine technology studies, andwingrotor aerodynamic interference. The proposed paper will bring the design up to date with the latestresults of such studies, then explore the limits of what aerodynamic improvements might hope toaccomplish. The purpose is two-fold: 1) determine where future technology studies might have the greatestpayoff, and 2) establish a stronger basis of comparison for studies of other vehicle configurations andmissions.

Large Civil Tiltrotor↗
NASA NTRS2014

Counter-Rotatable Fan Gas Turbine Engine with Axial Flow Positive Displacement Worm Gas Generator

A counter-rotatable fan turbine engine includes a counter-rotatable fan section, a worm gas generator, and a low pressure turbine to power the counter-rotatable fan section. The low pressure turbine maybe counter-rotatable or have a single direction of rotation in which case it powers the counter-rotatable fan section through a gearbox. The gas generator has inner and outer bodies having offset inner and outer axes extending through first, second, and third sections of a core assembly. At least one of the bodies is rotatable about its axis. The inner and outer bodies have intermeshed inner and outer helical blades wound about the inner and outer axes and extending radially outwardly and inwardly respectively. The helical blades have first, second, and third twist slopes in the first, second, and third sections respectively. A combustor section extends through at least a portion of the second section.

Giffin, Rollin George↗
NASA NTRS2014

Braided Composite Technologies for Rotorcraft Structures

A&P Technology has developed a braided material approach for fabricating lightweight, high-strength hybrid gears for aerospace drive systems. The conventional metallic web was replaced with a composite element made from A&P's quasi-isotropic braid. The 0deg, plus or minus 60 deg braid architecture was chosen so that inplane stiffness properties and strength would be nearly equal in all directions. The test results from the Phase I Small Spur Gear program demonstrated satisfactory endurance and strength while providing a 20 percent weight savings. (Greater weight savings is anticipated with structural optimization.) The hybrid gears were subjected to a proof-of-concept test of 1 billion cycles in a gearbox at 10,000 revolutions per minute and 490 in-lb torque with no detectable damage to the gears. After this test the maximum torque capability was also tested, and the static strength capability of the gears was 7x the maximum operating condition. Additional proof-of-concept tests are in progress using a higher oil temperature, and a loss-of-oil test is planned. The success of Phase I led to a Phase II program to develop, fabricate, and optimize full-scale gears, specifically Bull Gears. The design of these Bull Gears will be refined using topology optimization, and the full-scale Bull Gears will be tested in a full-scale gear rig. The testing will quantify benefits of weight savings, as well as noise and vibration reduction. The expectation is that vibration and noise will be reduced through the introduction of composite material in the vibration transmission path between the contacting gear teeth and the shaft-and-bearing system.

Jessie, Nathan↗
NASA NTRS2014

Embedded Data Acquisition Tools for Rotorcraft Diagnostic Sensors

Rotorcraft drive trains must withstand enormous pressure while operating continuously in extreme temperature and vibration environments. Captive components, such as planetary and spiral bevel gears, see enormous strain but are not accessible to fixed instrumentation, such as a piezoelectric transducer. Thus, it is difficult to directly monitor components that are most susceptible to damage. This innovation is a self-contained data processing unit within a specialized fixture that installs directly inside the rotating pinion gear in the gearbox. From this location, it detects and transmits high-resolution prognostic data to a fixed transceiver. The sensor is based on microelectromechanical systems (MEMS) technology and uses innovative circuit designs to capture high-bandwidth data and transmit it wirelessly from inside an operational helicopter transmission. With Ridgetop's advanced MEMS-based sensor, researchers have, for the first time, been able to extract high-resolution acoustic signatures wirelessly from sensors within the transmission that would otherwise be muffled by background gear noises. Ridgetop's innovative instrument will help researchers perform dynamic analysis of gear interaction and develop improved designs for gear components. In addition, data from this instrument can be used to validate new algorithms that detect and predict faults based on external acoustic signatures, for prognostic purposes. The result of this work will be an improvement in safety, performance, and cost for future generations of rotating components.

Wagoner, Robert↗
NASA NTRS2010

Mars Science Laboratory Rover Actuator Thermal Design

NASA will launch a 900 kg rover, part of the Mars Science Laboratory (MSL) mission, to Mars in October of 2011. The MSL rover is scheduled to land on Mars in August of 2012. The rover employs 31, electric-motor driven actuators to perform a variety of engineering and science functions including: mobility, camera pointing, telecommunications antenna steering, soil and rock sample acquisition and sample processing. This paper describes the MSL rover actuator thermal design. The actuators have stainless steel housings and planetary gearboxes that are lubricated with a "wet" lubricant. The lubricant viscosity increases with decreasing temperature. Warm-up heaters are required to bring the actuators up to temperature (above -55 C) prior to use in the cold wintertime environment of Mars (when ambient atmosphere temperatures are as cold as -113 C). Analytical thermal models of all 31 MSL actuators have been developed. The actuators have been analyzed and warm-up heaters have been designed to improve actuator performance in cold environments. Thermal hardware for the actuators has been specified, procured and installed. This paper presents actuator thermal analysis predicts, and describes the actuator thermal hardware and its operation. In addition, warm-up heater testing and thermal model correlation efforts for the Remote Sensing Mast (RSM) elevation actuator are discussed.

Novak, Keith S.↗
NASA NTRS2015

Braided Composite Technologies for Rotorcraft Structures

A&P Technology has developed a braided material approach for fabricating lightweight, high-strength hybrid gears for aerospace drive systems. The conventional metallic web was replaced with a composite element made from A&P's quasi-isotropic braid. The 0deg, +/-60deg braid architecture was chosen so that inplane stiffness properties and strength would be nearly equal in all directions. The test results from the Phase I Small Spur Gear program demonstrated satisfactory endurance and strength while providing a 20 percent weight savings. (Greater weight savings is anticipated with structural optimization.) The hybrid gears were subjected to a proof-of-concept test of 1 billion cycles in a gearbox at 10,000 revolutions per minute and 490 in-lb torque with no detectable damage to the gears. After this test the maximum torque capability was also tested, and the static strength capability of the gears was 7x the maximum operating condition. Additional proof-of-concept tests are in progress using a higher oil temperature, and a loss-of-oil test is planned. The success of Phase I led to a Phase II program to develop, fabricate, and optimize full-scale gears, specifically Bull Gears. The design of these Bull Gears will be refined using topology optimization, and the full-scale Bull Gears will be tested in a full-scale gear rig. The testing will quantify benefits of weight savings, as well as noise and vibration reduction. The expectation is that vibration and noise will be reduced through the introduction of composite material in the vibration transmission path between the contacting gear teeth and the shaft-and-bearing system.

Jessie, Nathan↗
NASA NTRS2016

Health Monitoring Survey of Bell 412EP Transmissions

Health and usage monitoring systems (HUMS) use vibration-based Condition Indicators (CI) to assess the health of helicopter powertrain components. A fault is detected when a CI exceeds its threshold value. The effectiveness of fault detection can be judged on the basis of assessing the condition of actual components from fleet aircraft. The Bell 412 HUMS-equipped helicopter is chosen for such an evaluation. A sample of 20 aircraft included 12 aircraft with confirmed transmission and gearbox faults (detected by CIs) and eight aircraft with no known faults. The associated CI data is classified into "healthy" and "faulted" populations based on actual condition and these populations are compared against their CI thresholds to quantify the probability of false alarm and the probability of missed detection. Receiver Operator Characteristic analysis is used to optimize thresholds. Based on the results of the analysis, shortcomings in the classification method are identified for slow-moving CI trends. Recommendations for improving classification using time-dependent receiver-operator characteristic methods are put forth. Finally, lessons learned regarding OEM-operator communication are presented.

mechanical components↗
NASA NTRS2016

A Review of Noise and Vibration Control Technologies for Rotorcraft Transmissions

An expanded commercial use of rotorcraft can alleviate runway congestion and improve the accessibility of routine air travel. To date, commercial use has been hindered by excessive cabin noise. The primary noise source is structure-borne vibration originating from the main rotor gearbox. Despite significant advancements in gear design, the gear mesh tones generated often exceed 100 dB. This paper summarizes the findings of a literature survey of vibration control technologies that serve to attenuate this vibration near the source, before it spreads into the airframe and produces noise. The scope is thus limited to vibration control treatments and modifications of the gears, driveline, housing structures, and the strut connections to the airframe. The findings of the literature are summarized and persistent and unresolved issues are identified. An emphasis is placed on components and systems that have been demonstrated in flight vehicles. Then, a discussion is presented of emerging technologies that have the potential to make significant advancements over the state of the art.

cabin noise↗
NASA NTRS2015

Gear Tooth Wear Detection Algorithm

Vibration-based condition indicators continue to be developed for Health Usage Monitoring of rotorcraft gearboxes. Testing performed at NASA Glenn Research Center have shown correlations between specific condition indicators and specific types of gear wear. To speed up the detection and analysis of gear teeth, an image detection program based on the Viola-Jones algorithm was trained to automatically detect spiral bevel gear wear pitting. The detector was tested using a training set of gear wear pictures and a blind set of gear wear pictures. The detector accuracy for the training set was 75 percent while the accuracy for the blind set was 15 percent. Further improvements on the accuracy of the detector are required but preliminary results have shown its ability to automatically detect gear tooth wear. The trained detector would be used to quickly evaluate a set of gear or pinion pictures for pits, spalls, or abrasive wear. The results could then be used to correlate with vibration or oil debris data. In general, the program could be retrained to detect features of interest from pictures of a component taken over a period of time.

Delgado, Irebert R.↗
NASA NTRS2017

Baseline Experimental Results on the Effect of Oil Temperature on Shrouded Meshed Spur Gear Windage Power Loss

Rotorcraft gearbox efficiencies are reduced at increased surface speeds due to viscous and impingement drag on the gear teeth. This windage power loss can affect overall mission range, payload, and frequency of transmission maintenance. Experimental and analytical studies on shrouding for single gears have shown it be potentially effective in mitigating windage power loss. Efficiency studies on unshrouded meshed gears have shown the effect of speed, oil viscosity, temperature, load, lubrication scheme, etc. on gear windage power loss. The open literature does not cite data on shrouded meshed spur gears. Gear windage power loss test results are presented on shrouded meshed spur gears at elevated oil inlet temperatures and constant oil pressure both with and without shrouding. Shroud effectiveness is compared at four oil inlet temperatures. The results are compared to the available literature and follow-up work is outlined.

windage↗
NASA NTRS2016

A Review of Noise and Vibration Control Technologies for Rotorcraft Transmissions

An expanded commercial use of rotorcraft can alleviate runway congestion and improve the accessibility of routine air travel. To date, commercial use has been hindered by excessive cabin noise. The primary noise source is structure-borne vibration originating from the main rotor gearbox. Despite significant advancements in gear design, the gear mesh tones generated often exceed 100 dB. This paper summarizes the findings of a literature survey of vibration control technologies that serve to attenuate this vibration near the source, before it spreads into the airframe and produces noise. The scope is thus limited to vibration control treatments and modifications of the gears, driveline, housing structures, and the strut connections to the airframe. The findings of the literature are summarized and persistent and unresolved issues are identified. An emphasis is placed on components and systems that have been demonstrated in flight vehicles. Then, a discussion is presented of emerging technologies that have the potential to make significant advancements over the state of the art.

cabin noise↗
NASA NTRS2017

Dynamic Analysis for a Geared Turbofan Engine with Variable Area Fan Nozzle

Aggressive design goals have been set for future aero-propulsion systems with regards to fuel economy, noise, and emissions. To meet these challenging goals, advanced propulsion concepts are being explored and current operating margins are being re-evaluated to find additional concessions that can be made. One advanced propulsion concept being evaluated is a geared turbofan with a variable area fan nozzle (VAFN), developed by NASA. This engine features a small core, a fan driven by the low pressure turbine through a reduction gearbox, and a shape memory alloy (SMA)-actuated VAFN. The VAFN is designed to allow both a small exit area for efficient operation at cruise, while being able to open wider at high power conditions to reduce backpressure on the fan and ensure a safe level of stall margin is maintained. The VAFN is actuated via a SMA-based system instead of a conventional system to decrease overall weight of the system, however, SMA-based actuators respond relatively slowly, which introduces dynamic issues that are investigated in this work. This paper describes both a control system designed specifically for issues associated with SMAs, and dynamic analysis of the geared turbofan VAFN with the SMA actuators. Also, some future recommendations are provided for this type of propulsion system.

N+3↗
NASA NTRS2017

Baseline Experimental Results on the Effect of Oil Temperature on Shrouded Meshed Spur Gear Windage Power Loss

Rotorcraft gearbox efficiencies are reduced at increased surface speeds due to viscous and impingement drag on the gear teeth. This windage power loss can affect overall mission range, payload, and frequency of transmission maintenance. Experimental and analytical studies on shrouding for single gears have shown it to be potentially effective in mitigating windage power loss. Efficiency studies on unshrouded meshed gears have shown the effect of speed, oil viscosity, temperature, load, lubrication scheme, etc. on gear windage power loss. The open literature does not contain experimental test data on shrouded meshed spur gears. Gear windage power loss test results are presented on shrouded meshed spur gears at elevated oil inlet temperatures and constant oil pressure both with and without shrouding. Shroud effectiveness is compared at four oil inlet temperatures. The results are compared to the available literature and follow-up work is outlined.

gear↗
NASA NTRS2018

The Jetting Phenomena in Meshed Spur Gears

Rotorcraft gearbox transmissions are required to efficiently transfer power from the turbine engine to the main and tail rotor blades. Losses in transmission efficiency impact mission payload and aircraft range. These systems are expected to deliver high power with high gear pitch line velocities. More recently, shrouding has been employed to reduce windage power losses associated with the high gear rotational speeds. However, recent experimental results from tests conducted by the authors show the negative impact of close clearance shrouds on windage power loss, particularly at the meshed region where flow is ejected, or jetted, from the collapsing tooth spaces. A literature review was conducted to gain further insight into the phenomenon of gear mesh jetting and strategies to mitigate and control the associated losses. An analysis was conducted on windage losses in the mesh region. Test results are given for a modified shroud configuration. Finally, a discussion on observed trends follows with suggestions on future research.

windage↗
NASA NTRS2017

Evaluation of a Variable Thickness Hybrid Composite Bull Gear

For several years, NASA Glenn Research Center and the U.S. Army Research Laboratory have been investigating hybrid (composite/steel) gear technology for use in vertical lift drive systems. The hybrid gear concept replaces the structural portion of a gear between the shaft and the gear rim with a lightweight carbon fiber composite, in an effort to reduce the overall weight of a gear and increase the drive system power density. Past research includes both small-scale and large-scale hybrid gear concepts, all of which have a constant composite thickness throughout. The design described in this paper is of a variable thickness, such that the composite is thickest at the inner diameter and this thickness is gradually reduced toward the outer diameter. The resulting "stair stepped" design stems from dropping plies of the braided carbon fiber prepreg composite fabric gradually with increased radius. Additionally, the interlock pattern at the inner metallic adapter was adjusted slightly from previous designs to obtain a better stress distribution on the inner metallic adapter. The manufactured variable thickness web was tested both in static torsion tests and operationally in a relevant gearbox environment. The results of these experiments will be presented and compared to a baseline steel configuration.

Gears; Drive Systems; Rotorcraft Propulsion;↗
NASA NTRS2018

Evaluation of a Variable Thickness Hybrid Composite Bull Gear

For several years, NASA Glenn Research Center and the U.S. Army Research Laboratory have been investigating hybrid (compositesteel) gear technology for use in vertical lift drive systems. The hybrid gear concept replaces the structural portion of a gear between the shaft and the gear rim with a lightweight carbon fiber composite, in an effort to reduce the overall weight of a gear and increase the drive system power density. An overview of the concept of the hybrid gear design is described in Ref. 1, 2, and 3. The research presented in these references includes both small-scale and large-scale hybrid gear concepts all of which have a constant composite thickness throughout. The design described in this paper is of a variable thickness, such that the composite is thickest at the inner diameter and this thickness is gradually reduced toward the outer diameter. The resulting stair stepped design stems from dropping plies of the braided carbon fiber composite fabric gradually with increased radius. Additionally, the interlock pattern at the inner metallic adapter was adjusted slightly from previous designs to obtain a better stress distribution on the inner metallic adapter. The manufactured variable thickness web was tested both in static torsion tests and operationally in a relevant gearbox environment. The results of these experiments will be presented and compared to a baseline steel configuration.

Rotorcraft Propulsion↗