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At least 271 records · Page 15

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NASA NTRS1992

High speed rotorcraft propulsion concepts to control power/speed characteristics

Recent NASA sponsored rotorcraft airframer studies have demonstrated the desire for constant power over a wide range of output speed for turboshaft propulsion systems. This study interrogated several different concepts aimed at maintaining constant power over a speed variation from 100-50 percent with minimum increase in fuel consumption. The baseline engine was an advanced technology 8000 shp, fixed turbine geometry, turboshaft engine. The concepts investigated included variable geometry turbines, variable geometry compressors, power transfer from the HP to LP shafts, counterrotating power turbine with a combiner gearbox, and variable speed transmission integrated with the baseline turboshaft engine. The concept that best satisfies the program objectives with superior engine performance and with the least technical risk is the baseline (fixed geometry turbines) turboshaft engine integrated with the variable speed transmission.

Bettner, J. L.↗

NASA NTRS1993

Multivariable control of the Space Shuttle Remote Manipulator System using linearization by state feedback

This paper demonstrates an approach to nonlinear control system design that uses linearization by state feedback to allow faster maneuvering of payloads by the Shuttle Remote Manipulator System (SRMS). A nonlinear feedback law is defined to cancel the nonlinear plant dynamics so that a linear controller can be designed for the SRMS. First a nonlinear design model was generated via SIMULINK. This design model included nonlinear arm dynamics derived from the Lagrangian approach, linearized servo model, and linearized gearbox model. The current SRMS position hold controller was implemented on this system. Next, a trajectory was defined using a rigid body kinematics SRMS tool, KRMS. The maneuver was simulated. Finally, higher bandwidth controllers were developed. Results of the new controllers were compared with the existing SRMS automatic control modes for the Space Station Freedom Mission Build 4 Payload extended on the SRMS.

Gettman, Chang-Ching L.↗

NASA NTRS1994

Analytical and Experimental Vibration Analysis of a Faulty Gear System

A comprehensive analytical procedure was developed for predicting faults in gear transmission systems under normal operating conditions. A gear tooth fault model is developed to simulate the effects of pitting and wear on the vibration signal under normal operating conditions. The model uses changes in the gear mesh stiffness to simulate the effects of gear tooth faults. The overall dynamics of the gear transmission system is evaluated by coupling the dynamics of each individual gear-rotor system through gear mesh forces generated between each gear-rotor system and the bearing forces generated between the rotor and the gearbox structure. The predicted results were compared with experimental results obtained from a spiral bevel gear fatigue test rig at NASA Lewis Research Center. The Wigner-Ville distribution (WVD) was used to give a comprehensive comparison of the predicted and experimental results. The WVD method applied to the experimental results were also compared to other fault detection techniques to verify the WVD's ability to detect the pitting damage, and to determine its relative performance. Overall results show good correlation between the experimental vibration data of the damaged test gear and the predicted vibration from the model with simulated gear tooth pitting damage. Results also verified that the WVD method can successfully detect and locate gear tooth wear and pitting damage.

Choy, F. K.↗

NASA NTRS1994

Analysis of the Effects of Surface Pitting and Wear on the Vibrations of a Gear Transmission System

A comprehensive procedure to simulate and analyze the vibrations in a gear transmission system with surface pitting, 'wear' and partial tooth fracture of the gear teeth is presented. An analytical model was developed where the effects of surface pitting and wear of the gear tooth were simulated by phase and magnitude changes in the gear mesh stiffness. Changes in the gear mesh stiffness were incorporated into each gear-shaft model during the global dynamic simulation of the system. The overall dynamics of the system were evaluated by solving for the transient dynamics of each shaft system simultaneously with the vibration of the gearbox structure. In order to reduce the number of degrees-of-freedom in the system, a modal synthesis procedure was used in the global transient dynamic analysis of the overall transmission system. An FFT procedure was used to transform the averaged time signal into the frequency domain for signature analysis. In addition, the Wigner-Ville distribution was also introduced to examine the gear vibration in the joint time frequency domain for vibration pattern recognition. Experimental results obtained from a gear fatigue test rig at NASA Lewis Research Center were used to evaluate the analytical model.

Choy, F. K.↗

NASA NTRS1995

Some mechanical design aspects of the European Robotic Arm

The European Robotic Arm (ERA) is a contribution to the Russian Segment of the International Space Station Alpha. It will start operating on the Russian Segment during the assembly phase. ERA is designed and produced by a large industrial consortium spread over Europe with Fokker Space & Systems as prime contractor. In this paper, we will describe some of the overall design aspects and focus on the development of several mechanisms within ERA. The operation of ERA during the approach of its end effector towards the grapple interface and the grapple operation is discussed, with a focus on mechanisms. This includes the geometry of the end effector leading edge, which is carefully designed to provide the correct and complete tactile information to a torque-force sensor (TFS). The data from this TFS are used to steer the arm such that forces and moments are kept below 20 N and 20 N.m respectively during the grappling operation. Two hardware models of the end effector are built. The problems encountered are described as well as their solutions. The joints in the wrists and the elbow initially used a harmonic drive lubricated by MoS2. During development testing, this combination showed an insufficient lifetime in air to survive the acceptance test program. The switch-over to a system comprising planetary gearboxes with grease lubrication is described. From these development efforts, conclusions are drawn and recommendations are given for the design of complex space mechanisms.

Lambooy, Peter J.↗

NASA NTRS1996

Quantification of Gear Tooth Damage by Optimal Tracking of Vibration Signatures

This paper presents a technique for quantifying the wear or damage of gear teeth in a transmission system. The procedure developed in this study can be applied as a part of either an onboard machine health-monitoring system or a health diagnostic system used during regular maintenance. As the developed methodology is based on analysis of gearbox vibration under normal operating conditions, no shutdown or special modification of operating parameters is required during the diagnostic process. The process of quantifying the wear or damage of gear teeth requires a set of measured vibration data and a model of the gear mesh dynamics. An optimization problem is formulated to determine the profile of a time-varying mesh stiffness parameter for which the model output approximates the measured data. The resulting stiffness profile is then related to the level of gear tooth wear or damage. The procedure was applied to a data set generated artificially and to another obtained experimentally from a spiral bevel gear test rig. The results demonstrate the utility of the procedure as part of an overall health-monitoring system.

Choy, F. K.↗

NASA NTRS2001

Minimizing Load Effects on NA4 Gear Vibration Diagnostic Parameter

NA4 is a vibration diagnostic parameter, developed by researchers at NASA Glenn Research Center, for health monitoring of gears in helicopter transmissions. The NA4 reacts to the onset of gear pitting damage and continues to react to the damage as it spreads. This research also indicates NA4 reacts similarly to load variations. The sensitivity of NA4 to load changes will substantially affect its performance on a helicopter gearbox that experiences continuously changing load throughout its flight regimes. The parameter NA4 has been used to monitor gear fatigue tests at constant load. At constant load, NA4 effectively detects the onset of pitting damage and tracks damage severity. Previous research also shows that NA4 reacts to changes in load applied to the gears in the same way it reacts to the onset of pitting damage. The method used to calculate NA4 was modified to minimize these load effects. The modified NA4 parameter was applied to four sets of experimental data. Results indicate the modified NA4 is no longer sensitive to load changes, but remains sensitive to pitting damage.

Dempsey, Paula J.↗

NASA NTRS2001

2000 NASA Seal/Secondary Air System Workshop

The 2000 NASA Seal/Secondary Air System Workshop covered four main areas: (1) overviews of NASA-sponsored Ultra-Efficient Engine Technology (UEET) and Access to Space Programs, with emphasis on program goals and seal needs; (2) review of turbine engine seal issues from the perspective of end users such as United Airlines; (3) reviews of sealing concepts, test results, experimental facilities, and numerical predictions; and (4) reviews of material development programs relevant to advanced seals development. The NASA UEET overview illustrates for the reader the importance of advanced technologies, including seals, in meeting future engine system efficiency and emission goals. GE, Pratt & Whitney, and Honeywell presented advanced seal development work being performed within their organizations. The NASA-funded GE/Stein Seal team has successfully demonstrated a large (3-ft. diam) aspirating seal that can withstand all anticipated pressures, speeds, and rotor runouts anticipated for a GE90 L.P. turbine balance piston location. GE/Stein Seal are fabricating a full-scale seal to be tested in a GE-90 ground test engine in early 2002. Pratt & Whitney and Stein Seal are investigating carbon seals to accommodate large radial movements anticipated in future geared-fan gearbox locations. Honeywell presented a finger seal design being considered for a high-temperature static combustor location incorporating ceramic finger elements. Successful demonstration of the braided carbon rope thermal barriers to extreme temperatures (5500 F) for short durations provide a new form of very high temperature thermal barrier for future Shuttle solid rocket motor nozzle joints. The X-37, X-38, and future highly reusable launch vehicles pose challenging control surface seal demands that require new seal concepts made from emerging high temperature ceramics and other materials.

Steinetz, Bruce M.↗

NASA NTRS1997

Fault Detection of Rotating Machinery using the Spectral Distribution Function

The spectral distribution function is introduced to characterize the process leading to faults in rotating machinery. It is shown to be a more robust indicator than conventional power spectral density estimates, but requires only slightly more computational effort. The method is illustrated with examples from seeded gearbox transmission faults and an analytical model of a defective bearing. Procedures are suggested for implementation in realistic environments.

Davis, Sanford S.↗

NASA NTRS2002

Investigation of Dynamic Force/Vibration Transmission Characteristics of Four-Square Type Gear Durability Test Machines

In this study, design requirements for a dynamically viable, four-square type gear test machine are investigated. Variations of four-square type gear test machines have been in use for durability and dynamics testing of both parallel- and cross-axis gear set. The basic layout of these machines is illustrated. The test rig is formed by two gear pairs, of the same reduction ratio, a test gear pair and a reaction gear pair, connected to each other through shafts of certain torsional flexibility to form an efficient, closed-loop system. A desired level of constant torque is input to the circuit through mechanical (a split coupling with a torque arm) or hydraulic (a hydraulic actuator) means. The system is then driven at any desired speed by a small DC motor. The main task in hand is the isolation of the test gear pair from the reaction gear pair under dynamic conditions. Any disturbances originated at the reaction gear mesh might potentially travel to the test gearbox, altering the dynamic loading conditions of the test gear mesh, and hence, influencing the outcome of the durability or dynamics test. Therefore, a proper design of connecting structures becomes a major priority. Also, equally important is the issue of how close the operating speed of the machine is to the resonant frequencies of the gear meshes. This study focuses on a detailed analysis of the current NASA Glenn Research Center gear pitting test machine for evaluation of its resonance and vibration isolation characteristics. A number of these machines as the one illustrated has been used over last 30 years to establish an extensive database regarding the influence of the gear materials, processes surface treatments and lubricants on gear durability. This study is intended to guide an optimum design of next generation test machines for the most desirable dynamic characteristics.

Kahraman, Ahmet↗

NASA NTRS2002

Development of Face Gear Technology for Industrial and Aerospace Power Transmission

Tests of a 250 horsepower proof-of-concept (POC) split torque face gear transmission were completed by The Boeing Company in Mesa, Arizona, while working under a Defense Advanced Research Projects Agency (DARPA) Technology Reinvestment Program (TRP) This report provides a summary of these cooperative tests, which were jointly funded by Boeing and DARPA Design, manufacture and testing of the scaled-power TRP split torque gearbox followed preliminary evaluations of the concept performed early in the program The testing demonstrated the theory of operation for the concentric, tapered face gear assembly The results showed that the use of floating pinions in a concentric face gear arrangement produces a nearly even torque split The POC split torque tests determined that, with some improvements, face gears can be applied effectively in a split torque configuration which yields significant weight, cost and reliability improvements over conventional designs.

Heath, Gregory F.↗

NASA NTRS2002

Report on Project to Characterize Multi-Junction Solar Cells in the Stratosphere using Low-Cost Balloon and Communication Technologies

Balloon, control and communication technologies are under development in our laboratory for testing multi-junction solar cells in the stratosphere to achieve near AM0 conditions. One flight, Suntracker I, has been carried out reported earlier. We report on our efforts in preparation for a second flight, Suntracker II, that was aborted due to hardware problems. The package for Suntracker I system has been modified to include separate electronics and battery packs for the 70 centimeter and 2 meter systems. The collimator control system and motor gearboxes have been redesigned to address problems with the virtual stops and backlash. Surface mount technology on a printed circuit board was used in place of the through-hole prototype circuit in efforts to reduce weight and size, and improve reliability. A mobile base station has been constructed that includes a 35' tower with a two axis rotator and multi-element yagi antennas. Modifications in Suntracker I and the factors that lead to aborting Suntracker II are discussed.

Mirza, Ali↗

NASA NTRS2003

Development of Novel Methods for the Reduction of Noise and Weight in Helicopter Transmissions

Over the 70-year evolution of the helicopter, man's understanding of vibration control has greatly increased. However, in spite of the increased performance, the extent of helicopter vibration problems has not significantly diminished. Crew vibration and noise remains important factors in the design of all current helicopters. With more complex and critical demands being placed on aircrews, it is essential that vibration and noise not impair their performance. A major source of helicopter cabin noise (which has been measured at a sound pressure level of over 100 dB) is the gearbox. Reduction of this noise has been a goal of NASA and the U.S. Army. Gear mesh noise is typically in the frequency range of 1000 to 3000 Hz, a range important for speech. A requirement for U.S. Army/NASA Advanced Rotorcraft Transmission project has been a 10-dB reduction compared to current designs. A combined analytical/experimental effort has been underway, since the end of the 80's, to study effects of design parameters on noise production. The noise generated by the gear mesh can be transmitted to the surrounding media through the bearings that support the gear shaft. Therefore, the use of fluid film bearings instead of rolling element bearings could reduce the transmission noise by 10 dB. In addition, the fluid film bearings that support the gear shaft can change the dynamics of the gear assembly by providing damping to the system and by being softer than rolling element bearings. Wave bearings can attenuate, and filter, the noise generated by a machine component due to the dynamic stiffness and damping coefficients. The attenuation ratio could be as large as 35-40 dB. The noise components at higher frequencies than a synchronous frequency can be almost eliminated.

Dimofte, Florin↗

NASA NTRS2003

Threshold Assessment of Gear Diagnostic Tools on Flight and Test Rig Data

A method for defining thresholds for vibration-based algorithms that provides the minimum number of false alarms while maintaining sensitivity to gear damage was developed. This analysis focused on two vibration based gear damage detection algorithms, FM4 and MSA. This method was developed using vibration data collected during surface fatigue tests performed in a spur gearbox rig. The thresholds were defined based on damage progression during tests with damage. The thresholds false alarm rates were then evaluated on spur gear tests without damage. Next, the same thresholds were applied to flight data from an OH-58 helicopter transmission. Results showed that thresholds defined in test rigs can be used to define thresholds in flight to correctly classify the transmission operation as normal.

Dempsey, Paula J.↗

NASA NTRS2004

Whirl Flutter Studies for a SSTOL Transport Demonstrator

A proposed new class of aircraft - the Advanced Theater Transport (ATT) will combine strategic range and high payload with 'Super-STOL' (short take-off and landing) capability. It is also proposed to modify a YC-15 into a technology demonstrator with a 20-deg tilt wing; four, eight-bladed propellers; cross-shafted gearboxes and V-22 engines. These constitute a unique combination of design features that potentially affect performance, loads and whirl-mode stability (whirl flutter). NASA Ames Research Center is working with Boeing and Hamilton Sundstrand on technology challenges presented by the concept; the purpose of NASA involvement is to establish requirements for the demonstrator and for early design guidance, with emphasis on whirl flutter. CAMRAD II is being used to study the effects of various design features on whirl flutter, with special attention to areas where such features differ from existing aircraft, notably tiltrotors. Although the stability margins appear to be more than adequate, the concept requires significantly different analytical methods, principally including far more blade modes, than typically used for tiltrotors.

Acree, C. W., Jr.↗

NASA NTRS2004

Model-Biased, Data-Driven Adaptive Failure Prediction

This final report, which contains a research summary and a viewgraph presentation, addresses clustering and data simulation techniques for failure prediction. The researchers applied their techniques to both helicopter gearbox anomaly detection and segmentation of Earth Observing System (EOS) satellite imagery.

Leen, Todd K.↗

NASA NTRS1996

Study of Gear Dynamic Forces Completed

Gearbox-generated noise and vibration is objectionable in many vehicles, particularly helicopters. This noise excitation is caused by the load fluctuation as gear teeth enter and leave mesh. In high-quality gears, a common technique to reduce gear noise and vibration is to modify the tooth profile. Gear noise reduction is a NASA and U.S. Army goal, and a NASA/U.S. Army research project sponsored development of gear dynamics computer codes to help design quiet gears. As part of this project, a series of experiments was performed in the NASA Lewis Research Center's Gear Noise Rig to develop a data base of dynamic test data and to validate the predictions of the codes for several gear designs under a variety of test conditions.

Source record↗

NASA NTRS2004

Refining the W1 and SE1 Facilities

The Engine Research Building (ERB) houses more than 60 test rigs that study all aspects of engine development. By working with Mary Gibson in the SE1 and W1A Turbine Facilities, I became aware of her responsibilities and better acquainted with the inner workings of the ERB. The SE1 Supersonic/Subsonic Wind Tunnel Facility contains 2 small wind tunnels. The first tunnel uses an atmospheric inlet, while the second uses treated 40-psig air. Both of the tunnels are capable of subsonic and supersonic operation. An auxiliary air supply and exhaust piping providing both test sections with suction, blowing, and crossfire capabilities. The current configuration of SE1 consists of a curved diffuser that studies the blockage along the endwalls. The W1A Low Speed Compressor Facility provides insight for the complex flow phenomena within its 4-stage axial compressor, sand the data obtained from W 1A is used to develop advanced models for fluid dynamic assessment. W1A is based off of a low speed research compressor developed by GE in the 1950's. This compressor has a removable casing treatment under rotor 1, which allows for various tip treatment studies. The increased size and low speed allows instrumentation to be located in the compressor s complex flow paths. Air enters the facility through a filtered roof vent, conditioned for temperature and turbulence, and then passed through the compressor W1A is described as a dynamic facility with many projects taking place simultaneously. This current environment makes it challenging to follow the various affairs that are taking place within the area. During my first 4 weeks at the NASA Glenn Research Center, I have assisted Mary Gibson in multiple tasks such as facility documents, record keeping, maintenance and upgrades. The facility has lube systems for its gearbox and compressor. These systems are critical in the successful operation of the facility. I was assigned the task of creating a facility estimate list, which included the filters and strainers required for the compressor. For my remaining time spent here, we expect to complete a facility parts listing and a virtual project summary so that W1A and SE1 will become ergonomic facilities that will make it easier for people to observe the capabilities and history of the area and the employees that operate. Bolstering our efforts in achieving these goal are the online technical tutorials, software such as Microsoft Excel. Macromedia Flash MX Macromedia Dreamweaver MX, Photoshop 6.0 and the assistance of several NASA employees.

Chambers, Rodney D.↗