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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 271 records · Page 15
All sourcesNASA NTRSDOE OSTI
NASA NTRS2010

International Space Station Powered Bolt Nut Anomaly and Failure Analysis Summary

A key mechanism used in the on-orbit assembly of the International Space Station (ISS) pressurized elements is the Common Berthing Mechanism (CBM). The mechanism that effects the structural connection of the CBM halves is the Powered Bolt Assembly. There are sixteen Powered Bolt Assemblies per CBM. The CBM has a bolt which engages a self aligning Powered Bolt Nut (PBN) on the mating interface; see Figure 1. The Powered Bolt Assemblies are preloaded to approximately 19 kilo pounds (KIPs) prior to pressurization of the CBM. The PBNs mentioned below, manufactured in 2009, will be used on ISS future missions. An on orbit functional failure of this hardware would be unacceptable and in some instances catastrophic due to the failure of modules to mate and seal the atmosphere, risking loss of crew and ISS functions. The manufacturing processes which create the PBNs need to be strictly controlled. Functional (torque vs. tension) acceptance test failures will be the result of processes not being strictly followed. Without the proper knowledge of thread tolerances, fabrication techniques, and dry film lubricant application processes, PBNs will be, and have been manufactured improperly. The knowledge gained from acceptance test failures and the resolution of those failures, thread fabrication techniques and thread dry film lubrication processes can be applied to many aerospace mechanisms to enhance their performance. Test data and manufactured PBN thread geometry will be discussed for both failed and successfully accepted PBNs.

Sievers, Daniel E.↗
NASA NTRS2010

International Space Station Powered Bolt Nut Anomaly and Failure Analysis Summary

A key mechanism used in the on-orbit assembly of the International Space Station (ISS) pressurized elements is the Common Berthing Mechanism. The mechanism that effects the structural connection of the Common Berthing Mechanism halves is the Powered Bolt Assembly. There are sixteen Powered Bolt Assemblies per Common Berthing Mechanism. The Common Berthing Mechanism has a bolt which engages a self aligning Powered Bolt Nut (PBN) on the mating interface (Figure 1). The Powered Bolt Assemblies are preloaded to approximately 84.5 kN (19000 lb) prior to pressurization of the CBM. The PBNs mentioned below, manufactured in 2009, will be used on ISS future missions. An on orbit functional failure of this hardware would be unacceptable and in some instances catastrophic due to the failure of modules to mate and seal the atmosphere, risking loss of crew and ISS functions. The manufacturing processes that create the PBNs need to be strictly controlled. Functional (torque vs. tension) acceptance test failures will be the result of processes not being strictly followed. Without the proper knowledge of thread tolerances, fabrication techniques, and dry film lubricant application processes, PBNs will be, and have been manufactured improperly. The knowledge gained from acceptance test failures and the resolution of those failures, thread fabrication techniques and thread dry film lubrication processes can be applied to many aerospace mechanisms to enhance their performance. Test data and manufactured PBN thread geometry will be discussed for both failed and successfully accepted PBNs.

Sievers, Daniel E.↗
NASA NTRS2010

Demonstration of an Aerocapture GN and C System Through Hardware-in-the-Loop Simulations

Aerocapture is an orbit insertion maneuver in which a spacecraft flies through a planetary atmosphere one time using drag force to decelerate and effect a hyperbolic to elliptical orbit change. Aerocapture employs a feedback Guidance, Navigation, and Control (GN&C) system to deliver the spacecraft into a precise postatmospheric orbit despite the uncertainties inherent in planetary atmosphere knowledge, entry targeting and aerodynamic predictions. Only small amounts of propellant are required for attitude control and orbit adjustments, thereby providing mass savings of hundreds to thousands of kilograms over conventional all-propulsive techniques. The Analytic Predictor Corrector (APC) guidance algorithm has been developed to steer the vehicle through the aerocapture maneuver using bank angle control. Through funding provided by NASA's In-Space Propulsion Technology Program, the operation of an aerocapture GN&C system has been demonstrated in high-fidelity simulations that include real-time hardware in the loop, thus increasing the Technology Readiness Level (TRL) of aerocapture GN&C. First, a non-real-time (NRT), 6-DOF trajectory simulation was developed for the aerocapture trajectory. The simulation included vehicle dynamics, gravity model, atmosphere model, aerodynamics model, inertial measurement unit (IMU) model, attitude control thruster torque models, and GN&C algorithms (including the APC aerocapture guidance). The simulation used the vehicle and mission parameters from the ST-9 mission. A 2000 case Monte Carlo simulation was performed and results show an aerocapture success rate of greater than 99.7%, greater than 95% of total delta-V required for orbit insertion is provided by aerodynamic drag, and post-aerocapture orbit plane wedge angle error is less than 0.5 deg (3-sigma). Then a real-time (RT), 6-DOF simulation for the aerocapture trajectory was developed which demonstrated the guidance software executing on a flight-like computer, interfacing with a simulated IMU and simulated thrusters, with vehicle dynamics provided by an external simulator. Five cases from the NRT simulations were run in the RT simulation environment. The results compare well to those of the NRT simulation thus verifying the RT simulation configuration. The results of the above described simulations show the aerocapture maneuver using the APC algorithm can be accomplished reliably and the algorithm is now at TRL-6. Flight validation is the next step for aerocapture technology development.

Masciarelli, James↗
NASA NTRS2019

High Speed Testing of a High Efficiency Concentric Magnetic Gear

This presentation presents measurements of the efficiency of NASA's 2nd magnetic gear prototype. A detailed discussion of the test rig used to make these measurements was presented, including a thorough uncertainty analysis. The reported uncertainties are 95% confidence intervals that include the effects of temperature and parasitic loads. The prototype's response was measured at output speeds between 124 rpm and 744 rpm for a controlled output torque of 10 Nm (8% of the prototype's maximum torque). After correcting for tare losses, the prototype's efficiency was found to decrease from 90.0% to 83.0% as speed increased. If the efficiency is extrapolated to a typical operating condition (85% of maximum torque) using the good assumption that energy loss is approximately independent of the transmitted torque,the expected efficiency would be 99.0% to 98.4%, which exceeds the state of the art for these speeds.

Scheidler, Justin↗
NASA NTRSDate not supplied

Scaling Climbing Collaborative Mobile Manipulators (C2M2) for Outfitting a Tall Lunar Tower (TLT) and Truss Structures

In-space and planetary truss structures like the Tall Lunar Tower (TLT) can greatly benefit from truss climbing collaborative mobile manipulators (C-CMMs) for outfitting and other servicing tasks. Mobile robotic systems traversing these structures will allow for improved access to the structure for placing equipment and routing cables after the structure has been assembled. The robotic system described in the proposed paper is designed to provide access to the structure through collaborative mobile robotics. The paper will provide a method to constrain the design of such a robot via the geometry of the truss structure and the controlling joint torques across various gaits. The focus of the design is on a six-degree of freedom (DOF) robot arranged with two-DOF at each end and at the center. The variable features of this system are the actuators and the length of the links connecting the two-DOF modules. The result of the analysis is a link sizing range which the robot can be designed within to ensure functionality on the truss structure. A C-CMM will be designed using the scaling utility and several constructed to demonstrate operating both independently and collaboratively.

in-space assembly↗
NASA NTRS1971

Computer simulation for attitude disturbance torques for the Tiros-series.

Description of the Tiros-M Magnetic Attitude Prediction Program (TMMGAP), a simulation program designed to assist in the rotational motion control of the Tiros-series spacecraft. The subsystems of the program include input, attitude simulation, executive, attitude control and output components, simulating solar radiation pressure torque, gravity gradient torque, residual magnetic moment torque, and magnetic attitude control torques. The program provides data for prelaunch studies for launch window selection and mission planning, facilitates spacecraft spin axis reorientation after launch, provides spin axis control recommendations to meet mission constraints, and assists in the interpretation of cloud cover data. The program is characterized as effective in controlling spin axis and in processing picture data.

Sugai, I.↗
NASA NTRSDate not supplied

Implementation of Field-Oriented Control in Joint Actuator Electronics for Satellite-Servicing Robotics

NASA’s OSAM-1 (On-orbit Servicing, Assembly, and Manufacturing 1) is a robotic spacecraft designed to extend the life of a satellite. Launching in 2026, the OSAM-1 servicer will use a robotic arm to grasp, refuel, and relocate Landsat 7. In order to accomplish the various servicing operations, including the critical auto-grapple capturing operation, the robot arm uses active compliance and visual servo control loops. These sophisticated control algorithms are enabled by the high performance Joint Control Boards (JCBs). At the core of the robot arm control architecture, the JCBs employ field-oriented control (FOC) to accurately commutate and efficiently control joint actuator torque. FOC offers numerous benefits over other current control methods, allowing the JCBs to achieve the high bandwidth and performance required by the outer control loops. As an added benefit, a torque feed-forward term allows the FOC loop to simulate microgravity actuator performance during ground testing. In this paper, a FOC implementation for space robotics applications and an end-to-end actuator calibration process are discussed.

Sam Zhao↗
NASA NTRSDate not supplied

Adaptive Control and Scaling Approach for the Emulation of Dynamic Subscale Torque Loads

Previous research by the authors proposed a control and scaling approach for emulating dynamic sub-scale torque loads. This approach produced an emulation controller that successfully regulated the dynamic behavior of a sub-scale electro-mechanical system intended to be a dynamical representation of the sub-scale turboelectric powertrain of a single-aisle commercial aircraft. The sub-scale system provides an environment without turbomachinery or rotors for the initial testing of electrified aircraft propulsion (EAP) control algorithms as they would be applied to a full-scale EAP system. The sub-scale turbomachinery/rotor torque loads were produced by electric machines (EMs) driven by the control and scaling approach, a full-scale turboelectric powertrain model, and an advanced EAP control algorithm. Although successfully tested, this approach produces an emulation controller that does not guarantee asymptotic stability. Modifying the original control law and integrating adaptive control techniques into the emulation controller allows the designer to guarantee asymptotic stability. This paper introduces the idea behind the emulation controller modifications, derives the controller, proves asymptotic stability, describes the implementation of the controller on a sub-scale electro-mechanical system intended to represent a parallel hybrid-electric turbofan engine, and describes the testing of a full-scale advanced EAP control algorithm. The turbofan engine and emulation controller performance are compared to results obtained using the previous, non-adaptive control and scaling approach.

adaptive↗
DOE OSTI2021

Integrated ELM and divertor power flux control using RMPs with low input torque in EAST in support of the ITER research plan

Experiments have been carried out at the EAST tokamak to study ITER-relevant scenario integration issues, related to edge localized mode (ELM) control in H-mode plasmas by the application of three-dimensional (3D) resonant magnetic perturbations (RMPs), which have a large impact on the execution of the ITER research plan. The EAST experiments have successfully demonstrated ELM suppression at normalized torque inputs similar to ITER. The application of RMP fields with high toroidal mode number (n = 4) reduces the impact of ELM control on energy and particle confinement compared to those use lower n (n = 1, 2) RMPs. Injection of successive pellets is found to be effective in increasing the plasma density in ELM-suppressed H-modes and reducing the divertor power without triggering large ELMs at EAST. Access to high recycling and radiative divertor conditions while maintaining ELM suppression has been demonstrated in EAST by the use of gas fuelling and neon impurity seeding. Both approaches have been found to be effective in reducing power fluxes to the divertor strike points in near-separatrix lobes for both n = 2 and n = 4 RMPs. Furthermore, reduction of power fluxes in off-separatrix lobes is only effective for n = 4 RMP application, which is consistent with magnetic topology modelling (including plasma response) results showing a shallow penetration into the confined plasma region of field lines connected to these lobes compared to n = 2. The EAST results support the use of high n 3D fields for ELM suppression in ITER high Q DT scenarios since they provide optimum integration features regarding energy and particle confinement, pellet fuelling, radiative divertor operation while eliminating ELM transient power loads and being compatible with low torque input.

pellet fuelling↗
NASA NTRS2010

Modeling Attitude Dynamics in Simulink: A Study of the Rotational and Translational Motion of a Spacecraft Given Torques and Impulses Generated by RMS Hand Controllers

In order to study and control the attitude of a spacecraft, it is necessary to understand the natural motion of a body in orbit. Assuming a spacecraft to be a rigid body, dynamics describes the complete motion of the vehicle by the translational and rotational motion of the body. The Simulink Attitude Analysis Model applies the equations of rigid body motion to the study of a spacecraft?s attitude in orbit. Using a TCP/IP connection, Matlab reads the values of the Remote Manipulator System (RMS) hand controllers and passes them to Simulink as specified torque and impulse profiles. Simulink then uses the governing kinematic and dynamic equations of a rigid body in low earth orbit (LE0) to plot the attitude response of a spacecraft for five seconds given known applied torques and impulses, and constant principal moments of inertia.

Mauldin, Rebecca H.↗
DOE OSTI2022

A New Shape Optimization Approach for Lightweighting Electric Machines Inspired by Additive Manufacturing

Minimizing the mass in electric machines while maintaining superior performance is a new requirement for the advancement of drivetrains used in wind energy and electric mobility. Topology optimization (TO) for lightweighting electric machines using traditional approaches typically explores a restricted design space allowed by standard parametrizable geometry and manufacturing, while advanced methods, such as cell-based density approaches, suffer from a lack of robust manufacturability constraints during the optimization process. To overcome these drawbacks, we explore a grid-independent, boundary optimization where the outer shape of the magnet is parameterized using Bezier curves. We conduct a design of experiments (DOE) to study the effect of different magnet shapes on machine performance by varying the control points on the Bezier curves. A machine-learning-based surrogate model is constructed using the data from the DOE to quantify the relationship between the control points, air-gap torque, and mass. The control points are then optimized to maximize the torque density. The approach is used for minimizing electrical steel mass in the International Energy Agency (IEA) 15-MW radial flux direct-drive wind turbine generator. The new approach to shape optimization resulted in smooth and concise shapes that can be easily additively manufactured with up to a 20-ton reduction in electrical steel mass.

additive manufacturing↗
DOE OSTI2022

A Boundary Topology Optimization Approach for Lightweighting Electric Machines Inspired by Additive Manufacturing

Minimizing the mass in electric machines while maintaining superior performance has become a new requirement for the advancement of drivetrains used in wind energy and electric mobility. Topology optimization for light-weighting electric machines using traditional approaches typically explore a restricted design space allowed by standard parametrizable geometry and manufacturing, while advanced methods like cell-based density approaches suffer from a lack of robust manufacturability constraints during the optimization process. To overcome these drawbacks, we explore a grid-independent, boundary TO where the outer shape of the magnet is parameterized using Bezier curves. We conduct a design of experiments (DOE) to study the effect of different magnet shapes on machine performance by varying the control points on the Bezier curves. A machine-learning based surrogate model is constructed using the data from the DOE to quantify the relationship between the control points, air-gap torque and mass. The control points are then optimized to maximize the torque density. The approach is used for minimizing electrical steel mass in the IEA-15MW radial flux direct-drive wind turbine generator. The free-from boundary TO resulted in smooth and concise shapes that can be easily additively manufactured with upto 20-ton reduction in electrical steel mass.

additive manufacturing↗
DOE OSTI2022

A New Shape Optimization Approach for Lightweighting Electric Machines Inspired by Additive Manufacturing: Preprint

Minimizing the mass in electric machines while maintaining superior performance is a new requirement for the advancement of drivetrains used in wind energy and electric mobility. Topology optimization (TO) for lightweighting electric machines using traditional approaches typically explores a restricted design space allowed by standard parametrizable geometry and manufacturing, while advanced methods, such as cell-based density approaches, suffer from a lack of robust manufacturability constraints during the optimization process. To overcome these drawbacks, we explore a grid-independent, boundary TO where the outer shape of the magnet is parameterized using Bezier curves. We conduct a design of experiments (DOE) to study the effect of different magnet shapes on machine performance by varying the control points on the Bezier curves. A machine-learning-based surrogate model is constructed using the data from the DOE to quantify the relationship between the control points, air-gap torque, and mass. The control points are then optimized to maximize the torque density. The approach is used for minimizing electrical steel mass in the International Energy Agency (IEA) 15-MW radial flux direct-drive wind turbine generator. The free-form boundary TO resulted in smooth and concise shapes that can be easily additively manufactured with up to a 20-ton reduction in electrical steel mass.

additive manufacturing↗
NASA NTRS1994

Adaptive Impedance Control Of Redundant Manipulators

Improved method of controlling mechanical impedance of end effector of redundant robotic manipulator based on adaptive-control theory. Consists of two subsystems: adaptive impedance controller generating force-control inputs in Cartesian space of end effector to provide desired end-effector-impedance characteristics, and subsystem implementing algorithm that maps force-control inputs into torques applied to joints of manipulator. Accurate control of end effector and effective utilization of redundancy achieved simultaneously by use of method. Potential use to improve performance of such typical impedance-control tasks as deburring edges and accommodating transitions between unconstrained and constrained motions of end effectors.

Seraji, Homayoun↗
NASA NTRS2016

Pattern Recognition Control Design

Spacecraft control algorithms must know the expected spacecraft response to any command to the available control effectors, such as reaction thrusters or torque devices. Spacecraft control system design approaches have traditionally relied on the estimated vehicle mass properties to determine the desired force and moment, as well as knowledge of the effector performance to efficiently control the spacecraft. A pattern recognition approach can be used to investigate the relationship between the control effector commands and the spacecraft responses. Instead of supplying the approximated vehicle properties and the effector performance characteristics, a database of information relating the effector commands and the desired vehicle response can be used for closed-loop control. A Monte Carlo simulation data set of the spacecraft dynamic response to effector commands can be analyzed to establish the influence a command has on the behavior of the spacecraft. A tool developed at NASA Johnson Space Center (Ref. 1) to analyze flight dynamics Monte Carlo data sets through pattern recognition methods can be used to perform this analysis. Once a comprehensive data set relating spacecraft responses with commands is established, it can be used in place of traditional control laws and gains set. This pattern recognition approach can be compared with traditional control algorithms to determine the potential benefits and uses.

Gambone, Elisabeth↗
NASA NTRS2018

Pattern Recognition Control Design

Spacecraft control algorithms must know the expected vehicle response to any command to the available control effectors, such as reaction thrusters or torque devices. Spacecraft control system design approaches have traditionally relied on the estimated vehicle mass properties to determine the desired force and moment, as well as knowledge of the effector performance to efficiently control the spacecraft. A pattern recognition approach was used to investigate the relationship between the control effector commands and spacecraft responses. Instead of supplying the approximated vehicle properties and the thruster performance characteristics, a database of information relating the thruster ring commands and the desired vehicle response was used for closed-loop control. A Monte Carlo simulation data set of the spacecraft dynamic response to effector commands was analyzed to establish the influence a command has on the behavior of the spacecraft. A tool developed at NASA Johnson Space Center to analyze flight dynamics Monte Carlo data sets through pattern recognition methods was used to perform this analysis. Once a comprehensive data set relating spacecraft responses with commands was established, it was used in place of traditional control methods and gains set. This pattern recognition approach was compared with traditional control algorithms to determine the potential benefits and uses.

Gambone, Elisabeth A.↗