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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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Several classes of system performance simulations of V/STOL propulsion systems are presented. A digital simulation approach for a typical system (a propulsion system made up of three engines, shafts and gearbox, and remote lift fan) is given with a description of the general philosophy, solution options and model flexibility.
The applicability of a once-through oil mist system to the lubrication of helicopter spur gears was investigated and compared to conventional jet spray lubrication. In the mist lubrication mode, cooling air was supplied at 366K (200 F) to the out of mesh location of the gear sets. The mist air was also supplied at 366K (200 F) to the radial position mist nozzle at a constant rate of 0.0632 mol/s (3 SCFM) per nozzle. The lubricant contained in the mist air varied between 32 - 44 cc/hour. In the recirculating jet spray mode, the flow rate was varied between 1893 - 2650 cc/hour. Visual inspection revealed the jet spray mode produced a superior surface finish on the gear teeth but a thermal energy survey showed a 15 - 20% increase in heat generated. The gear tooth condition in the mist lubrication mode system could be improved if the cooling air and lubricant/air flow ratio were increased. The test gearbox and the procedure used are described.
An electromechanical actuator was developed that will follow a proportional control command with minimum wasted energy to demonstrate the feasibility of meeting space vehicle actuator requirements using advanced electromechanical concepts. The approach was restricted to a four-channel redundant configuration. Each channel has independent drive and control electronics, a brushless electric motor with brake, and velocity and position feedback transducers. A differential gearbox sums the output velocities of the motors. Normally, two motors are active and the other two are braked.
Schematic diagrams are given for both the four-channel electromechanical actuator and the single-channel power electronics breadboard. Detailed design data is also given on the gears used in the differential gearbox and a copy of the operations manual for the system is included. Performance test results are given for the EMA motor and its current source indicator, the drive control electronics, and the overall system. The power converter waveform test results are also summarized.
Twenty-two candidate engine concepts and nineteen transmission concepts. Screening of these concepts, predominantly for fuel economy, cost and technical risk, resulted in a recommended powertrain consisting of a single-shaft engine, with a ceramic radial turbine rotor, connected through a differential split-power transmission utilizing a variable stator torque converter and a four speed automatic gearbox. Vehicle fuel economy and performance projections, preliminary design analyses and installation studies in a were completed. A cost comparison with the conventional spark ignited gasoline engine showed that the turbine engine would be more expensive initially, however, lifetime cost of ownership is in favor of the gas turbine. A powertrain research and development plan was constructed to gain information on timing and costs to achieve the required level of technology and demonstrate the engine in a vehicle by the year 1983.
Mounting for helicopter gearbox measures forces generated by rotor and isolates transmission from airframe. Mountings have frequency-dependent load/displacement relationship that gives statically rigid but dynamically soft support, lowering vibratory transfer. Previous isolation by springs or force-opposing devices required strain gages to measure rotor vibration and were operative at only one vibration frequency. Active system eliminates these limitations.
The performance characteristics of various steam Rankine engine configurations for solar electric power generation were investigated. A radial outflow steam turbine was investigated to determine: (1) a method for predicting performance from experimental data; (2) the flexibility of a single design with regard to power output and pressure ratio; and (3) the effect of varying the number of turbine stages. All turbine designs were restricted to be compatible with commercially available gearboxes and generators. A study of several operating methods and control schemes for the steam Rankine engine shows that from an efficiency and control simplicity standpoint, the best approach is to hold turbine inlet temperature constant, vary turbine inlet pressure to match load, and allow condenser temperature to float maintaining constant heat rejection load.
The quiet, clean, general aviation turbofan engine and nacelle system was designed and tested. The engine utilized the core of the AiResearch model TFE731-3 engine and incorporated several unique noise- and emissions-reduction features. Components that were successfully adapted to this core include the fan, gearbox, combustor, low-pressure turbine, and associated structure. A highly versatile workhorse nacelle incorporating interchangeable acoustic and hardwall duct liners, showed that large-engine attenuation technology could be applied to small propulsion engines. The application of the mixer compound nozzle demonstrated both performance and noise advantages on the engine. Major performance, emissions, and noise goals were demonstrated.
Application of the transfer function approach to predict the resulting interior noise contribution requires gearbox vibration sources and paths to be characterized in the frequency domain. Tooth-face deviations from perfect involute surfaces were represented in terms of Legendre polynomials which may be directly interpreted in terms of tooth-spacing errors, mean and random deviations associated with involute slope and fullness, lead mismatch and crowning, and analogous higher-order components. The contributions of these components to the spectrum of the static transmission error is discussed and illustrated using a set of measurements made on a pair of helicopter spur gears. The general methodology presented is applicable to both spur and helical gears.
Two latches were designed to mount payloads in the shuttle orbiter bay. Multiple retention latches attach a payload to the sill longerons and another latch device attaches it to the keel. Requirements for each actuator are defined and drive mechanisms are described. Other design aspects discussed include: switch mechanisms, motors, gearboxes, redundancy provisions, structural materials, and lubricants. A preliminary dry lubricant test program is also reviewed and results presented.
Propulsion system technologies applicable to the generation of commuter airline aircraft expected to enter service in the 1990's are identified and evaluated in terms of their impact on aircraft operating economics and fuel consumption. The most promising technologies in the areas of engine, propeller, gearbox, and nacelle design are recommended for future research. Each item under consideration is evaluated relative to a modern baseline engine, the General Electric CT7-5, in a current technology aircraft flying a fixed range and payload. The analysis is presented for two aircraft sizes (30 and 50 passenger), over a range of mission lengths (100 to 1100 km) and fuel costs ($264 to $396 per cu m).
The performance of four rolling bearing configurations for use on the input pinion shaft of a proposed commercial helicopter transmission was evaluated. The performance characteristics of a high speed tapered roller bearing operating under conditions comparable to those existing at this input pinion shaft were defined. The tapered roller bearing shaft support configuration was developed for the gearbox using commercially available bearing designings. The configuration was optimized and interactive thermomechanically system analyzed. Automotive pinion quality tapered roller bearings were found to be reliable under load and speed conditions in excess of those anticipated in the helicopter transmission. However, it is indicated that the elastohydrodynamic lubricant films are inadequate.
The powertrain consists of a single shaft regenerated gas turbine engine utilizing ceramic hot section components, coupled to a slit differential gearbox with an available variable stator torque converter and an available Ford intergral overdrive four-speed automatic transmission. Predicted fuel economy using gasoline fuel over the combined federal driving cycle (CFDC) is 15.3 km/1, which represents a 59% improvement over the spark-ignition-powered baseline vehicle. Using DF2 fuel, CFDC mileage estimates are 17.43 km/1. Zero to 96.6 km/hr acceleration time is 11.9 seconds with a four-second accleration distance of 21.0 m. The ceramic radial turbine rotor is discussed along with the control system for the powertrain.
Potential small wind energy conversion (SWECS) design problems were identified to improve product quality and reliability. Mass produced components such as gearboxes, generators, bearings, etc., are generally reliable due to their widespread uniform use in other industries. The likelihood of failure increases, though, in the interfacing of these components and in SWECS components designed for a specific system use. Problems relating to the structural integrity of such components are discussed and analyzed with techniques currently used in quality assurance programs in other manufacturing industries.
Circa 1990 propulsion improvement concepts are discussed for 1000 to 5000 SHP conventional turboprop powerplants including engines, gearboxes, and propellers. Cycle selection, power plant configurations and advanced technology elements are defined and evaluated using average stage length DOC for commuter aircraft as the primary merit criterion.
The Advanced Gas Turbine Powertrain System Development Project is oriented at providing the United States automotive industry the technology base necessary to produce gas turbine powertrains for automotive applications that will have: (1) reduced fuel consumption, (2) the ability to use a variety of fuels, (3) low emissions, and (4) competitive cost/performance. The AGT101 powertrain being developed consists of a regenerated single-shaft gas turbine engine flat rated at 74.6 kW (100 hp) coupled to a split-differential gearbox and a Ford automatic overdrive production transmission. Performance predictions for the AGT101 powertrain represent a 59-percent improvement in mileage estimates over a 1985 conventionally-powered automobile for the combined federal driving cycle.
An advanced gas turbine powertrain for automotive application is being developed. Objectives of the program include a fuel consumption of 42.8 mpg on No. 2 diesel fuel in a 3000 pound car, same overall vehicle performance as obtained with a conventional spark ignition internal combustion engine, low emission, multiple fuel capacity, reliability, and competitive cost. The AGT101 powertrain consists of a power section, gearbox and transmission, and the design and analysis conducted thus far support the initial engine concept, as no significant design changes have been required. The ceramic rotor design approach and component materials are discussed, and it is projected that the AGT powertrain will be competitive with any other alternative powertrain in meeting the design objectives.
A development program is described whose goal is the accumulation of the technology base needed by the U.S. automotive industry for the production of automotive gas turbine powertrains. Such gas turbine designs must exhibit reduced fuel consumption, a multi-fuel capability, and low exhaust emissions. The AGT101 powertrain described is a 74.6 kW, regenerated single-shaft gas turbine, operating at a maximum inlet temperature of 1644 K and coupled to a split differential gearbox and automatic overdrive transmission. The engine's single stage centrifugal compressor and single stage radial inflow turbine are mounted on a common shaft, and will operate at a maximum rotor speed of 100,000 rpm. All high temperature components, including the turbine rotor, are ceramic.