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Gas turbine automobile powertrain research is reported. The compressor, turbine, combustor, regenerator, gearbox, ceramic components/subsystems, bearings, and controls are discussed.
Development of a high temperature operating helicopter gearbox is discussed.
As an alternative to component development, the case for improved drive-train configuration is argued. In particular, the use of torque-splitting gear trains is proposed as a practicable means of improving the effectiveness of helicopter main gearboxes.
The Scaled Centrifugal Compressor, Collector and Running gear Program was conducted in support of an overall NASA strategy to improve small-compressor performance, durability, and reliability while reducing initial and life-cycle costs. Accordingly, Garrett designed and provided a test rig, gearbox coupling, and facility collector for a new NASA facility, and provided a scaled model of an existing, high-performance impeller for evaluation scaling effects on aerodynamic performance and for obtaining other performance data. Test-rig shafting was designed to operate smoothly throughout a speed range up to 60,000 rpm. Pressurized components were designed to operate at pressures up to 300 psia and at temperatures to 1000 F. Nonrotating components were designed to provide a margin-of-safety of 0.05 or greater; rotating components, for a margin-of-safety based on allowable yield and ultimate strengths. Design activities were supported by complete design analysis, and the finished hardware was subjected to check-runs to confirm proper operation. The test rig will support a wide range of compressor tests and evaluations.
The efficiency, weight, and cost of various propulsion system for 4-passenger electric vehicles are compared. These systems comprise the electric motor and the required speed reducing transmission to obtain the appropriate speed at the wheel. Three types of motors, dc synchronous, and squirrel-cage were considered at 6000 ycm and 24 000 rpm for a peak power of 40 kW. Two types of gearing selected were a single speed differential and a differential with a differential with a 4-speed gearbox. Only components that were readily realizable within present state-of-the-art were considered.
Technical work on the design and effort leading to the testing of a 74.5 kW (100 hp) automotive gas turbine is described. The general effort was concentrated on building an engine for test starting in July. The buildup progressed with only routine problems and the engine was delivered to the test stand 9 July. In addition to the engine build effort, work continued in selected component areas. Ceramic turbine parts were built and tested. Burst tests of ceramic rotors show strengths are approaching that achieved in test bars; proof testing is required for acceptable strength ceramic vanes. Over 25 hours was accumulated on the combustor rig in three test modes: pilot nozzle only, start nozzle, and main nozzle operation. Satisfactory ignition was achieved for a wide range of starting speeds and the lean blowout limit was as low as 0.06 kg/b (0.14 lb/hr). Lean blowout was more a function of nozzle atomization than fuel/air ratio. A variety of cycle points were tested. Transition from start nozzle flow to main nozzle flow was done manually without difficulty. Regenerator parts were qualification tested without incident and the parts were assembled on schedule. Rig based performance matched first build requirements. Repeated failures in the harmonic drive gearbox during rig testing resulted in that concept being abandoned for an alternate scheme.
A design of a propeller pitch control mechanism is described that meets the demanding requirements of a high-power, advanced turboprop. In this application, blade twisting moment torque can be comparable to that of the main reduction gearbox output: precise pitch control, reliability and compactness are all at a premium. A key element in the design is a compact, high-ratio hybrid traction drive which offers low torque ripple and high torsional stiffness. The traction drive couples a high speed electric motor/alternator unit to a ball screw that actuates the blade control links. The technical merits of this arrangement and the performance characteristics of the traction drive are discussed. Comparisons are made to the more conventional pitch control mechanisms.
A design of a propeller pitch control mechanism is described that meets the demanding requirements of a high-power, advanced turboprop. In this application, blade twisting moment torque can be comparable to that of the main reduction gearbox output: precise pitch control, reliability and compactness are all at a premium. A key element in the design is a compact, high-ratio hybrid traction drive which offers low torque ripple and high torsional stiffness. The traction drive couples a high speed electric motor/alternator unit to a ball screw that actuates the blade control links. The technical merits of this arrangement and the performance characteristics of the traction drive are discussed.
A prototype high speed balancing system was developed for assembled gas turbine engine modules. The system permits fully assembled gas turbine modules to be operated and balanced at selected speeds up to full turbine speed. The balancing system is a complete stand-alone system providing all necesary lubrication and support hardware for full speed operation. A variable speed motor provides the drive power. A drive belt and gearbox provide rotational speeds up to 21,000 rpm inside a vacuum chamber. The heart of the system is a dedicated minicomputer with attendant data acquisition, storage and I/O devices. The computer is programmed to be completely interactive with the operator. The system was installed at CCAD and evaluated by testing 20 T55 power turbines and 20 T53 power turbines. Engine test results verified the performance of the high speed balanced turbines.
The propfan is an advanced propeller concept which maintains the high efficiencies traditionally associated with conventional propellers at the higher aircraft cruise speeds associated with jet transports. The large-scale advanced propfan (LAP) program extends the research done on 2 ft diameter propfan models to a 9 ft diameter article. The program includes design, fabrication, and testing of both an eight bladed, 9 ft diameter propfan, designated SR-7L, and a 2 ft diameter aeroelastically scaled model, SR-7A. The LAP program is complemented by the propfan test assessment (PTA) program, which takes the large-scale propfan and mates it with a gas generator and gearbox to form a propfan propulsion system and then flight tests this system on the wing of a Gulfstream 2 testbed aircraft.
A test rig was designed to evaluate the performance of a spherical roller bearing with a geared outer ring operating under conditions similar to those of a planet bearing in a helicopter transmission. The configuration is an extension of the widely accepted four-square gearbox arrangement. It provides for testing of two bearings simultaneously with outer ring rotation, misalignment, diametrically opposed loading through the gear teeth, and under race lubrication. Instrumentation permits the measurement of inner and outer ring temperature, bearing drag torque, degree of misalignment, outer ring speed, cage speed, and applied load.
The propfan is an advanced propeller concept which maintains the high efficiencies traditionally associated with conventional propellers at the higher aircraft cruise speeds associated with jet transports. The large-scale advanced propfan (LAP) program extends the research done on 2 ft diameter propfan models to a 9 ft diameter article. The program includes design, fabrication, and testing of both an eight bladed, 9 ft diameter propfan, designated SR-7L, and a 2 ft diameter aeroelastically scaled model, SR-7A. The LAP program is complemented by the propfan test assessment (PTA) program, which takes the large-scale propfan and mates it with a gas generator and gearbox to form a propfan propulsion system and then flight tests this system on the wing of a Gulfstream 2 testbed aircraft.
Propeller-control system autonomous and tolerant of failure. Mounting electrical-power module and conditioning/control systems inboard rotating propeller hub eliminates failure-prone slipring devices and creates autonomous, failure-tolerant propeller-control system. Modular component design facilitates on-the-wing maintenance. System highly adaptive to various sizes and gearbox configurations. Features and capabilities described unmatched by any comparable PCM now in existence. These capabilities needed by large, fuel-efficient, commuter turboprop aircraft now being developed by aircraft industry.
Engine efficiency increased. Propeller blades required to be quite thin and highly swept to minimize compressibility losses and propeller noise during high-speed cruise. Use of 8 or 10 blades with highpropeller-power loading allows overall propeller diameter to be kept relatively small. Area-ruled spinner and integrated nacelle shape reduce compressibility losses in propeller hub region. Finally, large modern turboshaft engine and gearbox provide power to advanced propeller. Fuel savings of 30 to 50 percent over present systems anticipated. Propfan system adaptable to number of applications, such as highspeed (subsonic) business and general-aviation aircraft, and military aircraft including V/STOL.
Engine testing, ceramic component fabrication and evaluation, component performance rig testing, and producibility experiments at Pontiac comprised AGT 100 activities of this period, January to December 1984. Two experimental engines were available and allowed the evaluation of eight experimental assemblies. Operating time accumulated was 115 hr of burning and 156 hr total. Total cumulative engine operating time is now 225 hr. Build number 11 and 12 of engine S/N 1 totaled 28 burning hours and constituted a single assembly of the engine core--the compressor, both turbines, and the gearbox. Build number 11 of engine S/N 1 included a 1:07 hr continuous test at 100% gasifier speed (86,000 rpm). Build number 8 of engine S/N 2 was the first engine test with a ceramic turbine rotor. A mechanical loss test of an engine assembly revealed the actual losses to be near the original design allowance. Component development activity included rig testing of the compressor, combustor, and regenerator. Compressor testing was initiated on a rig modified to control the transfer of heat between flow path, lubricating oil, and structure. Results show successful thermal decoupling of the rig and lubricating/cooling oil. Rig evaluation of a reduced-friction compressor was initiated. Combustor testing covered qualification of ceramic parts for engine use, mapping of operating range limits, and evaluation of a relocated igniter plug. Several seal refinements were tested on the hot regenerator rig. An alternate regenerator disk, extruded MAS, was examined and found to be currently inadequate for the AGT 100 application. Also, a new technique for measuring leakage was explored on the regenerator rig. Ceramic component activity has focused on the development of state-of-the-art material strength characteristics in full-scale hardware. Injection-molded sintered alpha-SiC rotors were produced at Carborundum in an extensive process and tool optimization study.
The use of an active hinge to attenuate the transverse vibrations of a flexible beam is examined. A slender aluminum beam is suspended vertically, cantilevered at the top. An active hinge is placed at the node of the second vibration mode. The active hinge consists of a torque motor, strain gauge, and tachometer. A control law is implemented using both beam-bending strain and the relative angular velocity measured at this hinge, thereby configuring the hinge to act as an active damper. Results from implementing this control law show little improvement in the first mode damping ratio, 130 percent increase in the second mode damping ratio, and 180 percent increase in the third mode damping ratio. The merits of using a motor with a gearbox are discussed.
Unducted-fan (UDF(TM) engine advanced counterrotating-pusher-propeller propulsion system for high-subsonic (mach 0.7 to 0.85) aircraft. Combines modern high-pressure-ratio gas-turbine engine with multistage counterrotating power turbine directly coupled to counterrotating, advanced high-speed propellers. Key feature of system is unique direct turbine drive eliminating need for gearbox to transmit power to propeller blades.
Final design details of a helicopter transmission that is powered by GE twin T 700 engines each rated at 1800 hp are presented. It is demonstrated that in comparison with conventional helicopter transmission arrangements the split torque design offers: weight reduction of 15%; reduction in drive train losses of 9%; and improved reliability resulting from redundant drive paths between the two engines and the main shaft. The transmission fits within the NASA LeRC 3000 hp Test Stand and accepts the existing positions for engine inputs, main shaft, connecting drive shafts, and the cradle attachment points. One necessary change to the test stand involved gear trains of different ratio in the tail drive gearbox. Progressive uprating of engine input power from 3600 to 4500 hp twin engine rating is allowed for in the design. In this way the test transmission will provide a base for several years of analytical, research, and component development effort targeted at improving the performance and reliability of helicopter transmission.