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All sources NASA NTRS DOE OSTI

DOE OSTI2021

Stage 2 Sub-Scale Magnetic Gear

The goal of this project is to design, fabricate, and test a hermetically sealed 50 kilowatt (kW) multistage magnetically geared generator (MGG). In order to reduce risk, a sub-scale 5kW multistage MGG was first built. This project will benefit MHK device developers by providing an MHK PTO that overcomes the reliability concerns of the mechanical gears and the sizing constraints of the direct-drive generators. 7.67:1 gear ratio magnetic gear with a measured peak torque of 1796 N-m

16 TIDAL AND WAVE POWER↗

NASA NTRS1977

Study of lubricant jet flow phenomena in spur gears - Out of mesh condition

An analysis was conducted for oil jet lubrication on the disengaging side of a gear mesh. Results of the analysis were computerized and used to determine the oil jet impingement depth for several gear ratios and oil jet to pitch line velocity ratios. An experimental program was conducted on the NASA gear test rig using high-speed photography to experimentally determine the oil jet impingement depth on the disengaging side of mesh. Impingement depth reaches a maximum at gear ratio near 1.5 where chopping by the leading gear tooth limits the impingement depth. The pinion impingement depth is zero above a gear ratio of 1.172 for a jet velocity to pitch time velocity ratio of 1.0 and is similar for other velocity ratios. The impingement depth for gear and pinion are equal and approximately one-half the maximum at a gear ratio of 1.0. Impingement depth on either the gear or pinion many be improved by relocation of the jet from the pitch line or by changing the jet angle. Results of the analysis were verified by experimental results using a high-speed camera and a well lighted oil jet.

Townsend, D. P.↗

NASA NTRS1992

Effect of contact ratio on spur gear dynamic load

A computer simulation is presented which shows how the gear contact ratio affects the dynamic load on a spur gear transmission. The contact ratio can be affected by the tooth addendum, the pressure angle, the tooth size (diametral pitch), and the center distance. The analysis presented was performed using the NASA gear dynamics code, DANST. In the analysis, the contact ratio was varied over the range 1.20 to 2.40 by changing the length of the tooth addendum. In order to simplify the analysis, other parameters related to contact ratio were held constant. The contact ratio was found to have a significant influence on gear dynamics. Over a wide range of operating speeds, a contact ratio close to 2.0 minimized dynamic load. For low contact ratio gears (contact ratio less than 2.0), increasing the contact ratio reduced the gear dynamic load. For high contact ratio gears (contact ratio = or greater than 2.0), the selection of contact ratio should take into consideration the intended operating speeds. In general, high contact ratio gears minimized dynamic load better than low contact ratio gears.

Liou, Chuen-Huei↗

DOE OSTI2020

Investigating the Impact of Power-Take-Off System Parameters and Control Law on a Rotational Wave Energy Converter’s Peak-to-Average Power Ratio Reduction

Due to the irregular nature of real waves, the power captured in a wave energy converter (WEC) system is highly variable. This is an important barrier to the effective use of WECs. To address this challenge, this study focuses on a rotational WEC power-take-off system in which high-speed and high-efficiency generators along with a torque/power smoothing inertia element can be effectively utilized. In the first phase of this study, the U.S. Department of Energy’s reference model 3 (WEC-Sim RM3; two-body point absorber), along with a slider-crank WEC, were integrated for linear to rotational conversion. Relative motion between the float and spar in RM3 was the driving force for this slider-crank WEC, which is connected to a motor/generator set through a gearbox. RM3 geometry was scaled down by 25 times to work within the limits of the physical motor/generator set used in the experimentation. Once the integration in a hardware-in-the-loop simulation environment was successfully completed, data on the peak-to-average power ratio was collected for various wave conditions including regular and irregular waves. The control algorithm designed to keep the system in resonance with waves was able to maintain relatively high speed depending on the specific gear ratio and wave period. Initial results with hardware-in-the-loop simulations reveal that gear ratio and crank radius have a strong impact on the peak-to-average power ratio. In addition, it was found that output power from the generator was maximized at a larger gear ratio, as the crank radius was increased.

50 EE - Wind and Water Power Program - Water (EE-4↗

NASA NTRS1986

Predicted effect of dynamic load on pitting fatigue life for low-contact-ratio spur gears

How dynamic load affects the surface pitting fatigue life of external spur gears was predicted by using the NASA computer program TELSGE. Parametric studies were performed over a range of various gear parameters modeling low-contact-ratio involute spur gears. In general, gear life predictions based on dynamic loads differed significantly from those based on static loads, with the predictions being strongly influenced by the maximum dynamic load during contact. Gear mesh operating speed strongly affected predicted dynamic load and life. Meshes operating at a resonant speed or one-half the resonant speed had significantly shorter lives. Dynamic life factors for gear surface pitting fatigue were developed on the basis of the parametric studies. In general, meshes with higher contact ratios had higher dynamic life factors than meshes with lower contact ratios. A design chart was developed for hand calculations of dynamic life factors.

Lewicki, David G.↗

NASA NTRS1975

Analysis of dynamic capacity of low-contact-ratio spur gears using Lundberg-Palmgren theory

A concise mathematical model is developed for surface fatigue life of low-contact-ratio spur gears. The expected fatigue life of the pinion, gear, or gear sets may be calculated from the model. An equation for the dynamic capacity of the gear set was also derived in terms of the transmitted tangential tooth load which will give a 10-percent fatigue life of one million pinion revolutions. The theoretical life was compared with experimental data for a set of VAR AISI 9310 gears operating at a Hertz stress of 1.71X10 to the 9th power newtons per square meter (248,000 psi) and 10 000 revolutions per minute. Good agreement was obtained between the experimental and theoretical surface fatigue life of the gears.

Coy, J. J.↗

NASA NTRS1977

Dynamic tooth loads and stressing for high contact ratio spur gears

A time history, closed form solution is presented for a dynamic model of spur gear systems for all practical contact ratios. The analysis determines the dynamic response of the gear system and the associated tooth loads and stressing. The dynamic model assumes the two gears act as a rigid inertia and the teeth act as a variable spring of a dynamic system excited by the meshing action of the teeth. Included in the analysis are the effects of the nonlinearity of the tooth pair stiffness during mesh, the tooth errors, and the tooth profile modifications. Besides reviewing the features, solution, and program of this analysis, preliminary results from applying the analysis are presented, which show that tooth profile modification, system inertia and damping, and system critical speeds can affect the dynamic gear tooth loads and stressing significantly.

Cornell, R. W.↗

NASA NTRS1985

The design and analysis of single flank transmission error testor for loaded gears

Due to geometrical imperfections in gears and finite tooth stiffnesses, the motion transmitted from an input gear shaft to an output gear shaft will not have conjugate action. In order to strengthen the understanding of transmission error and to verify mathematical models of gear transmission error, a test stand that will measure the transmission error of a gear pair at operating loads, but at reduced speeds would be desirable. This document describes the design and development of a loaded transmission error tester. For a gear box with a gear ratio of one, few tooth meshing combinations will occur during a single test. In order to observe the effects of different tooth mesh combinations and to increase the ability to load test gear pairs with higher gear ratios, the system was designed around a gear box with a gear ratio of two.

Houser, D. R.↗

NASA NTRS1989

Generation Method Improves Spiral Bevel Gears

Conjugate tooth surfaces reduce kinematic errors. Method for generation of spiral bevel gears provides conjugated gear-tooth surfaces and improved bearing contact. Conjugated surfaces preferable because maintain constant gear ratios during tooth-contact cycles. Changing gear ratios of nonconjugated surfaces give rise to kinematical errors in transfer of motion from driving gears to driven gears. Errors major sources of noise in power transmissions. Computer program developed to simulate cutting and meshing processes for pinions and gears to minimize kinematical errors.

Litvin, Faydor L.↗

NASA NTRS1980

Experimental and analytical transonic flutter characteristics of a geared-elevator configuration

The flutter model represented the aft fuselage and empennage of a proposed supersonic transport airplane and had an all movable horizontal tail with a geared elevator. It was tested mounted from a sting in the transonic dynamics tunnel. Symmetric flutter boundaries were determined experimentally at Mach numbers from 0.7 to 1.14 for a geared elevator configuration (gear ratio of 2.8 to 1.0) and an ungeared elevator configuration (gear ratio of 1.0 to 1.0). Gearing the elevator increased the experimental flutter dynamic pressures about 20 percent. Flutter calculations were made for the geared elevator configuration by using two analytical methods based on subsonic lifting surface theory. Both methods analyzed the stabilizer and elevator as a single, deforming surface, but one method also allowed the elevator to be analyzed as hinged from the stabilizer. All analyses predicted lower flutter dynamic pressures than experiment with best agreement (within 12 percent) for the hinged elevator method. Considering the model as mounted from a flexible rather than rigid sting in the analyses, had only a slight effect on the flutter results but was significant in that a sting related vibration mode was identified as a potentially flutter critical mode.

Ruhlin, C. L.↗

DOE OSTI2025

Towards an intuitive application of WEC control co-design

A simple co-design example in a reduced parameter space is presented for an oscillating flap device. Initially, the WEC geometry and mass properties are considered along with drivetrain gear ratio, inertia, motor constant and stiffness under both PI and optimal control. This parameter space is reduced to those to which performance is most sensitive for a fixed geometry. The gear ratio, drivetrain stiffness, and flap mass are found to be the most impactful design criteria as they can create orders of magnitude variations in power performance. The performance of the optimized system is compared with several sub-optimal variants in terms of electrical and mechanical power capture, transmission coefficients, and transducer power gain. Notably, though substantial power capture improvements are demonstrated when an optimal controller is employed, this power capture remains sensitive to appropriate selections of drivetrain and flap design parameters, implying that control co-design procedures remain necessary for high-performing WECs. Furthermore, a number of practical caveats and extensions to the presented co-design methodology are suggested, including the characterization of system static friction, especially in the presence of high gear ratios.

Control co-design↗

NASA NTRS1992

Separation distance and static transmission error of involute spur gears

The effects of separation distance and deflection of gear teeth on the static transmission error of involute spur gears are investigated. In this paper, only low-contact-ratio gears with true involute profile are studied. Gear ratio and tooth addendum are varied to examine their effects on the separation distance and static transmission error. Results obtained from the investigation shows that the contact ratio and static transmission error are affected significantly if considering the separation distance. In general, the magnitude of contact ratio has been increased and the variation of static transmission error has been smoothed. The most significant change occurs for a gear pair with a theoretical contact ratio close to 1.95.

Tse, David K.↗

NASA NTRS1984

Efficiency of nonstandard and high contact ratio involute spur gears

A power loss prediction was extended to include involute spur gears of nonstandard proportions. The method is used to analyze the effects of modified addendum, tooth thickness, and gear center distance in addition to the parameters previously considered which included gear diameter, pitch, pressure angle, face width, oil viscosity, speed, and torque. Particular emphasis was placed on high contact ratio gearing (contact ratios greater than two). Despite their higher sliding velocities, high contact ratio gears are designed to levels of efficiency comparable to those of conventional gears while retaining their advantages through proper selection of gear geometry.

Anderson, N. E.↗

NASA NTRS1986

Efficiency of nonstandard and high contact ratio involute spur gears

Anderson, N. E.↗

NASA NTRS1976

Geared-elevator flutter study

An experimental and analytical study was made of the transonic flutter characteristics of a supersonic transport tail assembly model having an all-movable, horizontal tail with a geared elevator. Two model configurations, namely, one with a gear-elevator (2.8 to 1.0 gear ratio) and one with locked-elevator (1.0 to 1.0 gear ratio), were flutter tested in the Langley transonic dynamics tunnel with an empennage cantilever-mounted on a sting. The geared-elevator configuration fluttered experimentally at about 20% higher dynamic pressures than the locked-elevator configuration. The experimental flutter dynamic pressure boundaries for both configurations were nearly flat over a Mach number range from 0.9 to 1.1. Flutter calculations (mathematical models) were made for the geared-elevator configuration using three subsonic lifting-surface methods. In one method, the elevator was treated as a discrete surface, and in the other two methods, the stabilizer and elevator were treated as a single warped-surface with the primary difference between these two methods being in the mathematical implementation used. A comparison of the experimental and analytical results shows that the discrete-elevator method predicted best the experimental flutter dynamic pressure level. However, the single warped-surface methods predicts more closely the experimental flutter frequencies and Mach number trends.

Ruhlin, C. L.↗

NASA NTRS1990

Analysis and design of sidestick controller systems for general aviation aircraft

A method to design sidestick controllers for general aviation aircraft with reversible flight controls is proposed. The use of a sidestick in this type of flight vehicle generally increases the stick forces required for maneuvering; this is due to a reduction in the moment arm of application of the force. In the present study, the reduction of stick forces is achieved by incorporating geared tabs in the control-surface design. A complete analysis using the rigid-body aircraft longitudinal equations of motion and stick-force equation in coupled form is carried out. Lateral stick forces are predicted by solving the single-degree-of-freedom roll approximation and aileron stick-force equations. Data are presented for configurations with various tab areas and a wide range of gearing ratios. The results indicate that the method can be used successfully for geared-tab design and stick-force prediction. It is shown that gearing-ratio selection is critical but that tab area does not have a significant impact on the magnitude of stick forces and stick force to stick deflection gradients.

Martin, Daniel M.↗

NASA NTRS1992

Noncircular rolling joints for vibrational reduction in slewing maneuvers

A rolling joint is provided for obtaining slewing maneuvers for various apparatus including space structures, space vehicles, robotic manipulators, and simulators. Two noncircular cylinders, namely a drive and a driven cylinder, are provided in driving contact with one another. This contact is maintained by two pairs of generally S-shaped bands, each pair forming a generally 8-shaped coupling tightly about the circumferential periphery of the noncircular drive and driven cylinders. A stationarily fixed arm extends between and is rotatably journalled with a drive axle and a spindle axle respectively extending through selected rotational points of the drive cylinder and of the driven cylinder. The noncircular cylinders are profiled to obtain the desired varying gear ratio. The novelty of the present invention resides in using specifically profiled noncircular cylinders to obtain a desired varying gear ratio.

Chew, Meng-Sang↗

NASA NTRS1944

Altitude Performance of Allison V-1710-93 Engine and Two-Stage Supercharger

Bench tests have been made of an Allison V-1710-93 engine at simulated altitudes of 17,000 and 29,000 feet to determine the performance of the engine, the characteristics of the induction system, and the modifications required in the induction system for the center dot development of 1840 brake horsepower at 17,030 feet and 1200 horsepower at 29,000 feet. With the engine speed maintained at a constant value of 3000 rpm, the tip speed of the auxiliary-stage supercharger was varied from the minimum to the maximum speed. Measurements were made to determine engine power, fuel and air consumptions, and pressure and temperature changes introduced by each component of the induction system. Although the over-all pressure ratios of the superchargers agreed with those determined from previous sea-level bench tests of these units, the over-all temperature rise was -generally much lower than had been anticipated. In order to obtain the desired brake horsepower, some form of charge-air cooling is essential; the carburetor should either be enlarged or removed; and the minimum gear ratios of the engine-stage and the minimum gear ratios of the engine-stage and the auxiliary-stage superchargers should be 8.1:1 and 8.08:1, respectively.

Edward Glodeck↗