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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 37 records · Page 2
All sourcesNASA NTRSDOE OSTI
NASA NTRS1996

Improving the Performance of the Structure-Based Connectionist Network for Diagnosis of Helicopter Gearboxes

A diagnostic method is introduced for helicopter gearboxes that uses knowledge of the gear-box structure and characteristics of the 'features' of vibration to define the influences of faults on features. The 'structural influences' in this method are defined based on the root mean square value of vibration obtained from a simplified lumped-mass model of the gearbox. The structural influences are then converted to fuzzy variables, to account for the approximate nature of the lumped-mass model, and used as the weights of a connectionist network. Diagnosis in this Structure-Based Connectionist Network (SBCN) is performed by propagating the abnormal vibration features through the weights of SBCN to obtain fault possibility values for each component in the gearbox. Upon occurrence of misdiagnoses, the SBCN also has the ability to improve its diagnostic performance. For this, a supervised training method is presented which adapts the weights of SBCN to minimize the number of misdiagnoses. For experimental evaluation of the SBCN, vibration data from a OH-58A helicopter gearbox collected at NASA Lewis Research Center is used. Diagnostic results indicate that the SBCN is able to diagnose about 80% of the faults without training, and is able to improve its performance to nearly 100% after training.

Jammu, Vinay B.↗
NASA NTRS2017

Cryo-Gearbox Using Bulk Metallic Glasses

Harmonic drives are a highly efficient and compact gearing technology that are widely used in robotics and aerospace applications (e.g. Mars Science Lab) due to their excellent torque-to-mass ratio, low backlash, and high positional accuracy. One major problem using any gearing on other planetary bodies is the need for heaters to keep the gearbox from freezing. Currently the Mars Science Lab uses 40% of its daily power output to operate heaters to keep the grease in the gearboxes from freezing. Also wear can limit the lifetime and performance of these systems. One possible solution to this problem could be to use a relatively new material known as Bulk Metallic Glasses (BMGs, also known as Amorphous Metals). BMGs are non-crystalline metallic alloys that exhibit superior mechanical properties. Compared to modern aerospace steels BMGs have a higher strength, higher elastic limit, and lower density. BMGs used in harmonic drives (especially the flex spline) could lead to longer system lifetimes, lower mass, and increased performance. Jet Propulsion Laboratory (JPL) is researching a new method of manufacturing the flex spline by injection molding and is hoping to have reduced costs as well as the benefits listed above. In conjunction with Kennedy Space Center (KSC), JPL is providing gearboxes that KSC will test greaseless in an extreme environment. KSC has completed the assembly and checkout of a test stand that is capable of testing a gearbox in a vacuum of less than 2 milli torr, 100 Kelvin temperature, 250 Nm of load, input and output torque measurements and 120 RPM input speed.

Drew Smith↗
NASA NTRS1984

An analytical method to predict efficiency of aircraft gearboxes

A spur gear efficiency prediction method previously developed by the authors was extended to include power loss of planetary gearsets. A friction coefficient model was developed for MIL-L-7808 oil based on disc machine data. This combined with the recent capability of predicting losses in spur gears of nonstandard proportions allows the calculation of power loss for complete aircraft gearboxes that utilize spur gears. The method was applied to the T56/501 turboprop gearbox and compared with measured test data. Bearing losses were calculated with large scale computer programs. Breakdowns of the gearbox losses point out areas for possible improvement.

Anderson, N. E.↗
NASA NTRS1984

An analytical method to predict efficiency of aircraft gearboxes

A spur gear efficiency prediction method previously developed by the authors was extended to include power loss of planetary gearsets. A friction coefficient model was developed for MIL-L-7808 oil based on disc machine data. This combined with the recent capability of predicting losses in spur gears of nonstandard proportions allows the calculation of power loss for complete aircraft gearboxes that utilize spur gears. The method was applied to the T56/501 turboprop gearbox and compared with measured test data. Bearing losses were calculated with large scale computer programs. Breakdowns of the gearbox losses point out areas for possible improvement.

Anderson, N. E.↗
NASA NTRS1993

Pattern classifier for health monitoring of helicopter gearboxes

The application of a newly developed diagnostic method to a helicopter gearbox is demonstrated. This method is a pattern classifier which uses a multi-valued influence matrix (MVIM) as its diagnostic model. The method benefits from a fast learning algorithm, based on error feedback, that enables it to estimate gearbox health from a small set of measurement-fault data. The MVIM method can also assess the diagnosability of the system and variability of the fault signatures as the basis to improve fault signatures. This method was tested on vibration signals reflecting various faults in an OH-58A main rotor transmission gearbox. The vibration signals were then digitized and processed by a vibration signal analyzer to enhance and extract various features of the vibration data. The parameters obtained from this analyzer were utilized to train and test the performance of the MVIM method in both detection and diagnosis. The results indicate that the MVIM method provided excellent detection results when the full range of faults effects on the measurements were included in training, and it had a correct diagnostic rate of 95 percent when the faults were included in training.

Chin, Hsinyung↗
NASA NTRS1993

Efficient fault diagnosis of helicopter gearboxes

Application of a diagnostic system to a helicopter gearbox is presented. The diagnostic system is a nonparametric pattern classifier that uses a multi-valued influence matrix (MVIM) as its diagnostic model and benefits from a fast learning algorithm that enables it to estimate its diagnostic model from a small number of measurement-fault data. To test this diagnostic system, vibration measurements were collected from a helicopter gearbox test stand during accelerated fatigue tests and at various fault instances. The diagnostic results indicate that the MVIM system can accurately detect and diagnose various gearbox faults so long as they are included in training.

Chin, H.↗
NASA NTRS1988

AGBT Advanced Counter-Rotating Gearbox Detailed Design Report

An Advanced Counter-Rotating (CR) Gearbox was designed and fabricated to evaluate gearbox efficiency, durability and weight characteristics for emerging propfan-powered airplanes. Component scavenge tests showed that a constant volume collector had high scavenge effectiveness, which was uneffected by added airflow. Lubrication tests showed that gearbox losses could be reduced by controlling the air/oil mixture and by directing the oil jets radially, with a slight axial component, into the sun/planet gears.

Howe, D. C.↗
NASA NTRS1992

Gearbox vibration diagnostic analyzer

This report describes the Gearbox Vibration Diagnostic Analyzer installed in the NASA Lewis Research Center's 500 HP Helicopter Transmission Test Stand to monitor gearbox testing. The vibration of the gearbox is analyzed using diagnostic algorithms to calculate a parameter indicating damaged components.

Source record↗
NASA NTRS1995

Minimization of the Vibration Energy of Thin-Plate Structures and the Application to the Reduction of Gearbox Vibration

While the vibration analysis of gear systems has been developed, a systematic approach to the reduction of gearbox vibration has been lacking. The technique of reducing vibration by shifting natural frequencies is proposed here for gearboxes and other thin-plate structures using the theories of finite elements, modal analysis, and optimization. A triangular shell element with 18 degrees of freedom is developed for structural and dynamic analysis. To optimize, the overall vibration energy is adopted as the objective function to be minimized at the excitation frequency by varying the design variable (element thickness) under the constraint of overall constant weight. Modal analysis is used to determine the sensitivity of the vibration energy as a function of the eigenvalues and eigenvectors. The optimum design is found by the gradient projection method and a unidimensional search procedure. By applying the computer code to design problems for beams and plates, it was verified that the proposed method is effective in reducing vibration energy. The computer code is also applied to redesign the NASA Lewis gear noise rig test gearbox housing. As one example, only the shape of the top plate is varied, and the vibration energy levels of all the surfaces are reduced, yielding an overall reduction of 1/5 compared to the initial design. As a second example, the shapes of the top and two side plates are varied to yield an overall reduction in vibration energy of 1/30.

Inoue, Katsumi↗
NASA NTRS1998

Evaluation of Navy 9 cst Oil in Bell Helicopter M412 HP Gearboxes

Tests were conducted with 5 and 9 centistoke lubricants in three different helicopter gearboxes, a main transmission, a 42' gearbox and a tailrotor gearbox. The objective of the tests was to observe and measure the difference in the performance of the lubrication systems due to the viscosity difference between the two test lubricants. The 9 centistoke oil has been developed to provide higher component film thickness, increased load carrying capacity and improved corrosion resistance which will provide increased life for drive system gears and bearings.

TRANSMISSION FLUIDS↗
NASA NTRS2010

Summary of the Large Civil Tiltrotor (LCTR2) Engine Gearbox Study

In support of the Fundamental Aeronautics Program, Subsonic Rotary Wing Project, NASA is continuing to study the Large Civil Tiltrotor (LCTR) concept to help define/refine vehicle, system and subsystem attributes. These attributes can then be used to define performance requirements and identify new or advanced technologies to achieve an operational vehicle class. As part of this goal, NASA contracted with The Boeing Company and its subcontractor Rolls-Royce to perform an investigation of different combinations of engine and gearbox variability to achieve a maximum of 50 percent rotor tip speed reduction from hover to cruise conditions. Previous NASA studies identified the 50 percent rotor speed reduction minimized vehicle gross weight and fuel burn. The LCTR2 (LCTR-iteration 2) was the contracted study baseline for initial sizing. Rotor tip speed ratios (cruise to hover) of 100, 77, and 54 percent were analyzed for each combination of engine and gearbox speed reduction to achieve the chosen rotor tip speed ratio. Three different engine and gearbox technology levels were assumed; commercial off-the-shelf (COTS), entry-in-service (EIS) in 2025 and EIS in 2035. These technology levels were applied to determine each particular effect on vehicle gross weight and fuel burn, while other vehicle technologies were assumed constant. This report summarizes the work performed that is being put together into a comprehensive NASA contractor report. Some background on the LCTR concept and baseline vehicle will be given and then a discussion concerning the technical approach utilized. Major study assumptions and results will be presented and discussed. Finally conclusions will be drawn as well as suggestions provided for future efforts.

Snyder, Christopher A.↗
NASA NTRS2022

Genetic Optimization of Planetary Gearboxes Based on Analytical Gearing Equations

Electric and hybrid electric vertical takeoff and landing vehicles will require high performance electric motor driven propulsion systems to enable fuel burn and emissions benefits over traditional liquid fuel powered rotorcraft. One key to the design of a high performance electric motor driven propulsion systems is to be able to estimate the mass and efficiency of a gearbox at various motor and propellor operating speeds. Knowing how gearbox mass and efficiency trade with motor and propellor rotational speed, allows motor and propellor RPM to be traded in an overall optimization of the propulsion system. In this paper, a genetic optimization tool for estimating the mass and efficiency of gearboxes is presented. Example results from the tool are presented and compared to existing correlations in use by NASA aircraft design codes.

Thomas Tallerico↗
NASA NTRS1991

Modal analysis of multistage gear systems coupled with gearbox vibrations

An analytical procedure to simulate vibrations in gear transmission systems is presented. This procedure couples the dynamics of the rotor-bearing gear system with the vibration in the gear box structure. The model synthesis method is used in solving the overall dynamics of the system, and a variable time-stepping integration scheme is used in evaluating the global transient vibration of the system. Locally each gear stage is modeled as a multimass rotor-bearing system using a discrete model. The modal characteristics are calculated using the matrix-transfer technique. The gearbox structure is represented by a finite element models, and modal parameters are solved by using NASTRAN. The rotor-gear stages are coupled through nonlinear compliance in the gear mesh while the gearbox structure is coupled through the bearing supports of the rotor system. Transient and steady state vibrations of the coupled system are examined in both time and frequency domains. A typical three-geared system is used as an example for demonstration of the developed procedure.

Choy, F. K.↗
NASA NTRS1992

Effect of operating conditions on gearbox noise

Low contact ratio spur gears were tested in the NASA gear noise rig to study the noise radiated from the top of the gearbox. The measured sound power from the gearbox top was obtained from a near field acoustic intensity scan taken at 63 nodes just above the surface. The sound power was measured at a matrix of 45 operating speeds and torque levels. Results are presented in the form of a spectral speed map and as a plot of sound power versus torque (at constant speed) and as sound power versus speed (at constant torque). Because of the presence of vibration modes, operating speed was found to have more impact on noise generation than torque level. A NASA gear dynamics code was used to compute the gear tooth dynamic overload at the same 45 operating conditions used for the experiment. Similar trends were found between the analytical results for dynamic tooth overload and experimental results for sound power. Dynamic analysis may be used to design high quality gears with profile relief optimized for minimum dynamic load and noise.

Oswald, Fred B.↗
NASA NTRS1993

Fault detection of helicopter gearboxes using the multi-valued influence matrix method

In this paper we investigate the effectiveness of a pattern classifying fault detection system that is designed to cope with the variability of fault signatures inherent in helicopter gearboxes. For detection, the measurements are monitored on-line and flagged upon the detection of abnormalities, so that they can be attributed to a faulty or normal case. As such, the detection system is composed of two components, a quantization matrix to flag the measurements, and a multi-valued influence matrix (MVIM) that represents the behavior of measurements during normal operation and at fault instances. Both the quantization matrix and influence matrix are tuned during a training session so as to minimize the error in detection. To demonstrate the effectiveness of this detection system, it was applied to vibration measurements collected from a helicopter gearbox during normal operation and at various fault instances. The results indicate that the MVIM method provides excellent results when the full range of faults effects on the measurements are included in the training set.

Chin, Hsinyung↗
NASA NTRS1996

Non-Back-Drivable Gearboxes With Greater Efficiencies

Non-back-drivable gearboxes with power-transfer efficiencies greater than conventional non-back-drivable gearboxes undergoing development. Greater efficiencies made possible by novel design concept utilizing input torques in such way as to reduce frictional losses.

Ohm, Timothy R.↗
NASA NTRS1996

Model-based sensor location selection for helicopter gearbox monitoring

A new methodology is introduced to quantify the significance of accelerometer locations for fault diagnosis of helicopter gearboxes. The basis for this methodology is an influence model which represents the effect of various component faults on accelerometer readings. Based on this model, a set of selection indices are defined to characterize the diagnosability of each component, the coverage of each accelerometer, and the relative redundancy between the accelerometers. The effectiveness of these indices is evaluated experimentally by measurement-fault data obtained from an OH-58A main rotor gearbox. These data are used to obtain a ranking of individual accelerometers according to their significance in diagnosis. Comparison between the experimentally obtained rankings and those obtained from the selection indices indicates that the proposed methodology offers a systematic means for accelerometer location selection.

Jammu, Vinay B.↗
NASA NTRS1996

Unsupervised Pattern Classifier for Abnormality-Scaling of Vibration Features for Helicopter Gearbox Fault Diagnosis

A new unsupervised pattern classifier is introduced for on-line detection of abnormality in features of vibration that are used for fault diagnosis of helicopter gearboxes. This classifier compares vibration features with their respective normal values and assigns them a value in (0, 1) to reflect their degree of abnormality. Therefore, the salient feature of this classifier is that it does not require feature values associated with faulty cases to identify abnormality. In order to cope with noise and changes in the operating conditions, an adaptation algorithm is incorporated that continually updates the normal values of the features. The proposed classifier is tested using experimental vibration features obtained from an OH-58A main rotor gearbox. The overall performance of this classifier is then evaluated by integrating the abnormality-scaled features for detection of faults. The fault detection results indicate that the performance of this classifier is comparable to the leading unsupervised neural networks: Kohonen's Feature Mapping and Adaptive Resonance Theory (AR72). This is significant considering that the independence of this classifier from fault-related features makes it uniquely suited to abnormality-scaling of vibration features for fault diagnosis.

Jammu, Vinay B.↗