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NASA NTRS2022

Assessing Mars Curiosity Rover Wheel Damage

An alarming rate of wheel skin cracks were first observed on the Mars Science Laboratory (MSL) Curiosity rover about 14 months after the start of its surface mission. Nine years later (as of August 2, 2021), Curiosity has four broken wheelgrousers, three on the left middle wheel and one on the right middle wheel. There are a substantial number of wheel skin cracks on the left front, left middle, and right middle wheels such that the number of grousers on each that are consideredat risk of breaking are 10, 7, and 11, respectively. Although the current level of wheel damage does not significantly limit Curiosity’s mission objectives, a higher damage rate could impact surface operations, so the damage rate is closely monitored. OnNovember 30, 2013, the MSL Surface Operations team began periodically acquiring images of Curiosity’s wheels. In this paper, we describe the process the Mobility Operations team uses to assess wheel damage, the current state of Curiosity’swheels, and how the wheel damage assessments have influenced driving guidelines and wheel imaging frequency.

Rink, Kimberly↗

NASA NTRS1980

Thermal fatigue performance of integrally cast automotive turbine wheels

Fluidized bed thermal fatigue testing was conducted on 16 integrally cast automotive turbine wheels for 1000-10,000 (600 sec total) thermal cycles at 935/50 C. The 16 wheels consisted of 14 IN-792 + 1% Hf and 2 gatorized AF2-1DA wheels; 6 of the IN-792 + Hf wheels contained crack arrest pockets inside the blade root flange. Temperature transients during the thermal cycling were measured in three calibration tests using either 18 or 30 thermocouples per wheel. Thermal cracking based on crack length versus accumulated cycles was greatest for unpocketed wheels developing cracks in 8-13 cycles compared to 75-250 cycles for unpocketed wheels. However, pocketed wheels survived up to 10,000 cycles with crack lengths less than 20 mm, whereas two unpocketed wheels developed 45 mm long cracks in 1000-2000 cycles.

Humphreys, V. E.↗

NASA NTRS2013

Inflight Performance of Cassini Reaction Wheel Bearing Drag in 1997-2013

As the first spacecraft to achieve orbit at Saturn in 2004, Cassini has collected science data throughout its four-year prime mission (2004-08), and has since been approved for a first and second extended missions through September 2017. Cassini is a three-axis stabilized spacecraft. It uses reaction wheels to achieve high level of spacecraft pointing stability that is needed during imaging operations of several science instruments. The Cassini flight software makes in-flight estimates of reaction wheel bearing drag torque and made them available to the mission operations team. These telemetry data are being trended for the purpose of monitoring the long-term health of the reaction wheel bearings. Anomalous drag torque signatures observed over the past 15 years are described in this paper. One of these anomalous drag conditions is bearing cage instability that appeared (and disappeared) spontaneously and unpredictably. Cage instability is an uncontrolled vibratory motion of the bearing cage that can produce high-impact forces internal to the bearing that will cause intermittent and erratic torque transients. Characteristics of the observed cage instabilities and other drag torque "spikes" are described in this paper. In day-to-day operations, the reaction wheels' rates must be neither too high nor too low. To protect against operating the wheels in any undesirable conditions (such as prolonged low spin rate operations), a ground software tool named Reaction Wheel Bias Optimization Tool (RBOT) was developed for the management of the wheels. Disciplined and long-term use of this ground software has led to significant reduction in the daily consumption rate of the wheels' low spin rate dwell time. Flight experience on the use of this ground software tool as well as other lessons learned on the management of Cassini reaction wheels is given in this paper.

Cassini/Huygens Mission↗

NASA NTRSDate not supplied

Utilizing 3D-DIC on Mars 2020 Rover Wheel Assembly: Test-Analysis Correlation

Following the successful implementation of full-field photogrammetry, more specifically three-dimensional Digital Image Correlation (3D-DIC), on the Mars 2020 Heat Shield Structural Failure Review assessment, 3D-DIC was selected as one of the primary measurement techniques for the Mars 2020 Rover wheel assembly qualification test at the NASA Jet Propulsion Laboratory (JPL). To validate the Rover wheel landing loads simulations, it was extremely important to have high confidence in the wheel models. Due to the large deformations and strains that the wheel would be subject to during landing, traditional instrumentation such as linear variable displacement transducers (LVDTs), electrical-resistance strain gages and string potentiometers, would not be sufficient on their own to provide all the necessary validation data. Therefore, the NASA Engineering and Safety Center (NESC) provided the 3D-DIC expertise and support to measure the high deformation and strain in the wheel flexures and qualify the overall structural response of the Mars 2020 rover wheel assembly. There were two key objectives for the photogrammetry technique: (1) monitor the wheel response in real-time, guarding against anomalous behavior and failure, and (2) provide test data for test-analysis correlation to validate and/or improve the high-fidelity computational model. The contents of this paper will focus on the challenges of applying 3D-DIC to the Mars 2020 Rover wheel assembly and how these challenges were overcome. Examples of test-analysis correlation during the stiffness characterization and structural qualification will be presented and discussed in detail. Experimental results were compared with the analysis and showed excellent agreement between the predicted behavior and helped validate the high-fidelity models.

Mars 2020 Rover Wheel↗

NASA NTRS1981

Suspension system for a wheel rolling on a flat track

An improved suspension system for an uncrowned wheel rolling on a flat track is presented. It is characterized by a wheel frame assembly including a wheel frame and at least one uncrowned wheel connected in supporting relation with the frame. It is adapted to be seated in rolling engagement with a flat track, a load supporting bed, and a plurality of flexural struts interconnecting the bed in supported relation with the frame. Each of said struts is disposed in a plane passing through the center of the uncrowned wheel surface along a line substantially bisecting the line of contact established between the wheel surface and the flat surface of the truck and characterized by a modulus of elasticity sufficient for maintaining the axis of rotation for the wheel in substantial parallelism with the line of contact established between the surfaces of the wheel and track.

Mcginness, H. D.↗

NASA NTRS1998

Thickness-Independent Ultrasonic Imaging Applied to Abrasive Cut-Off Wheels: An Advanced Aerospace Materials Characterization Method for the Abrasives Industry. A NASA Lewis Research Center Technology Transfer Case History

Abrasive cut-off wheels are at times unintentionally manufactured with nonuniformity that is difficult to identify and sufficiently characterize without time-consuming, destructive examination. One particular nonuniformity is a density variation condition occurring around the wheel circumference or along the radius, or both. This density variation, depending on its severity, can cause wheel warpage and wheel vibration resulting in unacceptable performance and perhaps premature failure of the wheel. Conventional nondestructive evaluation methods such as ultrasonic c-scan imaging and film radiography are inaccurate in their attempts at characterizing the density variation because a superimposing thickness variation exists as well in the wheel. In this article, the single transducer thickness-independent ultrasonic imaging method, developed specifically to allow more accurate characterization of aerospace components, is shown to precisely characterize the extent of the density variation in a cut-off wheel having a superimposing thickness variation. The method thereby has potential as an effective quality control tool in the abrasives industry for the wheel manufacturer.

Roth, Don J.↗

NASA NTRS2008

Reaction Wheel Disturbance Modeling, Jitter Analysis, and Validation Tests for Solar Dynamics Observatory

The Solar Dynamics Observatory (SDO) aims to study the Sun's influence on the Earth by understanding the source, storage, and release of the solar energy, and the interior structure of the Sun. During science observations, the jitter stability at the instrument focal plane must be maintained to less than a fraction of an arcsecond for two of the SDO instruments. To meet these stringent requirements, a significant amount of analysis and test effort has been devoted to predicting the jitter induced from various disturbance sources. One of the largest disturbance sources onboard is the reaction wheel. This paper presents the SDO approach on reaction wheel disturbance modeling and jitter analysis. It describes the verification and calibration of the disturbance model, and ground tests performed for validating the reaction wheel jitter analysis. To mitigate the reaction wheel disturbance effects, the wheels will be limited to operate at low wheel speeds based on the current analysis. An on-orbit jitter test algorithm is also presented in the paper which will identify the true wheel speed limits in order to ensure that the wheel jitter requirements are met.

Liu,Kuo-Chia↗

NASA NTRS2009

Maximum Torque and Momentum Envelopes for Reaction Wheel Arrays

Spacecraft reaction wheel maneuvers are limited by the maximum torque and/or angular momentum that the wheels can provide. For an n-wheel configuration, the torque or momentum envelope can be obtained by projecting the n-dimensional hypercube, representing the domain boundary of individual wheel torques or momenta, into three-dimensional space via the 3 n matrix of wheel axes. In this paper, the properties of the projected hypercube are discussed, and algorithms are proposed for determining this maximal torque or momentum envelope for general wheel configurations. Practical strategies for distributing a prescribed torque or momentum among the n wheels are presented, with special emphasis on a six-wheel configuration.

Markley, F. Landis↗

NASA NTRS2009

The Development of Wheels for the Lunar Roving Vehicle

The Lunar Roving Vehicle (LRV) was developed for NASA s Apollo program so astronauts could cover a greater range on the lunar surface, carry more science instruments, and return more soil and rock samples than by foot. Because of the unique lunar environment, the creation of flexible wheels was the most challenging and time consuming aspect of the LRV development. Wheels developed for previous lunar systems were not sufficient for use with this manned vehicle; therefore, several new designs were created and tested. Based on criteria set by NASA, the choices were narrowed down to two: the wire mesh wheel developed by General Motors (GM), and the hoop spring wheel developed by the Bendix Corporation. Each of these underwent intensive mechanical, material, and terramechanical analyses, and in the end, the wire mesh wheel was chosen for the LRV. Though the wire mesh wheel was determined to be the best choice for its particular application, it may be insufficient towards achieving the objectives of future lunar missions that could require higher tractive capability, increased weight capacity, or extended life. Therefore lessons learned from the original LRV wheel development and suggestions for future Moon wheel projects are offered.

Asnani, Vivake↗

NASA NTRS2009

Maximum Torque and Momentum Envelopes for Reaction Wheel Arrays

Spacecraft reaction wheel maneuvers are limited by the maximum torque and/or angular momentum that the wheels can provide. For an n-wheel configuration, the torque or momentum envelope can be obtained by projecting the n-dimensional hypercube, representing the domain boundary of individual wheel torques or momenta, into three dimensional space via the 3xn matrix of wheel axes. In this paper, the properties of the projected hypercube are discussed, and algorithms are proposed for determining this maximal torque or momentum envelope for general wheel configurations. Practical strategies for distributing a prescribed torque or momentum among the n wheels are presented, with special emphasis on configurations of four, five, and six wheels.

Markley, F. Landis↗

NASA NTRS2011

Charging and Subsequent Dissipation of a Rover Wheel in the Lunar Polar Regions

As a roving vehicle moves along the lunar surface, electric charge will build up through tribo-charging. This charge collected by the roving object will have a dissipative path to either the surface or the ambient plasma, depending upon which path is most conductive. At the lunar terminator region and into nightside regions, the surface is very cold and becomes a very poor conductor. leaving the plasma as the dominant remediating current for dissipation. However, within lunar craters, even plasma currents become substantially reduced which then greatly increases electric 'dissipation times, This work will involve the advancement of the stepping astronaut charge model, by considering the charging and plasma dissipation of a rolling rover wheel, The objective of this work is to determine the nature of charging and discharging for a rover wheel as it rolls along the cold, plasma-starved lunar polar regions. The rotating wheel accumulates charge via contact electrification (tribo-charging) with the lunar regolith. This tribo-charging is dependent on the composition of the objects in contact, with insulators and conductors charging differently. Given the environmental plasma in the region, we then determine the dissipation time for the wheel to bleed off its excess charge into the surrounding plasma. A model of the rover wheel rotating continuously over a surface regolith within a polar crater has been applied. The environmental plasma has been described previously. We define a new tribo-charging term specifically for the rotating system, with charge levels defined as a function of the wheel size, area in contact with the regolith, regolith particle size distribution, as well as the velocity at which the wheel is turning. We recognize that as charged dust accumulates and sticks to the wheel, this behaves effectively as a new current. Hence, the overall charging of the system should no longer vary linearly. and begin to show signs of saturation, We are devising a dust current term to model this charge-limiting effect, and will present the results in discussion.

Jackson, T. L.↗

NASA NTRS2016

Propulsion Wheel Motor for an Electric Vehicle

A wheel assembly for an electric vehicle includes a wheel rim that is concentrically disposed about a central axis. A propulsion-braking module is disposed within an interior region of the wheel rim. The propulsion-braking module rotatably supports the wheel rim for rotation about the central axis. The propulsion-braking module includes a liquid cooled electric motor having a rotor rotatable about the central axis, and a stator disposed radially inside the rotor relative to the central axis. A motor-wheel interface hub is fixedly attached to the wheel rim, and is directly attached to the rotor for rotation with the rotor. The motor-wheel interface hub directly transmits torque from the electric motor to the wheel rim at a 1:1 ratio. The propulsion-braking module includes a drum brake system having an electric motor that rotates a cam device, which actuates the brake shoes.

Figuered, Joshua M.↗

NASA NTRS2018

Performance of Cassini Reaction Wheel Friction Compensation Scheme During Spin Rate Zero-Crossing and Drag Spikes

Cassini uses reaction wheels to achieve the spacecraft pointing stability that is needed during imaging operations of several science instruments. The Cassini flight software makes inflight estimates of reaction wheel bearing drag torque and the reaction wheel controller uses these estimates to achieve a high level of spacecraft pointing stability. However, the Cassini drag torque estimator was designed to accurately track the bearing drag torque only in the steady state. When the physical drag torque changes abruptly (for example, during a reaction wheel spin rate reversal or when wheel bearings experienced drag spikes), the drag estimator will not be able to track the physical drag closely. This will lead to a degradation in the spacecraft pointing stability performance. For Cassini, this was not a problem because of the significant performance margin in pointing stability. However, for missions that have very challenging pointing stability requirements and that must perform well in the presence of frequent wheel rate reversals, alternative drag-compensating control schemes must be considered. To this end, alternative drag torque compensating control schemes (such as the adaptive model reference control scheme) are briefly reviewed in this paper. Selected design features used in these friction compensation schemes may be incorporated in reaction wheel controller design to improve the robustness of spacecraft pointing stability performance with regard to a wide range of reaction wheel drag torque anomalous behavior.

Lee, Allan Y↗

NASA NTRS1993

Judging rolling wheels: Dynamic and kinematic aspects of rotation-translation coupling

Four experiments were carried out to investigate observers' abilities to judge rolling motions. The experiments were designed to assess whether two important aspects of such motions are appreciated: the kinematic coupling of rotation and translation, and the dynamic effects of gravity. Different motion contexts of rolling wheels were created using computer-generated displays. The first experiment involved wheels rolling down an inclined plane. Observers spontaneously appreciated the anomaly of wheels that failed to accelerate, but they were not able to differentiate between different acceleration functions. Moreover, their judgements were almost exclusively based on the translation component of the rolling motion, neglecting the rotation component. In a second experiment it was found that observers could accurately estimate the perimeter of various objects. Thus, their inability to consider rotation information is not attributable to misperceptions of the geometry of wheels. In a third experiment the finding that rolling wheels appear to overrotate was replicated; however, findings from this experiment also showed, together with those from a fourth experiment, that observers are able to make very accurate judgments about translation-rotation coupling in rolling wheels when information is provided about the orientation of the wheel and the texture of the surface on which it rolls.

Hecht, Heiko↗

NASA NTRS2001

Maximum Torque and Momentum Envelopes for Reaction Wheel Arrays

Spacecraft reaction wheel maneuvers are limited by the maximum torque and/or angular momentum which the wheels can provide. For an n-wheel configuration, the torque or momentum envelope can be obtained by projecting the n-dimensional hypercube, representing the domain boundary of individual wheel torques or momenta, into three dimensional space via the 3xn matrix of wheel axes. In this paper, the properties of the projected hypercube are discussed, and algorithms are proposed for determining this maximal torque or momentum envelope for general wheel configurations. Practical implementation strategies for specific wheel configurations are also considered.

Reynolds, R. G.↗

NASA NTRS2004

Minimum-Time and Vibration Avoidance Attitude Maneuver for Spacecraft with Torque and Momentum Limit Constraints in Redundant Reaction Wheel Configuration

In this paper, we present an optimal open-loop slew trajectory algorithm developed at GSFC for the so-called "Yardstick design" of the James Webb Space Telescope (JWST). JWST is an orbiting infrared observatory featuring a lightweight, segmented primary mirror approximately 6 meters in diameter and a sunshield approximately the size of a tennis court. This large, flexible structure will have significant number of lightly damped, dominant flexible modes. With very stringent requirements on pointing accuracy and image quality, it is important that slewing be done within the required time constraint and with minimal induced vibration in order to maximize observing efficiency. With reaction wheels as control actuators, initial wheel speeds as well as individual wheel torque and momentum limits become dominant constraints in slew performance. These constraints must be taken into account when performing slews to ensure that unexpected reaction wheel saturation does not occur, since such saturation leads to control failure in accurately tracking commanded motion and produces high frequency torque components capable of exciting structural modes. A minimum-time constraint is also included and coupled with reaction wheel limit constraints in the optimization to minimize both the effect of the control torque on the flexible body motion and the maneuver time. The optimization is on slew command parameters, such as maximum slew velocity and acceleration, for a given redundant reaction wheel configuration and is based on the dynamic interaction between the spacecraft and reaction wheel motion. Analytical development of the slew algorithm to generate desired slew position, rate, and acceleration profiles to command a feedback/feed forward control system is described. High-fidelity simulation and experimental results are presented to show that the developed slew law achieves the objectives.

Ha, Kong Q.↗

NASA NTRS2007

Multispectral Imager With Improved Filter Wheel and Optics

Figure 1 schematically depicts an improved multispectral imaging system of the type that utilizes a filter wheel that contains multiple discrete narrow-band-pass filters and that is rotated at a constant high speed to acquire images in rapid succession in the corresponding spectral bands. The improvement, relative to prior systems of this type, consists of the measures taken to prevent the exposure of a focal-plane array (FPA) of photodetectors to light in more than one spectral band at any given time and to prevent exposure of the array to any light during readout. In prior systems, these measures have included, variously the use of mechanical shutters or the incorporation of wide opaque sectors (equivalent to mechanical shutters) into filter wheels. These measures introduce substantial dead times into each operating cycle intervals during which image information cannot be collected and thus incoming light is wasted. In contrast, the present improved design does not involve shutters or wide opaque sectors, and it reduces dead times substantially. The improved multispectral imaging system is preceded by an afocal telescope and includes a filter wheel positioned so that its rotation brings each filter, in its turn, into the exit pupil of the telescope. The filter wheel contains an even number of narrow-band-pass filters separated by narrow, spoke-like opaque sectors. The geometric width of each filter exceeds the cross-sectional width of the light beam coming out of the telescope. The light transmitted by the sequence of narrow-band filters is incident on a dichroic beam splitter that reflects in a broad shorter-wavelength spectral band that contains half of the narrow bands and transmits in a broad longer-wavelength spectral band that contains the other half of the narrow spectral bands. The filters are arranged on the wheel so that if the pass band of a given filter is in the reflection band of the dichroic beam splitter, then the pass band of the adjacent filter is in the longer-wavelength transmission band of the dichroic beam splitter (see Figure 2). Each of the two optical paths downstream of the dichroic beam splitter contains an additional broad-band-pass filter: The filter in the path of the light transmitted by the dichroic beam splitter transmits and attenuates in the same bands that are transmitted and reflected, respectively, by the beam splitter; the filter in the path of the light reflected by the dichroic beam splitter transmits and attenuates in the same bands that are reflected and transmitted, respectively, by the dichroic beam splitter. In each of these paths, the filtered light is focused onto an FPA. As the filter wheel rotates at a constant angular speed, its shaft angle is monitored, and the shaft-angle signal is used to synchronize the exposure times of the two FPAs. When a single narrowband-pass filter on the wheel occupies the entire cross section of the beam of light coming out of the telescope, the spectrum of light that reaches the dichroic beam splitter lies entirely within the pass band of that filter. Therefore, the beam in its entirety is either transmitted by the dichroic beam splitter and imaged on the longer-wavelength FPA or reflected by the beam splitter and imaged onto the shorter-wavelength FPA.

Bremer, James C.↗

NASA NTRS2019

Soil Displacement Terramechanics for Wheel-Based Trenching with a Planetary Rover

Planetary exploration rovers are expensive, weight constrained, and cannot be serviced once deployed. Here, we explore one way to increase their capabilities while avoiding the cost, mass, and complexity leading to these issues. We propose to re-use the large wheel actuators for trenching and other digging operations, which will enable a range of missions such as sampling deeper layers of soil. We present a new, closed-form model of the soil displaced by an angled, spinning wheel to analyze the trenching potential of a driving strategy and inform the control of the wheel. The model is demonstrated with single wheel experiments under different driving conditions. The model suggests: that a deep trench does not require large tractive efforts; that the shape of the trench can be controlled; and that a rear wheel has a lower risk of entrapment when trenching than a front wheel. Ultimately this model could be used in a nonprehensile manipulation planning or learning algorithm to enable autonomous trenching.

Wheels↗