Slow-speed drives for miniature devices
Hysteresis motor minimizes motor torque variations during shaft revolution when operated at high frequency and with a sinusoidal motor current. Motor speed is stabilized by a feedback servo.
Bahm, E. J.↗
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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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Navy GTE seal development activity
Under the auspices of the Integrated High Performance Turbine Engine Technology Initiative, the Naval Air Warfare Center conducts advanced development programs for demonstration in the next generation of air-breathing propulsion systems. Among the target technologies are gas path and lube oil seals. Two development efforts currently being managed by NAWCAD are the High Performance Compressor Discharge Film-Riding Face Seal and the Subsonic Core High Speed Air/Oil Seal. The High Performance Compressor Discharge Film-Riding Face Seal Program aims at reducing parasitic leakage through application of a film-riding face sea concept to the compressor discharge location of a Phase 2 IHPTET engine. An order-of-magnitude leakage reduction relative to current labyrinth seal configurations is expected. Performance goals for these seals are (1) 1200 F air temperature, (2) 800 feet-per-second surface velocity, and (3) 600 SPI differential pressure. The two designs chosen for fabrication and rig test are a spiral groove and a Rayleigh step seal. Rig testing is currently underway. The Subsonic Core High Speed Air/Oil Seal Program is developing shaft-to-ground seals for next-generation propulsion systems that will minimize leakage and provide full life. Significantly higher rotor speeds and temperatures will be experienced. Technologies being exploited include, hydrodynamic lift assist features, ultra light weight designs, and improved cooling schemes. Parametric testing has been completed; a final seal design is entering the endurance test phase.
Grala, Carl P.↗
Synchronization trigger control system for flow visualization
The use of cinematography or holographic interferometry for dynamic flow visualization in an internal combustion engine requires a control device that globally synchronizes camera and light source timing at a predefined shaft encoder angle. The device is capable of 0.35 deg resolution for rotational speeds of up to 73 240 rpm. This was achieved by implementing the shaft encoder signal addressed look-up table (LUT) and appropriate latches. The developed digital signal processing technique achieves 25 nsec of high speed triggering angle detection by using direct parallel bit comparison of the shaft encoder digital code with a simulated angle reference code, instead of using angle value comparison which involves more complicated computation steps. In order to establish synchronization to an AC reference signal whose magnitude is variant with the rotating speed, a dynamic peak followup synchronization technique has been devised. This method scrutinizes the reference signal and provides the right timing within 40 nsec. Two application examples are described.
Chun, K. S.↗
Improved circumferential shaft seal for aircraft gear transmissions
Operation under simulated aircraft transmission conditions of speeds to 2850 m/min (9350 ft/min), lubricant temperatures to 394 K (250 F), shaft radial runouts to 0.254 mm (0.010 in.) F.I.R. (full indicator reading), and pressure differentials to 1.03 N/cm2 (1.5 psi) revealed that conventional circumferential seals leaked excessively. Modifying the conventional seal by adding helical grooves to the seal bore reduced leakage rates to within the acceptable level of 10 cm3/hr. The leakage rate of this modified seal was not significantly affected by lubricant flooding or by shaft radial runout.
Ludwig, L. P.↗
An Assessment of Gas Foil Bearing Scalability and the Potential Benefits to Civilian Turbofan Engines
Over the past several years the term oil-free turbomachinery has been used to describe a rotor support system for high speed turbomachinery that does not require oil for lubrication, damping, or cooling. The foundation technology for oil-free turbomachinery is the compliant foil bearing. This technology can replace the conventional rolling element bearings found in current engines. Two major benefits are realized with this technology. The primary benefit is the elimination of the oil lubrication system, accessory gearbox, tower shaft, and one turbine frame. These components account for 8 to 13 percent of the turbofan engine weight. The second benefit that compliant foil bearings offer to turbofan engines is the capability to operate at higher rotational speeds and shaft diameters. While traditional rolling element bearings have diminished life, reliability, and load capacity with increasing speeds, the foil bearing has a load capacity proportional to speed. The traditional applications for foil bearings have been in small, lightweight machines. However, recent advancements in the design and manufacturing of foil bearings have increased their potential size. An analysis, grounded in experimentally proven operation, is performed to assess the scalability of the modern foil bearing. This analysis was coupled to the requirements of civilian turbofan engines. The application of the foil bearing to larger, high bypass ratio engines nominally at the 120 kN (approx.25000 lb) thrust class has been examined. The application of this advanced technology to this system was found to reduce mission fuel burn by 3.05 percent.
Bruckner, Robert J.↗
Touch and Go Surface Sampler (TGSS)
The Touch and Go Surface Sampler (TGSS) is a new class of planetary and small body sample acquisition tool that can be used for the surface exploration of Europa, Titan and comets. TGSS in its basic configuration consists of a high speed sampling head attached to the end of a flexible shaft. The sampling head consists of counter rotating cutters that rotates at speeds of 3000 to 15000 RPM. The attractive feature of this if touch and go type sampler is that there are no requirements for a lander type spacecraft. Additional information is contained in the original extended abstract.
Gorevan, S. P.↗
Directional gear ratio transmissions
Epicyclic gear transmissions which transmit output at a gear ratio dependent only upon the input's direction are considered. A transmission housing envelops two epicyclic gear assemblies, and has shafts extending from it. One shaft is attached to a sun gear within the first epicyclic gear assembly. Planet gears are held symmetrically about the sun gear by a planet gear carrier and are in mesh with both the sun gear and a ring gear. Two unidirectional clutches restrict rotation of the first planet gear carrier and ring gear to one direction. A connecting shaft drives a second sun gear at the same speed and direction as the first planet gear carrier while a connecting portion drives a second planet gear carrier at the same speed and direction as the first ring gear. The transmission's output is then transmitted by the second ring gear to the second shaft. Input is transmitted at a higher gear ratio and lower speed for all inputs in the first direction than in the opposite direction.
Lafever, A. E.↗
Development of small bore, high speed tapered roller bearing
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.
Morrison, F. R.↗
Air speed and attitude probe
An air speed and attitude probe characterized by a pivot shaft normally projected from a data boom and supported thereby for rotation about an axis of rotation coincident with the longitudinal axis of the shaft is described. The probe is a tubular body supported for angular displacement about the axis of rotation and has a fin mounted on the body for maintaining one end of the body in facing relation with relative wind and has a pair of transducers mounted in the body for providing intelligence indicative of total pressure and static pressure for use in determining air speed. A stack of potentiometers coupled with the shaft to provide intelligence indicative of aircraft attitude, and circuitry connecting the transducers and potentiometers to suitable telemetry circuits are described.
Baker, G. J.↗
Manufacturing Process Development of a Carbon Fiber Reinforced Polymer Composite Shaft for Electric Motors
Electric aircraft applications require electric motors with increased specific power and efficiency. Composite structural components in motors are a potential solution for reducing motor mass, reducing magnetic losses, and limiting undesired conduction paths for fault, electromagnetic interference, or common-mode currents. In this report, manufacturing trials for a high-speed carbon fiber reinforced polymer composite motor shaft are presented. Four prototype shafts were produced using a hybrid biaxial/triaxial fabric that was circumferentially wrapped onto an additively manufactured high-temperature washout mandrel. An additional traditional overbraid approach was also evaluated and shows promise for high-rate, high-performance parts using automated manufacturing. This paper discusses the shaft design, manufacturing methods explored, material selection, the manufacturing trials, and the lessons learned. The results of this manufacturing investigation show feasibility for manufacturing composite shafts for electric motors.
Electric moto shaft↗
Acoustic measurements of a full-scale coaxial helicopter
Acoustic data were obtained during a full-scale test of the XH-59A Advancing Blade Concept (ABC) Technology Demonstrator in the NASA Ames 40- by 80-Foot Wind Tunnel. The XH-59A is a research helicopter with two coaxial rotors and hingeless blades. Performance, vibration, noise at various forward speeds, rotor lift coefficients, and rotor shaft angles of attack were investigated. In general, the noise level is shown to increase with rotor lift coefficient except under certain operating conditions where it is increased by significant impulsive blade/vortex interactions. The impulsivity appears to depend upon how the lift is distributed between the two rotors. The noise levels measured are shown to be slightly higher than on a modern conventional rotor tested in the same facility.
Mosher, M.↗
Effect of a wing-tip mounted pusher turboprop on the aerodynamic characteristics of a semi-span wing
An exploratory investigation has been conducted at the NASA Langley Research Center to determine the installed performance of a wing tip-mounted pusher turboprop. Tests were conducted using a semispan model having an unswept, untapered wing with a air-driven motor located on the tip of the wing, with an SR-2 design high speed propeller installed on the rear shaft of the motor. All tests were conducted at a Mach number of 0.70, at angles of attack of approximately -2 to +4 deg, and at a Reynolds number of 3.82 million based on the wing chord of 13 inches. The data indicate that, as a result of locating the propeller behind the wing trailing edge, at the wingtip, in the cross flow of the tip vortex, it is possible to recover part of the vortex energy as an increase in propeller thrust and, therefore, a reduction in the lift-induced drag as well.
Patterson, J. C., Jr.↗
A model propulsion simulator for evaluating counter rotating blade characteristics
Three Model Propulsion Simulators (MPS) were designed and built to evaluate candidate counterrotation Ultra bypass fan model blade designs of nominally 2-ft (0.61 m) tip diameter for an advanced 'pusher-type' aircraft engine. These propulsion simulators (nominally 1/5 engine size) are capable of operation over a wide range of subsonic conditions and can deliver up to 750 shaft horsepower per rotor at rotor speeds of 10,000 rpm. The rotor thrust and torque, dynamic blade stresses, and system temperature data are transmitted through an integral telemetry system to facilitate data acquisition. Salient features of the design, instrumentation, and operation of these simulators are described in this paper.
Delaney, B. R.↗
Results of a sub-scale model rotor icing test
A heavily instrumented sub-scale model of a helicopter main rotor was tested in the NASA Lewis Research Center Icing Research Tunnel (IRT) in September and November 1989. The four-bladed main rotor had a diameter of 1.83 m (6.00 ft) and the 0.124 m (4.9 in) chord rotor blades were specially fabricated for this experiment. The instrumented rotor was mounted on a Sikorsky Aircraft Powered Force Model, which enclosed a rotor balance and other measurement systems. The model rotor was exposed to a range of icing conditions that included variations in temperature, liquid water content, and median droplet diameter, and was operated over ranges of advance ratio, shaft angle, tip Mach number (rotor speed) and weight coefficient to determine the effect of these parameters on ice accretion. In addition to strain gage and balance data, the test was documented with still, video, and high speed photography, ice profile tracings, and ice molds. The sensitivity of the model rotor to the test parameters, is given, and the result to theoretical predictions are compared. Test data quality was excellent, and ice accretion prediction methods and rotor performance prediction methods (using published icing lift and drag relationships) reproduced the performance trends observed in the test. Adjustments to the correlation coefficients to improve the level of correlation are suggested.
Flemming, Robert J.↗
Model rotor icing tests in the NASA Lewis icing research tunnel
Tests of a lightly instrumented two-bladed teetering rotor and a heavily instrumented sub-scale articulated main rotor were conducted in the NASA Lewis Research Center Icing Research Tunnel (IRT) in August 1988 and September and November 1989. The first was an OH-58 tail rotor which had a diameter of 1.575 m and a blade chord of 0.133 m, and was mounted on a NASA designed test rig. The second, a four bladed articulated rotor, had a diameter of 1.83 m with 0.124 m chord blades specially fabricated for the experiment. This rotor was mounted on a Sikorsky Aircraft Powered Force Model, which enclosed a rotor balance and other measurement systems. The models were exposed to variations in temperature, liquid water content, and medium droplet diameter, and were operated over ranges of advance ratio, shaft angle, tip Mach number (rotor speed), and weight coefficient to determine the effect of these parameters on ice accretion. In addition to strain gage and balance data, the test was documented with still, video, and high speed photography, ice profile tracing, and ice molds. Presented here are the sensitivity of the model rotors to the test parameters and a comparison of the results to theoretical predictions.
Flemming, Robert J.↗
Results of a sub-scale model rotor icing test
A heavily instrumented sub-scale model of a helicopter main rotor was tested in the NASA Lewis Research Center Icing Research Tunnel (IRT) in September and November 1989. The four-bladed main rotor had a diameter of 1.83 m (6.00 ft) and the 0.124 m (4.9 in) chord rotor blades were specially fabricated for this experiment. The instrumented rotor was mounted on a Sikorsky Aircraft Powered Force Model, which enclosed a rotor balance and other measurement systems. The model rotor was exposed to a range of icing conditions that included variations in temperature, liquid water content, and median droplet diameter, and was operated over ranges of advance ratio, shaft angle, tip Mach number (rotor speed) and weight coefficient to determine the effect of these parameters on ice accretion. In addition to strain gage and balance data, the test was documented with still, video, and high speed photography, ice profile tracings, and ice molds. The sensitivity of the model rotor to the test parameters is given, and the result to theoretical predictions are compared. Test data quality was excellent, and ice accretion prediction methods and rotor performance prediction methods (using published icing lift and drag relationships) reproduced the performance trends observed in the test. Adjustments to the correlation coefficients to improve the level of correlation are suggested.
Flemming, Robert J.↗
Model rotor icing tests in the NASA. Lewis Icing Research Tunnel
Tests of a lightly instrumented two bladed teetering rotor and a heavily instrumented subscale articulated main rotor were conducted in the NASA Lewis Icing Research Tunnel (IRT). The first was an OH-58 tail rotor which had a diameter of 1.575 m and a blade chord of 0.133 m, and was mounted on a NASA designed test rig. The second, a four bladed articulated rotor, had a diameter of 1.83 m with 0.124 m chord blades specifically fabricated for the experiment. This rotor was mounted on a Sikorsky Aircraft Powered Force Model, which enclosed a rotor balance and other measurement systems. The models were exposed to variations in temperature, liquid water content, and medium droplet diameter, and were operated over ranges of advance ratio, shaft angle, tip Mach number (rotor speed), and weight coefficient to determine the effect of these parameters on ice accretion. In addition to strain gage and balance data, the test was documented with still, video, and high speed photography, ice profile tracing, and ice molds. The sensitivity is presented of the model rotors to the test parameter and a comparison of the results to theoretical predictions.
Flemming, Robert J.↗
A New 1000 F Magnetic Bearing Test Rig
NASA and the Army are currently exploring the possibility of using magnetic bearings in gas turbine engines. The use of magnetic bearings in gas turbine engines could increase the reliability by eliminating the lubrication system. The use of magnetic bearings could also increase the speed and the size of the shafts in the engine, thus reducing vibrations and possibly eliminating third bearings. Magnetic bearings can apply forces to the shafts and move them so that blade tips and seals do not rub. This could be part of an active vibration cancellation system. Also, whirling (displacing the shaft center line) may delay rotating stall and increase the stall margin of the engine. Magnetic bearings coupled with an integral starter generator could result in a more efficient 'more electric' engine. The IHPTET program, a joint DOD-industry program, has identified a need for a high temperature, (as high as 1200 F), magnetic bearing that could be demonstrated in a phase m engine. A magnetic bearing is similar to an electric motor. The magnetic bearing has a laminated rotor and stator made out of cobalt steel. The stator has a series of coils of wire wound around it. These coils f u. a series of electromagnets around the circumference. These magnets exert a force on the rotor to keep the rotor in the center of the cavity. The centering force is commanded by a controller based on shaft position, (measured by displacement probes). The magnetic bearing can only pull and is basically unstable before active control is applied The engine shafts, bearings, and case form a flexible structure which contain a large number of modes. A controller is necessary to stabilize these modes. A power amplifier is also necessary to provide the current prescribed by the controller to the magnetic bearings. In case of very high loads, a conventional back up bearing will engage and stop the rotor and stator from rubbing.
Kascak, Albert F.↗