SEARCH · Engineering Papers
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.
Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.
Set of alignment jigs hold fittings during adhesive bonding of fittings to ends of truss members. For each member, jigs hold two end fittings collinear while member allowed to move slightly, within dimensional tolerances, during injection and curing of adhesive. Once adhesive cured, fittings remain collinear even though member not necessarily perfectly straight between them.
The dynamic behavior of a reconfigurable adaptive truss structure with non-linear joints is investigated. The objective is to experimentally examine the effects of the local non-linearities on the global dynamics of the structure. Amplitude changes in the frequency response functions are measured at micron levels of motion. The amplitude and frequency variations of a number of modes indicate a non-linear Coulomb friction response. Hysteretic bifurcation behavior is also measured at an amplitude approximately equal to the specified free-play in the joint. Under the 1 g pre-load, however, the non-linearity was dominantly characteristic of Coulomb friction with little evidence of free-play stiffening.
Space Station requirements for power have resulted in a need for photovoltaic solar arrays possessing large blanket surface area. However, due to the limited Shuttle payload volume solar array designers have been driven to a deployable concept that by nature is extremely flexible. The principal support for this array system is the Folding Articulating Square Truss Mast (FASTMast). In order to accommodate service loads the FASTMast is expected to exhibit nonlinear behavior which could possibly result in structural instability. Presented herein are the results of the Lewis Research Center test and analysis efforts performed in an effort to characterize the FASTMast structural behavior in terms of stability. Results include those obtained from recent nonlinear testing and analysis involving a 1/10 segment of the FASTMast flight article. Implications of these results as they relate to expected behavior of the flight unit will also be discussed.
Many initiatives under study by both the space science and earth science communities require large space systems, i.e. with apertures greater than 15 m or dimensions greater than 20 m. This paper reviews the effort in NASA Langley Research Center's Automated Structural Assembly Laboratory which laid the foundations for robotic construction of these systems. In the Automated Structural Assembly Laboratory reliable autonomous assembly and disassembly of an 8 meter planar structure composed of 102 truss elements covered by 12 panels was demonstrated. The paper reviews the hardware and software design philosophy which led to reliable operation during weeks of near continuous testing. Special attention is given to highlight the features enhancing assembly reliability.
The purpose of this paper is to utilize the genetic algorithm (GA) optimization method for structural design of a nuclear propulsion vehicle. Genetic algorithms provide a guided, random search technique that mirrors biological adaptation. To verify the GA capabilities, other traditional optimization methods were used to generate results for comparison to the GA results, first for simple two-dimensional structures, and then for full-scale three-dimensional truss designs.
Structural optimization is a field of research that has experienced noteworthy growth for many years. Researchers in this area have developed optimization tools to successfully design and model structures, typically minimizing mass while maintaining certain deflection and stress constraints. Numerous optimization studies have been performed to minimize mass, deflection and stress on a benchmark cantilever truss problem. Predominantly traditional optimization theory is applied to this problem. The cross-sectional area of each member is optimized to minimize the aforementioned objectives. This paper will present a structural optimization technique that has been previously applied to compliant mechanism design. This technique demonstrates a method that combines topology optimization, geometric refinement, finite element analysis, and two forms of evolutionary computation: Genetic Algorithms and Differential Evolution to successfully optimize a benchmark structural optimization problem. An non-traditional solution to the benchmark problem is presented in this paper, specifically a geometrically refined topological solution. The design process begins with an alternate control mesh formulation, multilevel geometric smoothing operation, and an elastostatic structural analysis. The design process is wrapped in an evolutionary computing optimization toolset.
In the present paper a set of performance metrics are derived from first principals to assess the efficiency of competing space truss structural concepts in terms of mass, stiffness, and strength, for designs that are constrained by packaging. The use of these performance metrics provides unique insight into the primary drivers for lowering structural mass and packaging volume as well as enabling quantitative concept performance evaluation and comparison. To demonstrate the use of these performance metrics, data for existing structural concepts are plotted and discussed. Structural performance data is presented for various mechanical deployable concepts, for erectable structures, and for rigidizable structures.
An artificial intelligence approach to planning the robotic assembly of large tetrahedral truss structures is presented.
Structural optimization is a field of research that has experienced noteworthy growth for many years. Researchers in this area have developed optimization tools to successfully design and model structures, typically minimizing mass while maintaining certain deflection and stress constraints. Numerous optimization studies have been performed to minimize mass, deflection, and stress on a benchmark cantilever truss problem. Predominantly traditional optimization theory is applied to this problem. The cross-sectional area of each member is optimized to minimize the aforementioned objectives. This Technical Publication (TP) presents a structural optimization technique that has been previously applied to compliant mechanism design. This technique demonstrates a method that combines topology optimization, geometric refinement, finite element analysis, and two forms of evolutionary computation: genetic algorithms and differential evolution to successfully optimize a benchmark structural optimization problem. A nontraditional solution to the benchmark problem is presented in this TP, specifically a geometrically refined topological solution. The design process begins with an alternate control mesh formulation, multilevel geometric smoothing operation, and an elastostatic structural analysis. The design process is wrapped in an evolutionary computing optimization toolset.
An integrally formed three-dimensional truss structure, including molds and methods for production of same, containing outer top and bottom plane surfaces thereof comprising interconnected rod segments integrally formed at their points of intersection on the outer top and bottom surfaces, the top and bottom surfaces also integrally joined together through additional interconnected rod segments passing through an integrally formed intersection, wherein the additional interconnected rod segments passing through the integrally formed intersection form a three-dimensional continuous array of triangles.
A solar energy concentrator system comprises an offset reflector structure made up of a plurality of solar energy reflector panel sections interconnected with one another to form a piecewise approximation of a portion of a (parabolic) surface of revolution rotated about a prescribed focal axis. Each panel section is comprised of a plurality of reflector facets whose reflective surfaces effectively focus reflected light to preselected surface portions of the interior sidewall of a cylindrically shaped solar energy receiver. The longitudinal axis of the receiver is tilted at an acute angle with respect to the optical axis such that the distribution of focussed solar energy over the interior surface of the solar engine is optimized for dynamic solar energy conversion. Each reflector panel section comprises a flat, hexagonally shaped truss support framework and a plurality of beam members interconnecting diametrically opposed corners of the hexagonal framework recessed within which a plurality of (spherically) contoured reflector facets is disposed. The depth of the framework and the beam members is greater than the thickness of a reflector facet such that a reflector facet may be tilted (for controlling the effective focus of its reflected light through the receiver aperture) without protruding from the panel section.
A paper describes the laser truss sensor (LTS) for detecting piston motion between two adjacent telescope segment edges. LTS is formed by two point-to-point laser metrology gauges in a crossed geometry. A high-resolution (<30 nm) LTS can be implemented with existing laser metrology gauges. The distance change between the reference plane and the target plane is measured as a function of the phase change between the reference and target beams. To ease the bandwidth requirements for phase detection electronics (or phase meter), homodyne or heterodyne detection techniques have been used. The phase of the target beam also changes with the refractive index of air, which changes with the air pressure, temperature, and humidity. This error can be minimized by enclosing the metrology beams in baffles. For longer-term (weeks) tracking at the micron level accuracy, the same gauge can be operated in the absolute metrology mode with an accuracy of microns; to implement absolute metrology, two laser frequencies will be used on the same gauge. Absolute metrology using heterodyne laser gauges is a demonstrated technology. Complexity of laser source fiber distribution can be optimized using the range-gated metrology (RGM) approach.
We describe an Intelligent Precision Jigging Robot (IPJR), which allows high precision assembly of commodity parts with low-precision bonding. We present preliminary experiments in 2D that are motivated by the problem of assembling a space telescope optical bench on orbit using inexpensive, stock hardware and low-precision welding. An IPJR is a robot that acts as the precise "jigging", holding parts of a local assembly site in place while an external low precision assembly agent cuts and welds members. The prototype presented in this paper allows an assembly agent (in this case, a human using only low precision tools), to assemble a 2D truss made of wooden dowels to a precision on the order of millimeters over a span on the order of meters. We report the challenges of designing the IPJR hardware and software, analyze the error in assembly, document the test results over several experiments including a large-scale ring structure, and describe future work to implement the IPJR in 3D and with micron precision.
Hardware and software design and system integration for an intelligent precision jigging robot (IPJR), which allows high precision assembly using commodity parts and low-precision bonding, is described. Preliminary 2D experiments that are motivated by the problem of assembling space telescope optical benches and very large manipulators on orbit using inexpensive, stock hardware and low-precision welding are also described. An IPJR is a robot that acts as the precise "jigging", holding parts of a local structure assembly site in place, while an external low precision assembly agent cuts and welds members. The prototype presented in this paper allows an assembly agent (for this prototype, a human using only low precision tools), to assemble a 2D truss made of wooden dowels to a precision on the order of millimeters over a span on the order of meters. The analysis of the assembly error and the results of building a square structure and a ring structure are discussed. Options for future work, to extend the IPJR paradigm to building in 3D structures at micron precision are also summarized.
The Subsonic Ultra Green Aircraft Research (SUGAR) Truss-Braced Wing (TBW) aeroservoelastic (ASE) wind-tunnel test was conducted in the NASA Langley Transonic Dynamics Tunnel (TDT) and was completed in April, 2014. The primary goals of the test were to identify the open-loop flutter boundary and then demonstrate flutter suppression. A secondary goal was to demonstrate gust load alleviation (GLA). Open-loop flutter and limit cycle oscillation onset boundaries were identified for a range of Mach numbers and various angles of attack. Two sets of control laws were designed for the model and both sets of control laws were successful in suppressing flutter. Control laws optimized for GLA were not designed; however, the flutter suppression control laws were assessed using the TDT Airstream Oscillation System. This paper describes the experimental apparatus, procedures, and results of the TBW wind-tunnel test. Acquired system ID data used to generate ASE models is also discussed.2 study.
Considerable attention has been given in recent years to the design of highly flexible aircraft. The results of numerous studies demonstrate the significant performance benefits of strut-braced wing (SBW) and trussbraced wing (TBW) configurations. Critical aspects of the TBW configuration are its larger aspect ratio, wing span and thinner wings. These aspects increase the importance of considering fluid/structure and control system coupling. This paper presents high-fidelity Navier-Stokes simulations of the dynamic response of the flexible Boeing Subsonic Ultra Green Aircraft Research (SUGAR) truss-braced wing wind-tunnel model. The latest version of the SUGAR TBW finite element model (FEM), v.20, is used in the present simulations. Limit cycle oscillations (LCOs) of the TBW wing/strut/nacelle are simulated at angle-of-attack (AoA) values of -1, 0 and +1 degree. The modal data derived from nonlinear static aeroelastic MSC.Nastran solutions are used at AoAs of -1 and +1 degrees. The LCO amplitude is observed to be dependent on AoA. LCO amplitudes at -1 degree are larger than those at +1 degree. The LCO amplitude at zero degrees is larger than either -1 or +1 degrees. These results correlate well with both wind-tunnel data and the behavior observed in previous studies using linear aerodynamics. The LCO onset at zero degrees AoA has also been computed using unloaded v.20 FEM modes. While the v.20 model increases the dynamic pressure at which LCO onset is observed, it is found that the LCO onset at and above Mach 0.82 is much different than that produced by an earlier version of the FEM, v. 19.
This report summarizes the Truss Braced Wing (TBW) work accomplished by the Boeing Subsonic Ultra Green Aircraft Research (SUGAR) team, consisting of Boeing Research and Technology, Boeing Commercial Airplanes, General Electric, Georgia Tech, Virginia Tech, NextGen Aeronautics, and Microcraft. A multi-disciplinary optimization (MDO) environment defined the geometry that was further refined for the updated SUGAR High TBW configuration. Airfoil shapes were tested in the NASA TCT facility, and an aeroelastic model was tested in the NASA TDT facility. Flutter suppression was successfully demonstrated using control laws derived from test system ID data and analysis models. Aeroelastic impacts for the TBW design are manageable and smaller than assumed in Phase I. Flutter analysis of TBW designs need to include pre-load and large displacement non-linear effects to obtain a reasonable match to test data. With the updated performance and sizing, fuel burn and energy use is reduced by 54% compared to the SUGAR Free current technology Baseline (Goal 60%). Use of the unducted fan version of the engine reduces fuel burn and energy by 56% compared to the Baseline. Technology development roadmaps were updated, and an airport compatibility analysis established feasibility of a folding wing aircraft at existing airports.
This Test Report summarizes the Truss Braced Wing (TBW) Aeroelastic Test (Task 3.1) work accomplished by the Boeing Subsonic Ultra Green Aircraft Research (SUGAR) team, which includes the time period of February 2012 through June 2014. The team consisted of Boeing Research and Technology, Boeing Commercial Airplanes, Virginia Tech, and NextGen Aeronautics. The model was fabricated by NextGen Aeronautics and designed to meet dynamically scaled requirements from the sized full scale TBW FEM. The test of the dynamically scaled SUGAR TBW half model was broken up into open loop testing in December 2013 and closed loop testing from January 2014 to April 2014. Results showed the flutter mechanism to primarily be a coalescence of 2nd bending mode and 1st torsion mode around 10 Hz, as predicted by analysis. Results also showed significant change in flutter speed as angle of attack was varied. This nonlinear behavior can be explained by including preload and large displacement changes to the structural stiffness and mass matrices in the flutter analysis. Control laws derived from both test system ID and FEM19 state space models were successful in suppressing flutter. The control laws were robust and suppressed flutter for a variety of Mach, dynamic pressures, and angle of attacks investigated.