Radio astronomy Explorer apogee kick motor Final report, 5 May 1966 - 31 Mar. 1967
Design, development, and static firing tests of apogee kick motor for Radio Astronomy Explorer Satellite
Jones, H. G.↗
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Atlas V Launch Incorporated NASA Glenn Thermal Barrier
In the Spring of 2002, Aerojet experienced a major failure during a qualification test of the solid rocket motor that they were developing for the Atlas V Enhanced Expendable Launch Vehicle. In that test, hot combustion gas reached the O-rings in the nozzle-to-case joint and caused a structural failure that resulted in loss of the nozzle and aft dome sections of the motor. To improve the design of this joint, Aerojet decided to incorporate three braided carbon-fiber thermal barriers developed at the NASA Glenn Research Center. The thermal barriers were used to block the searing-hot 5500 F pressurized gases from reaching the temperature-sensitive O-rings that seal the joint. Glenn originally developed the thermal barriers for the nozzle joints of the space shuttle solid rocket motors, and Aerojet decided to use them on the basis of the results of several successful ground tests of the thermal barriers in the shuttle rockets. Aerojet undertook an aggressive schedule to redesign the rocket nozzle-to-case joint with the thermal barriers and to qualify it in time for a launch planned for the middle of 2003. They performed two successful qualification tests (Oct. and Dec. 2002) in which the Glenn thermal barriers effectively protected the O-rings. These qualification tests saved hundreds of thousands of dollars in development costs and put the Lockheed-Martin/Aerojet team back on schedule. On July 17, 2003, the first flight of an Atlas V boosted with solid rocket motors successfully launched a commercial satellite into orbit from Cape Canaveral Air Force Station. Aero-jet's two 67-ft solid rocket boosters performed flawlessly, with each providing thrust in excess of 250,000 lbf. Both motors incorporated three Glenn-developed thermal barriers in their nozzle-to-case joints. The Cablevision satellite launched on this mission will be used to provide direct-to-home satellite television programming for the U.S. market starting in late 2003. The Atlas V is a product of the military's Enhanced Expendable Launch Vehicle program designed to provide assured military access to space. It can lift payloads up to 19,100 lb to geosynchronous transfer orbit and was designed to meet Department of Defense, commercial, and NASA needs. The Atlas V and Delta IV are two launch systems being considered by NASA to launch the Orbital Space Plane/Crew Exploration Vehicle. The launch and rocket costs of this mission are valued at $250 million. Successful application of the Glenn thermal barrier to the Atlas V program was an enormous breakthrough for the program's technical and schedule success.
Dunlap, Patrick H., Jr.↗
Amorphous Metal Ribbon (AMR) and Metal Amorphous Nanocomposite (MANC) Materials Enabled High Power Density Vehicle Motor Applications (Final Technical Report)
A collaborative team from Carnegie Mellon Univ. (CMU), North Carolina State Univ. (NCSU) and Metglas, South Carolina have studied new high speed motors (HSMs) with high-power density for traction motor applications. These are enabled by hybrid designs, including Flux Switching with Permanent Magnets (FSWPM) motors, exploiting permanent magnets without heavy rare earths (RE-lean) and high induction/high resistivity soft magnetic materials that allow for high switching frequencies needed to increase power densities. Team members include Michael E. McHenry, Prof. Materials Science & Eng., CMU, with > 30 years experience in magnetic materials development; Subashish Bhattacharya, Prof. Electrical Eng. and Freedom Center Director at NCSU with > 30 years experience in development of power electronic components and systems and Eric Theisen, Director of Research at Metglas, the only US located supplier of AMR and MANC materials. The team offers novel axial motor architectures exploiting soft magnetic materials (SMMs) that switch with low loss at high frequencies and heavy rare earth free permanent magnets that address materials criticality issues, supply chain risks, and high costs for traction motors. Axial-flux permanent magnet motors (APFM), offer efficiency improvements reducing rotor losses and also significantly higher power density. Axial-flux construction requires less core material, high torque-to-weight ratio. Since AFPM machines have thin magnets, they are smaller than radial flux motors making them attractive in space-limited applications. Noise and vibration are less and planar air gaps are easily adjusted. Flexibility in air-gap direction allows many topologies.
36 MATERIALS SCIENCE↗
A First Look at Electric Motor Noise For Future Propulsion Systems
Motor tone predictions using a vibration analysis and input from design parameters for high power density motors show that the noise can be significantly higher or lower than the empirical correlations and exceeds the stated uncertainty.
aircraft noise↗
Design and Development of a Fluid Immersion Cooled, SiC MOSFET, 37.5 kW, Bi-Directional Motor Converter
NASA's SUb-sonic Single Aft eNgine (SUSAN) aircraft is a concept aircraft whose architecture is that of a subsonic regional jet transport aircraft. SUSAN contains a single turbofan engine coupled to an electrified aircraft propulsion (EAP) system. To provide a path towards this goal, a 25% scale version of the SUSAN aircraft is being researched. A main component of the 25% power train is the Motor And Generator Intelligent Converter (MAGIC). This paper presents the design, development, and initial test results from MAGIC, a 37.5 kW, fluid immersion cooled, silicon carbide (SiC) MOSFET-based, bi-directional converter and controller.
PAO↗
Design and Development of a Fluid Immersion Cooled, SiC MOSFET, 37.5 kW, Bi-Directional Motor Converter
NASA's SUb-sonic Single Aft eNgine (SUSAN) aircraft is a concept aircraft whose architecture is that of a subsonic regional jet transport aircraft. SUSAN contains a single turbofan engine coupled to an electrified aircraft propulsion (EAP) system. To provide a path towards this goal, a 25% scale version of the SUSAN aircraft is being researched. A main component of the 25% power train is the Motor And Generator Intelligent Converter (MAGIC). This paper presents the design, development, and initial test results from MAGIC, a 37.5 kW, fluid immersion cooled, silicon carbide (SiC) MOSFET-based, bi-directional converter and controller.
Immersion↗
Object-Oriented Control System Design Using On-Line Training of Artificial Neural Networks
This report deals with the object-oriented model development of a neuro-controller design for permanent magnet (PM) dc motor drives. The system under study is described as a collection of interacting objects. Each object module describes the object behaviors, called methods. The characteristics of the object are included in its variables. The knowledge of the object exists within its variables, and the performance is determined by its methods. This structure maps well to the real world objects that comprise the system being modeled. A dynamic learning architecture that possesses the capabilities of simultaneous on-line identification and control is incorporated to enforce constraints on connections and control the dynamics of the motor. The control action is implemented "on-line", in "real time" in such a way that the predicted trajectory follows a specified reference model. A design example of controlling a PM dc motor drive on-line shows the effectiveness of the design tool. This will therefore be very useful in aerospace applications. It is expected to provide an innovative and noval software model for the rocket engine numerical simulator executive.
Rubaai, Ahmed↗
Sensory-Feedback Exoskeletal Arm Controller
An electromechanical exoskeletal arm apparatus has been designed for use in controlling a remote robotic manipulator arm. The apparatus, called a force-feedback exoskeleton arm master (F-EAM) is comfortable to wear and easy to don and doff. It provides control signals from the wearer s arm to a robot arm or a computer simulator (e.g., a virtual-reality system); it also provides force and torque feedback from sensors on the robot arm or from the computer simulator to the wearer s arm. The F-EAM enables the wearer to make the robot arm gently touch objects and finely manipulate them without exerting excessive forces. The F-EAM features a lightweight design in which the motors and gear heads that generate force and torque feedback are made smaller than they ordinarily would be: this is achieved by driving the motors to power levels greater than would ordinarily be used in order to obtain higher torques, and by providing active liquid cooling of the motors to prevent overheating at the high drive levels. The F-EAM (see figure) includes an assembly that resembles a backpack and is worn like a backpack, plus an exoskeletal arm mechanism. The FEAM has five degrees of freedom (DOFs) that correspond to those of the human arm: 1. The first DOF is that of the side-to-side rotation of the upper arm about the shoulder (rotation about axis 1). The reflected torque for this DOF is provided by motor 1 via drum 1 and a planar four-bar linkage. 2. The second DOF is that of the up-and-down rotation of the arm about the shoulder. The reflected torque for this DOF is provided by motor 2 via drum 2. 3. The third DOF is that of twisting of the upper arm about its longitudinal axis. This DOF is implemented in a cable remote-center mechanism (CRCM). The reflected torque for this DOF is provided by motor 3, which drives the upper-arm cuff and the mechanism below it. A bladder inflatable by gas or liquid is placed between the cuff and the wearer s upper arm to compensate for misalignment between the exoskeletal mechanism and the shoulder. 4. The fourth DOF is that of flexion and extension of the elbow. The reflected torque for this DOF is provided by motor 4 and drum 4, which are mounted on a bracket that can slide longitudinally by a pin-and-slot engagement with the upper-arm cuff to compensate for slight variations in the position of the kinematic center of the elbow. Attached to drum 4 is an adapter plate to which is attached a CRCM for the lower arm. 5. The lower-arm CRCM implements the fifth DOF, which is the twist of the forearm about its longitudinal axis. Motor 5 provides the reflected torque for this DOF by driving the lower-arm cuff. A rod transmits twist and torsion between the lower-arm cuff and the hand cuff. With this system, the motion of the wearer s joints and the reflected torques applied to these joints can be measured and controlled in a relatively simple manner. This is because the anthropomorphic design of the mechanism imitates the kinematics of the human arm, eliminating the need for kinematic conversion of joint-torque and joint-angle data.
An, Bin↗
Designing for auto safety
Safety design features in the motor vehicle and highway construction fields result from systems analysis approach to prevent or lessen death, injury, and property damage results. Systems analysis considers the prevention of crashes, increased survivability in crashes, and prompt medical attention to injuries as well as other postcrash salvage measures. The interface of these system elements with the driver, the vehicle, and the environment shows that action on the vehicle system produces the greatest safety payoff through design modifications. New and amended safety standards developed through hazard analysis technique improved accident statistics in the 70'; these regulations include driver qualifications and countermeasures to identify the chronic drunken driver who is involved in more than two-thirds of all auto deaths.
Elwood T. Driver↗
Internal Flow Analysis of Large L/D Solid Rocket Motors
Traditionally, Solid Rocket Motor (SRM) internal ballistic performance has been analyzed and predicted with either zero-dimensional (volume filling) codes or one-dimensional ballistics codes. One dimensional simulation of SRM performance is only necessary for ignition modeling, or for motors that have large length to port diameter ratios which exhibit an axial "pressure drop" during the early burn times. This type of prediction works quite well for many types of motors, however, when motor aspect ratios get large, and port to throat ratios get closer to one, two dimensional effects can become significant. The initial propellant grain configuration for the Space Shuttle Reusable Solid Rocket Motor (RSRM) was analyzed with 2-D, steady, axi-symmetric computational fluid dynamics (CFD). The results of the CFD analysis show that the steady-state performance prediction at the initial burn geometry, in general, agrees well with 1-D transient prediction results at an early time, however, significant features of the 2-D flow are captured with the CFD results that would otherwise go unnoticed. Capturing these subtle differences gives a greater confidence to modeling accuracy, and additional insight with which to model secondary internal flow effects like erosive burning. Detailed analysis of the 2-D flowfield has led to the discovery of its hidden 1-D isentropic behavior, and provided the means for a thorough and simplified understanding of internal solid rocket motor flow. Performance parameters such as nozzle stagnation pressure, static pressure drop, characteristic velocity, thrust and specific impulse are discussed in detail and compared for different modeling and prediction methods. The predicted performance using both the 1-D codes and the CFD results are compared with measured data obtained from static tests of the RSRM. The differences and limitations of predictions using ID and 2-D flow fields are discussed and some suggestions for the design of large L/D motors and more critically, motors with port to throat ratios near one, are covered.
Laubacher, Brian A.↗
Nondestructive Evaluation Correlated with Finite Element Analysis
Advanced materials are being developed for use in high-temperature gas turbine applications. For these new materials to be fully utilized, their deformation properties, their nondestructive evaluation (NDE) quality and material durability, and their creep and fatigue fracture characteristics need to be determined by suitable experiments. The experimental findings must be analyzed, characterized, modeled and translated into constitutive equations for stress analysis and life prediction. Only when these ingredients - together with the appropriate computational tools - are available, can durability analysis be performed in the design stage, long before the component is built. One of the many structural components being evaluated by the NDE group at the NASA Lewis Research Center is the flywheel system. It is being considered as an energy storage device for advanced space vehicles. Such devices offer advantages over electrochemical batteries in situations demanding high power delivery and high energy storage per unit weight. In addition, flywheels have potentially higher efficiency and longer lifetimes with proper motor-generator and rotor design. Flywheels made of fiber-reinforced polymer composite material show great promise for energy applications because of the high energy and power densities that they can achieve along with a burst failure mode that is relatively benign in comparison to those of flywheels made of metallic materials Therefore, to help improve durability and reduce structural uncertainties, we are developing a comprehensive analytical approach to predict the reliability and life of these components under these harsh loading conditions. The combination of NDE and two- and three-dimensional finite element analyses (e.g., stress analyses and fracture mechanics) is expected to set a standardized procedure to accurately assess the applicability of using various composite materials to design a suitable rotor/flywheel assembly.
Abdul-Azid, Ali↗
Real-Time Inhibitor Recession Measurements in Two Space Shuttle Reusable Solid Rocket Motors
Real-time internal motor insulation char line recession measurements have been evaluated for two full-scale static tests of the Space Shuttle Reusable Solid Rocket Motor (RSRM). These char line recession measurements were recorded on the forward facing propellant grain inhibitors to better understand the thermal performance of these inhibitors. The RSRM propellant grain inhibitors are designed to erode away during motor operation, thus making it difficult to use post-fire observations to determine inhibitor thermal performance. Therefore, this new internal motor instrumentation is invaluable in establishing an accurate understanding of inhibitor recession versus motor operation time. The data for the first test was presented at the 37th AIAA/ASME/SAE/ASEE Joint Propulsion Conference and Exhibit (AIAA 2001-3280) in July 2001. Since that time, a second full scale static test has delivered additional real-time data on inhibitor thermal performance. The evaluation of this data is presented in this paper. The second static test, in contrast to the first test, used a slightly different arrangement of instrumentation in the inhibitors. This instrumentation has yielded a better understanding of the inhibitor time dependent inboard tip recession. Graphs of inhibitor recession profiles with time are presented. Inhibitor thermal ablation models have been created from theoretical principals. The model predictions compare favorably with data from both tests. This verified modeling effort is important to support new inhibitor designs for a five segment Space Shuttle solid rocket motor. The internal instrumentation project on RSRM static tests is providing unique opportunities for other real-time internal motor measurements that could not otherwise be directly quantified.
McWhorter, B. B.↗
Robust Control Design for Uncertain Nonlinear Dynamic Systems
Robustness to parametric uncertainty is fundamental to successful control system design and as such it has been at the core of many design methods developed over the decades. Despite its prominence, most of the work on robust control design has focused on linear models and uncertainties that are non-probabilistic in nature. Recently, researchers have acknowledged this disparity and have been developing theory to address a broader class of uncertainties. This paper presents an experimental application of robust control design for a hybrid class of probabilistic and non-probabilistic parametric uncertainties. The experimental apparatus is based upon the classic inverted pendulum on a cart. The physical uncertainty is realized by a known additional lumped mass at an unknown location on the pendulum. This unknown location has the effect of substantially altering the nominal frequency and controllability of the nonlinear system, and in the limit has the capability to make the system neutrally stable and uncontrollable. Another uncertainty to be considered is a direct current motor parameter. The control design objective is to design a controller that satisfies stability, tracking error, control power, and transient behavior requirements for the largest range of parametric uncertainties. This paper presents an overview of the theory behind the robust control design methodology and the experimental results.
Kenny, Sean P.↗
Practical application of power conditioning to electric propulsion for passenger vehicles
A functional model 15 HP, 120 volt, 4-pole, 7600 r.p.m. samarium-cobalt permanent magnet type brushless dc motor-transistorized power conditioner unit was designed, fabricated and tested for specific use in propulsion of electric passenger vehicles. This new brushless motor system, including its power conditioner package, has a number of important advantages over existing systems such as reduced weight and volume, higher reliability, and potential for improvements in efficiencies. These advantages are discussed in this paper in light of the substantial test data collected during experimentation with the newly developed conditioner motor propulsion system. Details of the power conditioner design philosophy and particulars are given in the paper. Also, described here are the low level electronic design and operation in relation to the remainder of the system.
Demerdash, N. A.↗
Improved Underwater Excitation-Emission Matrix Fluorometer
A compact, high-resolution, two-dimensional excitation-emission matrix fluorometer (EEMF) has been designed and built specifically for use in identifying and measuring the concentrations of organic compounds, including polluting hydrocarbons, in natural underwater settings. Heretofore, most EEMFs have been designed and built for installation in laboratories, where they are used to analyze the contents of samples collected in the field and brought to the laboratories. Because the present EEMF can be operated in the field, it is better suited to measurement of spatially and temporally varying concentrations of substances of interest. In excitation-emission matrix (EEM) fluorometry, fluorescence is excited by irradiating a sample at one or more wavelengths, and the fluorescent emission from the sample is measured at multiple wavelengths. When excitation is provided at only one wavelength, the technique is termed one-dimensional (1D) EEM fluorometry because the resulting matrix of fluorescence emission data (the EEM) contains only one row or column. When excitation is provided at multiple wavelengths, the technique is termed two-dimensional (2D) EEM fluorometry because the resulting EEM contains multiple rows and columns. EEM fluorometry - especially the 2D variety - is well established as a means of simultaneously detecting numerous dissolved and particulate compounds in water. Each compound or pool of compounds has a unique spectral fluorescence signature, and each EEM is rich in information content, in that it can contain multiple fluorescence signatures. By use of deconvolution and/or other mixture-analyses techniques, it is often possible to isolate the spectral signature of compounds of interest, even when their fluorescence spectra overlap. What distinguishes the present 2D EEMF over prior laboratory-type 2D EEMFs are several improvements in packaging (including a sealed housing) and other aspects of design that render it suitable for use in natural underwater settings. In addition, the design of the present 2D EEMF incorporates improvements over the one prior commercial underwater 2D EEMF, developed in 1994 by the same company that developed the present one. Notable advanced features of the present EEMF include the following: 1) High sensitivity and spectral resolution are achieved by use of an off-the-shelf grating spectrometer equipped with a sensor in the form of a commercial astronomical- grade 256 532-pixel charge-coupled-device (CCD) array. 2) All of the power supply, timing, control, and readout circuits for the illumination source and the CCD, ancillary environmental monitoring sensors, and circuitry for controlling a shutter or filter motor are custom-designed and mounted compactly on three circuit boards below a fourth circuit board that holds the CCD (see figure). 3) The compactness of the grating spectrometer, CCD, and circuit assembly makes it possible to fit the entire instrument into a compact package that is intended to be maneuverable underwater by one person. 4) In mass production, the cost of the complete instrument would be relatively low - estimated at approximately $30,000 at 2005 prices.
Moore, Casey↗
Magnetically suspended stepping motors for clean room and vacuum environments
To answer the growing needs for super-clean or contact free actuators for uses in clean rooms, vacuum chambers, and space, innovative actuators which combine the functions of stepping motors and magnetic bearings in one body were developed. The rotor of the magnetically suspended stepping motor is suspended like a magnetic bearing and rotated and positioned like a stepping motor. The important trait of the motor is that it is not a simple mixture or combination of a stepping motor and conventional magnetic bearing, but an amalgam of a stepping motor and a magnetic bearing. Owing to optimal design and feed-back control, a toothed stator and rotor are all that are needed structurewise for stable suspension. More than ten types of motors such as linear type, high accuracy rotary type, two-dimensional type, and high vacuum type were built and tested. This paper describes the structure and design of these motors and their performance for such applications as precise positioning rotary table, linear conveyor system, and theta-zeta positioner for clean room and high vacuum use.
Higuchi, Toshiro↗
Design and development of liquid hydrogen mixer unit
A dc brushless motor driven mixer unit (a vaneaxial fan) was designed and evaluated for use in cryogenic fluids (liquids and gases). It was found to operate well in all fluids in which it was tested. The test fluids were liquid and gaseous helium, hydrogen in the liquid phase gas phase and mixtures of the two phases, and liquid nitrogen. It operated for over 100 hr at cryogenic temperatures without damage to the bearings and at the conclusion of testing the condition of the bearings was such that an operational life of 5000 hr appeared possible. The unit demonstrated that (with the brushless dc motor principle) useful pumping of cryogenic fluids could be accomplished with very small power inputs to the mixer motor. During test, the motor input power varied from approximately 0.5 W to 2.5 W, depending on fluid density. The high power input produced a mixer efficiency of over 49 percent. In an earlier program (see NASA Report CR-72365), a mixer using an ac induction motor demonstrated an efficiency of 17.7 percent under the same conditions, illustrating the advantage of the dc brushless motor driven unit. The mixer also demonstrated its ability to automatically vary speed as a function of the density of the fluid being pumped. This causes the unit to deliver higher volumetric flow rates as fluid density decreases.
Morgan, R. W.↗
G2 Flywheel Module Design
Design of a flywheel module, designated the G2 module, is described. The G2 flywheel is a 60,000 RPM, 525 W-hr, 1 kW system designed for a laboratory environment; it will be used for component testing and system demonstrations, with the goal of applying flywheels to aerospace energy storage and integrated power and attitude control (IPACS) applications. G2 has a modular design, which allows for new motors, magnetic bearings, touchdown bearings, and rotors to be installed without a complete redesign of the system. This design process involves several engineering disciplines, and requirements are developed for the speed, energy storage, power level, and operating environment. The G2 rotor system consists of a multilayer carbon fiber rim with a titanium hub on which the other components mount, and rotordynamics analysis is conducted to ensure rigid and flexible rotor modes are controllable or outside of the operating speed range. Magnetic bearings are sized using 1-D magnetic circuit analysis and refined using 3-D finite element analysis. The G2 magnetic bearing system was designed by Texas A&M and has redundancy which allows derated operation after the loss of some components, and an existing liquid cooled two pole permanent magnet motor/generator is used. The touchdown bearing system is designed with a squeeze film damper system allowing spin down from full operating speed in case of a magnetic bearing failure. The G2 flywheel will enable module level demonstrations of component technology, and will be a key building block in system level attitude control and IPACS demonstrations.
Jensen, Ralph H.↗