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All sourcesNASA NTRSDOE OSTI
NASA NTRS2010

Foldable Instrumented Bits for Ultrasonic/Sonic Penetrators

Long tool bits are undergoing development that can be stowed compactly until used as rock- or ground-penetrating probes actuated by ultrasonic/sonic mechanisms. These bits are designed to be folded or rolled into compact form for transport to exploration sites, where they are to be connected to their ultrasonic/ sonic actuation mechanisms and unfolded or unrolled to their full lengths for penetrating ground or rock to relatively large depths. These bits can be designed to acquire rock or soil samples and/or to be equipped with sensors for measuring properties of rock or soil in situ. These bits can also be designed to be withdrawn from the ground, restowed, and transported for reuse at different exploration sites. Apparatuses based on the concept of a probe actuated by an ultrasonic/sonic mechanism have been described in numerous prior NASA Tech Briefs articles, the most recent and relevant being "Ultrasonic/ Sonic Impacting Penetrators" (NPO-41666) NASA Tech Briefs, Vol. 32, No. 4 (April 2008), page 58. All of those apparatuses are variations on the basic theme of the earliest ones, denoted ultrasonic/sonic drill corers (USDCs). To recapitulate: An apparatus of this type includes a lightweight, low-power, piezoelectrically driven actuator in which ultrasonic and sonic vibrations are generated and coupled to a tool bit. The combination of ultrasonic and sonic vibrations gives rise to a hammering action (and a resulting chiseling action at the tip of the tool bit) that is more effective for drilling than is the microhammering action of ultrasonic vibrations alone. The hammering and chiseling actions are so effective that the size of the axial force needed to make the tool bit advance into soil, rock, or another material of interest is much smaller than in ordinary twist drilling, ordinary hammering, or ordinary steady pushing. Examples of properties that could be measured by use of an instrumented tool bit include electrical conductivity, permittivity, magnetic field, magnetic permeability, temperature, and any other properties that can be measured by fiber-optic sensors. The problem of instrumenting a probe of this type is simplified, relative to the problem of attaching electrodes in a rotating drill bit, in two ways: (1) Unlike a rotating drill bit, a bit of this type does not have flutes, which would compound the problem of ensuring contact between sensors and the side wall of a hole; and (2) there is no need for slip rings for electrical contact between sensor electronic circuitry and external circuitry because, unlike a rotating drill, a tool bit of this type is not rotated continuously during operation. One design for a tool bit of the present type is a segmented bit with a segmented, hinged support structure (see figure). The bit and its ultrasonic/sonic actuator are supported by a slider/guiding fixture, and its displacement and preload are controlled by a motor. For deployment from the folded configuration, a spring-loaded mechanism rotates the lower segment about the hinges, causing the lower segment to become axially aligned with the upper segment. A latching mechanism then locks the segments of the bit and the corresponding segments of the slider/guiding fixture. Then the entire resulting assembly is maneuvered into position for drilling into the ground. Another design provides for a bit comprising multiple tubular segments with an inner alignment string, similar to a foldable tent pole comprising multiple tubular segments with an inner elastic cable connecting the two ends. At the beginning of deployment, all segments except the first (lowermost) one remain folded, and the ultrasonic/sonic actuator is clamped to the top of the lowermost segment and used to drive this segment into the ground. When the first segment has penetrated to a specified depth, the second segment is connected to the upper end of the first segment to form a longer rigid tubular bit and the actuator is moved to the upper end of the second segnt. The process as described thus far is repeated, adding segments until the desired depth of penetration has been attained. Yet other designs provide for bits in the form of bistable circular- or rectangular- cross-section tubes that can be stowed compactly like rolls of flat tape and become rigidified upon extension to full length, in a manner partly similar to that of a common steel tape measure. Albeit not marketed for use in tool bits, a bistable reeled composite product that transforms itself from a flat coil to a rigid tube of circular cross section when unrolled, is commercially available under the trade name RolaTube(TradeMark) and serves as a model for the further development of tool bits of this subtype.

Bar-Cohen, Yoseph↗
NASA NTRS2010

Nearly Seamless Vacuum-Insulated Boxes

A design concept, and a fabrication process that would implement the design concept, have been proposed for nearly seamless vacuum-insulated boxes that could be the main structural components of a variety of controlled-temperature containers, including common household refrigerators and insulating containers for shipping foods. In a typical case, a vacuum-insulated box would be shaped like a rectangular parallelepiped conventional refrigerator box having five fully closed sides and a hinged door on the sixth side. Although it is possible to construct the five-closed-side portion of the box as an assembly of five unitary vacuum-insulated panels, it is not desirable to do so because the relatively high thermal conductances of the seams between the panels would contribute significant amounts of heat leakage, relative to the leakage through the panels themselves. In contrast, the proposal would make it possible to reduce heat leakage by constructing the five-closed-side portion of the box plus the stationary portion (if any) of the sixth side as a single, seamless unit; the only remaining seam would be the edge seal around the door. The basic cross-sectional configuration of each side of a vacuum-insulated box according to the proposal would be that of a conventional vacuum-insulated panel: a low-density, porous core material filling a partially evacuated space between face sheets. However, neither the face sheets nor the core would be conventional. The face sheets would be opposite sides of a vacuum bag. The core material would be a flexible polymer-modified silica aerogel of the type described in Silica/Polymer and Silica/Polymer/Fiber Composite Aero - gels (MSC-23736) in this issue of NASA Tech Briefs. As noted in that article, the stiffness of this core material against compression is greater than that of prior aerogels. This is an important advantage because it translates to greater retention of thickness and, hence, of insulation performance when pressure is applied across the thickness, in particular, when the space between the face sheets is evacuated, causing the core material to be squeezed between the face sheets by atmospheric pressure. Fabrication of a typical vacuum-insulated box according to the proposal would begin with fabrication of a cross-shaped polymer-modified aerogel blanket. The dimensions of the cross would be chosen so that (1) the central rectangular portion of the cross would form the core for the back of the box and (2) the arms of the cross could be folded 90 from the back plane to form the cores of the adjacent four sides of the box. Optionally, the blanket could include tabs for joining the folded sides of the blanket along mating edges and tabs that could serve as hinges for the door. Vacuum bags in the form of similar five-sided boxes would be made of a suitable polymeric film, one bag to fit the outer core surface, the other to fit the inner core surface. By use of commercially available film-sealing equipment, these box-shaped bags would be seamed together to form a single vacuum bag encasing the box-shaped core. Also, a one-way valve would be sealed to the bag. Through this valve, the interior of the bag would be evacuated to a pressure between 1 and 10 torr (approximately between 0.13 and 1.3 kPa). The polymer-modified aerogel core material is known to perform well as a thermal insulator in such a partial vacuum.

Stepanian, Christopher J.↗
NASA NTRS2011

Lockout/Tagout (LOTO) Simulator

The Lockout/Tagout (LOTO) Simulator is a portable training aid, or demonstration tool, designed to physically illustrate real-time critical-safety concepts of electrical lockout/tagout. The objective is to prevent misinterpretations of what is off and what is on during maintenance and repair of complex electrical systems. The simulator is designed in the form of a hinged box that opens up and stands on its own as an easel for demonstrations. On the outer face of the unit is a simulated circuit breaker box housing the switches. The breakers control the main power to the unit, a light bulb, and an electrical control cabinet. The light bulb is wired so that either of two breakers can provide power to it. When power is sent to the electrical control cabinet, a red indicator light illuminates. Inside the cabinet is the power supply from a personal computer. The power supply produces a 12-V dc output that is sent over to a small fan next to it, also from a computer, and an amber light on the front of the cabinet illuminates. A separate switch powers the fan on and off. The power supply is behind a plastic shield to protect against exposure to live conductors. Electrical banana jacks are mounted in the plastic shield to allow a voltmeter to be connected safely when opening the cabinet and taking a meter reading to verify de-energization as part of a simulation exercise. This LOTO simulator prototype is designed and fabricated as an all-in-one unit. All accessories can be stored inside the hinged case, and there is a handle on top for ease of transport. The circuit breaker labels attach with hook and loop fasteners so that they may be moved and changed to fit the training or demonstration scenario. The warning signs and labels on the electrical control box are magnetic, allowing for easy reconfiguration to emulate different equipment setups. A specially designed magnetic cover was made to disguise the indicator lights for demonstrations when these indicators are not used. The cover is disguised as an arc flash safety label that would typically be found on such a cabinet. One indicator light has a separate switch that can take it offline. This is to allow for demonstration to trainees on why it is important not to completely rely on indicator lights, but that they should always take a meter reading at the exposed conductors to absolutely verify de-energization before exposure. A clear plastic barrier and banana jacks inside the cabinet provide a safe way to plug in a voltmeter for demonstrations without exposure to the hazards of energized equipment. A small remote control unit is wired into the fan circuit. The remote allows the demonstrator to turn the fan on and off, provided that all of the breakers and switches leading to it are configured on as well. The remote feature was added in order to demonstrate the importance of starting the lockout/tagout task with energized equipment, then powering it down, isolating it, and locking it out to ensure that the correct breakers have been locked out.

Scheer, Jennifer↗
NASA NTRS2012

The Damper Spring Unit of the Sentinel 1 Solar Array

The Damper Spring Unit (DSU, see Figure 1) has been designed to provide the damping required to control the deployment speed of the spring driven solar array deployment in an ARA Mk3 or FRED based Solar Array in situations where the standard application of a damper at the root-hinge is not feasible. The unit consists of four major parts: a main bracket, an eddy current damper, a spring unit, an actuation pulley which is coupled via Kevlar cables to a synchro-pulley of a hinge. The damper slows down the deployment speed and prevents deployment shocks at deployment completion. The spring unit includes 4 springs which overcome the resistances of the damper and the specific DSU control cable loop. This means it can be added to any spring driven deployment system without major modifications of that system. Engineering models of the Sentinel 1 solar array wing have been built to identify the deployment behavior, and to help to determine the optimal pulley ratios of the solar array and to finalize the DSU design. During the functional tests, the behavior proved to be very sensitive for the alignment of the DSU. This was therefore monitored carefully during the qualification program, especially prior to the TV cold testing. During TV "Cold" testing the measured retarding torque exceeded the max. required value: 284 N-mm versus the required 247 N-mm. Although this requirement was not met, the torque balance analysis shows that the 284 N-mm can be accepted, because the spring unit can provide 1.5 times more torque than required. Some functional tests of the DSU have been performed without the eddy current damper attached. It provided input data for the ADAMS solar array wing model. Simulation of the Sentinel-1 deployment (including DSU) in ADAMS allowed the actual wing deployment tests to be limited in both complexity and number of tests. The DSU for the Sentinel-1 solar array was successfully qualified and the flight models are in production.

Doejaaren, Frans↗
NASA NTRS2014

The Use, Evolution and Lessons Learnt of Deployable Static Solar Array Mechanisms

This paper focuses on the mechanisms incorporated into SSTL's static deployable arrays; namely the sprung-hinges and hold down and release mechanism (HDRM). Combined, the HDRM and hinges form the hold down release system (HDRS). The deployable static solar array HDRS has been successfully used on several missions, first launched upon the DMC-CFESAT spacecraft in 2007 for a U.S. customer (Figure 1), and later used on DMC-UK2 and EXACTVIEW-1 launched in 2009 and 2012, respectively. The simple, robust and low-cost solution HDRS has been evident in allowing missions to satisfy an ever increasing power demand, allowing the solar arrays to increase in size and have a preferable sun angle for increased cell efficiency. The system is now being employed on the first mission out of SSTL's U.S. office (SST-US) on the Orbital Test Bed platform. This paper shall cover details of the original design and development program, problems incurred on latter missions, and evolution of the HDRS for the present Orbital Test Bed mission. Both the original development and recent evolutions have taken place in rapid timescales, to satisfy the high-turnaround of SSTL missions.

Ferris, Mark↗
NASA NTRS2015

Tension Stiffened and Tendon Actuated Manipulator

A tension stiffened and tendon actuated manipulator is provided performing robotic-like movements when acquiring a payload. The manipulator design can be adapted for use in-space, lunar or other planetary installations as it is readily configurable for acquiring and precisely manipulating a payload in both a zero-g environment and in an environment with a gravity field. The manipulator includes a plurality of link arms, a hinge connecting adjacent link arms together to allow the adjacent link arms to rotate relative to each other and a cable actuation and tensioning system provided between adjacent link arms. The cable actuation and tensioning system includes a spreader arm and a plurality of driven and non-driven elements attached to the link arms and the spreader arm. At least one cable is routed around the driven and non-driven elements for actuating the hinge.

Doggett, William R.↗
NASA NTRS2017

High Lift Common Research Model for Wind Tunnel Testing: An Active Flow Control Perspective

This paper provides an overview of a research and development effort sponsored by the NASA Advanced Air Transport Technology Project to achieve the required high-lift performance using active flow control (AFC) on simple hinged flaps while reducing the cruise drag associated with the external mechanisms on slotted flaps of a generic modern transport aircraft. The removal of the external fairings for the Fowler flap mechanism could help to reduce drag by 3.3 counts. The main challenge is to develop an AFC system that can provide the necessary lift recovery on a simple hinged flap high-lift system while using the limited pneumatic power available on the aircraft. Innovative low-power AFC concepts will be investigated in the flap shoulder region. The AFC concepts being explored include steady blowing and unsteady blowing operating in the spatial and/or temporal domain. Both conventional and AFC-enabled high-lift configurations were designed for the current effort. The high-lift configurations share the cruise geometry that is based on the NASA Common Research Model, and therefore, are also open geometries. A 10%-scale High Lift Common Research Model (HL-CRM) is being designed for testing at the NASA Langley Research Center 14- by 22-Foot Subsonic Tunnel during fiscal year 2018. The overall project plan, status, HL-CRM configurations, and AFC objectives for the wind tunnel test are described.

Lin, John C.↗
NASA NTRS2016

Three-Dimensional Modeling of Aircraft High-Lift Components with Vehicle Sketch Pad

Vehicle Sketch Pad (OpenVSP) is a parametric geometry modeler that has been used extensively for conceptual design studies of aircraft, including studies using higher-order analysis. OpenVSP can model flap and slat surfaces using simple shearing of the airfoil coordinates, which is an appropriate level of complexity for lower-order aerodynamic analysis methods. For three-dimensional analysis, however, there is not a built-in method for defining the high-lift components in OpenVSP in a realistic manner, or for controlling their complex motions in a parametric manner that is intuitive to the designer. This paper seeks instead to utilize OpenVSP's existing capabilities, and establish a set of best practices for modeling high-lift components at a level of complexity suitable for higher-order analysis methods. Techniques are described for modeling the flap and slat components as separate three-dimensional surfaces, and for controlling their motion using simple parameters defined in the local hinge-axis frame of reference. To demonstrate the methodology, an OpenVSP model for the Energy-Efficient Transport (EET) AR12 wind-tunnel model has been created, taking advantage of OpenVSP's Advanced Parameter Linking capability to translate the motions of the high-lift components from the hinge-axis coordinate system to a set of transformations in OpenVSP's frame of reference.

Olson, Erik D.↗
NASA NTRS2018

Lessons Learned in the Flight Qualification of the S-NPP and NOAA-20 Solar Array Mechanisms

Deployable solar arrays are the energy source used on almost all Earth orbiting spacecraft and their release and deployment are mission-critical; fully testing them on the ground is a challenging endeavor. The 8 meter long deployable arrays flown on two sequential NASA weather satellites were each comprised of three rigid panels almost 2 meters wide. These large panels were deployed by hinges comprised of stacked constant force springs, eddy current dampers, and were restrained through launch by a set of four releasable hold-downs using shape memory alloy release devices. The ground qualification testing of such unwieldy deployable solar arrays, whose design was optimized for orbital operations, proved to be quite challenging and provides numerous lessons learned. A paperwork review and follow-up inspection after hardware storage determined that there were negative torque margins and missing lubricant, this paper will explain how these unexpected issues were overcome. The paper will also provide details on how the hinge subassemblies, the fully-assembled array, and mechanical ground support equipment were subsequently improved and qualified for a follow-on flight with considerably less difficulty. The solar arrays built by Ball Aerospace Corp. for the Suomi National Polar Partnership (S-NPP) satellite and the Joint Polar Satellite System (JPSS-1) satellite (now NOAA-20) were both successfully deployed on-obit and are performing well.

Helfrich, Daniel↗
NASA NTRS2018

Lessons Learned in the Flight Qualification of the S-NPP and NOAA-20 Solar Array Mechanisms

Deployable solar arrays are the energy source used on almost all Earth orbiting spacecraft and their release and deployment are mission-critical; fully testing them on the ground is a challenging endeavor. The 8 meter long deployable arrays flown on two sequential NASA weather satellites were each comprised of three rigid panels almost 2 meters wide. These large panels were deployed by hinges comprised of stacked constant force springs, eddy current dampers, and were restrained through launch by a set of four releasable hold-downs using shape memory alloy release devices. The ground qualification testing of such unwieldy deployable solar arrays, whose design was optimized for orbital operations, proved to be quite challenging and provides numerous lessons learned. A paperwork review and follow-up inspection after hardware storage determined that there were negative torque margins and missing lubricant, this paper will explain how these unexpected issues were overcome. The paper will also provide details on how the hinge subassemblies, the fully-assembled array, and mechanical ground support equipment were subsequently improved and qualified for a follow-on flight with considerably less difficulty. The solar arrays built by Ball Aerospace Corp. for the Suomi National Polar Partnership (SNPP) satellite and the Joint Polar Satellite System (JPSS-1) satellite (now NOAA-20) were both successfully deployed on-obit and are performing well.

Sexton, Adam↗
NASA NTRS2018

Active Flow Control for Trailing Edge Flap Separation

Active flow control (AFC) in the form of sweeping jet (SWJ) excitation and discrete steady jet excitation is used to control the flow separation on an NACA 0015 semispan wing with a deflected, simple-hinged, trailing edge flap. This geometry has been the focus of several recent publications that investigated methods to improve the efficiency of sweeping jet actuators. In the current study, the interaction of the AFC excitation with the separated flowfields present at several flap deflection angles was examined. Previous studies with this model have been limited to a maximum flap deflection angle of 40°. The flap deflection range was extended to 60! because systems studies have indicated that a high-lift system with simple-hinged flaps may require larger flap deflections than the Fowler flaps found on most high-lift systems. The results obtained at flap deflection angles of 20°, 40°, and 60° are presented and compared. Force and moment data, Particle Image Velocimetry (PIV) data, and steady and unsteady surface pressure data are used to describe the flowfield with and without AFC. With a flap deflection of 60°, increasing the SWJ actuator momentum at the flap shoulder increased lift due to an increase in circulation but did not completely eliminate the recirculation region above the flap surface. AFC using the discrete steady jet actuators of this study increased lift as well but required more mass flow than the SWJ actuators and had a detrimental effect on lift at the highest mass flow level tested. PIV results showed that the angle between the excitation and the flap surface was not optimal for attaching the separated shear layer.

Melton, LaTunia Pack↗
NASA NTRS2019

Comparative Study of Active Flow Control Strategies for Lift Enhancement of a Simplified High-Lift Configuration

Numerical simulations have been performed for a simplified high-lift (SHL) version of the Common Research Model (CRM) configuration, where the Fowler flaps of the conventional high-lift (CRM-HL) configuration are replaced by a set of simple hinged flaps. These hinged flaps are equipped with integrated modular active flow control (AFC) cartridges on the suction surface, and the resulting geometry is known as the CRM-SHL-AFC configuration. The main objective is to make use of AFC devices on the CRM-SHL-AFC configuration to recover the aerodynamic performance (lift) of the CRM-HL configuration. In the current paper, a Lattice Boltzmann method-based computational fluid dynamics (CFD) code, known as PowerFLOWQ® is used to simulate the entire flow field associated with the CRM-SHL-AFC configuration equipped with several different types of AFC devices. The transonic version of the PowerFLOWQ® code that has been validated for high speed flows is used to accurately simulate the flow field generated by the high-momentum actuators required to mitigate reversed flow regions on the suction surfaces of the main wing and the flap. The numerical solutions predict the expected trends in aerodynamic forces as the actuation levels are increased. More efficient AFC systems and actuator arrangements emerged based on the parametric studies performed prior to a Fall 2018 wind tunnel test. Preliminary comparisons of the numerical solutions for lift and surface pressures are presented here with the experimental data, demonstrating the usefulness of CFD for predicting the flow field and lift characteristics of AFC-enabled high-lift configurations.

Vatsa, Veer N.↗
NASA NTRS2019

Wind Tunnel Testing of Active Flow Control on High-Lift Common Research Model

A 10%-scale high-lift version of the Common Research Model (CRM-HL) and an Active Flow Control (AFC) version of the model equipped with a simple-hinged flap (CRM-SHLAFC) were successfully tested. The tests were performed in the 14- by 22-Foot Subsonic Tunnel (14x22) at the NASA Langley Research Center (LaRC). The CRM-HL has a set of 37° inboard and outboard single-element Fowler flaps. The CRM-SHL-AFC has a set of 50° inboard and 55° outboard simple-hinged flaps equipped with integrated modular AFC cartridges on the flap shoulder. Both high-lift configurations share the same 30° slats and engine nacelle. Three new types of AFC devices were examined: the Double-Row Sweeping Jets (DRSWJ), the Alternating Pulsed Jets (APJ), and the High Efficiency Low Power (HELP) actuators. The DRSWJ and the APJ actuators used two rows of unsteady jets, whereas the HELP actuators used a combination of unsteady and steady jets, to overcome strong adverse pressure gradients while minimizing the mass flow usage. Nozzle pressure ratio, mass flow consumption and the power coefficient, which takes account of both supply air pressure and mass flow usage for the actuators, were used for judging the performance efficiency of the AFC devices. A prestall lift performance degradation for the CRM-HL configuration was resolved with a properly placed nacelle chine. The configuration with nacelle chine was chosen as the representative reference conventional high-lift case for comparison with the CRMSHL- AFC. The AFC-induced lift coefficient increment (DCL) was maintained for the entire lift curve over the CRM-SHL-AFC case with no AFC for almost all flow-control cases examined. The lift curve of the reference CRM-HL have a slightly steeper slope compared to those of the CRM-SHL-AFC configurations. The HELP actuation concept was extremely effective in controlling flow separation in the “linear region” of the curves comparing lift coefficient to mass flow rate. The HELP actuation achieved a targeted DCL of 0.50 using a moderate amount of mass flow and supply air pressure. The CRM-SHL-AFC configuration equipped with HELP actuation was able to match or exceed the lift performance of the reference conventional high-lift configuration (i.e., CRM-HL equipped with a nacelle chine), thus meeting the NASA Advanced Air Transport Technology (AATT) project goal.

Lin, John C.↗
NASA NTRSDate not supplied

Analyzing Natural Language Context in Human-Machine Teaming using Supervised Machine Learning

Building a foundation for trustworthiness and trust verification in multi-asset teaming is the research challenge of Autonomy Teaming and TRAjectories for Complex Trusted Operational Reliability (ATTRACTOR). The Design Reference Mission (DRM) for ATTRACTOR is a search and rescue mission objective governed by a multi-member team consisting of human and machine operators. A crucial component to the effort is the communication between humans and autonomous agents throughout both planning and execution stages of the mission. Intuitive communication methods and modalities are posited as critical enablers for certifying trust and trustworthiness. This paper reports on the data collection and analysis conducted in support of the Human Informed Natural-language GANs Evaluation (HINGE)project to attain explainable and trusted communication between human-machine assets. Two identically curated image description datasets were acquired for HINGE, both consisting of two unique input modalities (typed vs. verbal) and retrieved in two distinct contexts (general vs. specific). The gathered datasets were assessed and compared using Parts-of-Speech (POS)features, sentence similarity metrics, and linguistic analysis. Then, the datasets were modeled and tested separately and in combination with one another using machine learning algorithms. The comparison and testing results reveal a superior dataset, by which a preferred context and input is understood, for generating image representations of missing persons using a Generative Adversarial Network (GAN).

Bryan A Barrows↗
NASA NTRSDate not supplied

CFD and Experimental Data Comparisons for Conventional and AFC-Enabled CRM High-Lift Configurations

Numerical simulations have been performed for a simplified high-lift (SHL) version of the Common Research Model (CRM) configuration, where the Fowler flaps of a representative conventional high-lift (CRM-HL) configuration are replaced by a set of simple hinged flaps. These hinged flaps are equipped with integrated modular active flow control (AFC) cartridges on the suction surface of the flap shoulder, and the resulting geometry is known as the CRM-SHL-AFC configuration. The main objective is to make use of AFC devices on the CRM-SHL-Configuration to produce the aerodynamic performance (lift) comparable to that of the CRM-HL configuration over a large angle of attack range encompassing maximum lift conditions. For comparison purposes, computations are also per-formed for the CRM-HL configuration. In the current paper, PowerFLOWR©, a CFD code based on the Lattice Boltzmann method (LBM), is used to simulate the entire flow field associated with the CRM-SHL-AFC configuration equipped with a combination of two different types of AFC actuators. The transonic version of the PowerFLOWR© code that has been validated for high-speed flows is used to simulate the flow field generated by the high-momentum actuators required to mitigate reversed flow regions on the suction surfaces of the main wing and the flap. This study is focused on the AFC systems and actuator arrangements that had emerged based on the parametric studies conducted previously at the nominal landing condition. Comparisons of the numerical solutions for lift and surface pressures are presented here with the experimental data, demonstrating the usefulness of CFD for predicting the flow field and lift characteristics of AFC-enabled high-lift configurations over a broad angle of attack range. The numerical solutions predict the expected trends in aerodynamic forces with angle of attack variation.

Veer N Vatsa↗
NASA NTRS2022

Design of Rigid-Flex PCB Robotics Leveraging Validated Finite Element Simulations

The use of rigid-flex printed circuit board (PCB) as primary structure has the potential to reduce the weight and volume of robotic systems. In the case of robotics for interplanetary exploration, these systems can leverage origami-inspired folding for increased mobility options and reduced storage volume. Folding rigid-flex PCB robotics can be constructed with rigid PCB connected by short Nomex fabric hinges coupled with flex PCB ribbon cables that permits enhanced system flexibility and energy dissipation to promote impact survivability. This paper presents a design methodology of rigid-flex PCB systems with an emphasis on impact resistance. The design process considers solder joint adequacy, panel bending, and fracture using a finite element (FE) model. The proposed design methodology is developed using a case study with NASA JPL's Pop-Up Folding Flat Explorer Robot (PUFFER). First, the finite-element (FE) modeling methodology is presented with consideration to both frequency and time-domain modeling applications, which include operational self-contact analysis and high impact scenarios. The time-domain impact modeling methodology utilizes hyperelastic material properties for the Nomex hinges. This modeling method is validated using image correlation of PUFFER drop tests. A flowchart is presented to guide users through a validated Abaqus modeling procedure for highly flexible rigid-flex systems. Next, a case study is presented in which PUFFER is subject to drop heights representative of falls into Lunar pits and then the design is refined for a more optimum impact performance. Finally, the results of the case study are used to inform a generalized design methodology for rigid-flex PCB robotics subject to high-impact loads with the considerations presented.

John Bell↗
NASA NTRSDate not supplied

Effect of Rotor Blade Elasticity on UAM Quadrotor Acoustics

The 6-passenger quadrotor concept vehicle designed under the NASA Revolutionary Vertical Lift Technology (RVLT) Project is considered for acoustic analysis. The tip speed is 550 ft/sec, with three blades per rotor (550/3). Originally, the blades were rigid, uniform spanwise, and with flap and pitch degrees of freedom. The blade model has since been updated: a lag hinge was added, and nonuniformities and elastic properties were introduced. Four blade models are considered: 1) original model, rigid uniform flap-pitch; 2) rigid uniform flap-lag-pitch; 3) rigid nonuniform flap-lag-pitch; and 4) elastic nonuniform flap-lag-torsion. Predictions are made for three flight conditions (approach, flyover, and takeoff) using the four blade models. The RVLT Toolchain is exercised using CAMRAD II and pyaaron/AARON/ANOPP2. Quadrotor trim and performance, 0.75R vertical blade loading for all four rotors, and noise sources are analyzed. Also, the contributions of the front and rear rotor pairs to noise are studied. In approach and flyover, a 2 dBA loading noise difference (delta) is predicted between blade models 1 and 4 (delta for takeoff is smaller, 1 dBA). Most of this noise delta is due to the lag hinge and nonuniformities, which is consistent with the results of a 2022 study that had considered only the approach condition; the current results extend this conclusion to flyover and takeoff also. The insensitivity of quadrotor noise to blade elasticity is currently attributed to the high blade torsional stiffness (frequency 6.41 per rev) and the small blade radius (9 ft) of the 550/3 design. Suggestions for potential follow-on work are given.

Rotor Blade↗
NASA NTRS2022

SWOT and NISAR Boom Ground Deployment Test Challenges & Resolution

NASA’s Jet Propulsion Laboratory is developing two new spacecraft that use radar instruments to characterize temporal changes in the Earth’s surface with unprecedented precision (Figure 1). Both the Surface Water Ocean Topography (SWOT) and the NASA-ISRO Synthetic Aperture Radar (NISAR) spacecraft utilize large, precision flight deployable booms to properly position and support their instrument reflectors. The SWOT spacecraft includes two nearly identical reflector booms, each of which have similar flight deployable hinge designs. The NISAR spacecraft has a single reflector boom, with four unique hinge designs. These booms each undergo a multi-staged flight deployment sequence on orbit to transition from the launch stowed configuration to the science configuration within days of launch (Figure 2). The SWOT and NISAR Projects faced significant challenges relevant to requirement verification as well as hardware safety in their approach to ground testing these large flight deployables. This report summarizes flight deployable system design decisions that contributed to ground testing challenges. The report also summarizes the architecture trade study conducted for ground deployment testing. A summary of key issues encountered during flight deployable ground testing with the chosen common gravity offload system ensues, with discussion of the issues and mitigation measures implemented by both Projects that ultimately enabled successful flight subsystem-level full range of motion ground tests. Recommendations and lessons learned are offered to facilitate ground testability of future analogous large scale flight deployables.

Waters, Kyle C.↗