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At least 469 records · Page 26

Beam builder for space fabrication

Construction of a beam builder for producing triangular truss aluminum beams for use on large space structures is described. The machine will fabricate 0.04 cm thick 2024-T3 aluminum alloy into beams weighing 1.265 kg-m with side braces spot-welded to end caps to fabricate a triangular truss configuration up to 305 m long. The design characteristics, the electrical subsystems, the power requirements of the spot welding equipment, and the computer system for coordinating the motion of the Yoder rolling mills for forming caps from aluminum coils are described. Spot welding was compared with ultrasonic welding, stapling, wire stitching, riveting, grommets, stamp-lok, and pierce and fold joining methods with respect to ease of operation, safety, practicality, and ease of energy consumption. The beam builder will be evaluated to identify design requirements which can be utilized for the space flight version of its concept.

Ehl, J. H.↗

Ultrasonic seam welding on thin silicon solar cells

The ultrathin silicon solar cell has progressed to where it is a serious candidate for future light weight or radiation tolerant spacecraft. The ultrasonic method of producing welds was found to be satisfactory. These ultrathin cells could be handled without breakage in a semiautomated welding machine. This is a prototype of a machine capable of production rates sufficiently large to support spacecraft array assembly needs. For comparative purposes, this project also welded a variety of cells with thicknesses up to 0.23 mm as well as the 0.07 mm ultrathin cells. There was no electrical degradation in any cells. The mechanical pull strength of welds on the thick cells was excellent when using a large welding force. The mechanical strength of welds on thin cells was less since only a small welding force could be used without cracking these cells. Even so, the strength of welds on thin cells appears adequate for array application. The ability of such welds to survive multiyear, near Earth orbit thermal cycles needs to be demonstrated.

Stofel, E. J.↗

Producing Silicon Carbide/Silicon Nitride Fibers

Manufacturing process makes CxSiyNz fibers. Precursor fibers spun from extruding machine charged with polycarbosilazane resin. When pyrolyzed, resin converted to cross-linked mixture of silicon carbide and silicon nitride, still in fiber form. CxSiyNz fibers promising substitutes for carbon fibers in high-strength, low-weight composites where high electrical conductivity unwanted.

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Semiconductor cooling apparatus

Gas derived graphite fibers generated by the decomposition of an organic gas are joined with a suitable binder. This produces a high thermal conductivity composite material which passively conducts heat from a source, such as a semiconductor, to a heat sink. The fibers may be intercalated. The intercalate can be halogen or halide salt, alkaline metal, or any other species which contributes to the electrical conductivity improvement of the graphite fiber. The fibers are bundled and joined with a suitable binder to form a high thermal conductivity composite material device. The heat transfer device may also be made of intercalated highly oriented pyrolytic graphite and machined, rather than made of fibers.

Banks, Bruce A.↗

The Manned Maneuvering Unit - 'A nice flying machine'

The need for untethered maneuvers in extravehicular space was recognized early in the NASA manned spaceflight program, leading to experiments during the Gemini flights. The Space Shuttle crews are now equipped with a Manned Maneuvering Unit (MMU) which employs 24 gaseous nitrogen thrusters to furnish six-degree-of-freedom mobility and is fitted with fully redundant electronics, electrical, and propulsion subsystems. The MMU thrusters are operated with translational and rotational hand controllers at the ends of the MMU arms.

Bollendonk, W. W.↗

Work Term Assignment Spring 2017

My tour in the Engineering Robotics directorate exceeded my expectations. I learned lessons about Creo, manufacturing and assembly, collaboration, and troubleshooting. During my first tour, last spring, I used Creo on a smaller project, but had limited experience with it before starting in the Dynamic Systems Test branch this spring. I gained valuable experience learning assembly design, sheet metal design and designing with intent for manufacturing and assembly. These skills came from working both on the hatch and the floor. I also learned to understand the intent of other designers on models I worked with. While redesigning the floor, I was modifying an existing part and worked to understand what the previous designer had done to make it fit with the new model. Through working with the machine shop and in the mock-up, I learned much more about manufacturing and assembly. I used a Dremel, rivet gun, belt sander, and countersink for the first time. Through taking multiple safety training for different machine shops, I learned new machine shop safety skills specific to each one. This semester also gave me new collaborative opportunities. I collaborated with engineers within my branch as well as with Human Factors and the building 10 machine shop. This experience helped me learn how to design for functionality and assembly, not only for what would be easiest in my designs. In addition to these experiences, I learned many lessons in troubleshooting. I was the first person in my office to use a Windows 10 computer. This caused unexpected issues with NASA services and programs, such as the Digital Data Management Server (DDMS). Because of this, I gained experience finding solutions to lockout and freeze issues as well as Creo specific settings. These will be useful skills to have in the future and will be implemented in future rotations. This co-op tour has motivated me more to finish my degree and pursue my academic goals. I intend to take a machining Career Gateway Elective in the Fall to improve my skills in building as well as designing with manufacturing intent. I am also inspired to take more mechatronics CGE courses before I graduate to learn more about the crossover between mechanical and electrical engineering. This semester, I worked on multiple projects and had the opportunity to learn from engineers of different disciplines. I became proficient in Creo 2.0, a program I had not used significantly before. I finished modifying the hatch for 3D print and made sizeable modifications to the nose floor support design. I also gained hands-on experience that will be useful in my engineering career in the future. I would consider all of these major achievements from this spring semester. Lastly, I learned to ask more questions and to search for the right people to find answers which I know will be a valuable skill in the future. This summer, I will be completing my last rotation in the Flight Operations Directorate at Ellington Air Field. After this last tour, I will be returning to school for the Fall, Spring and Summer. I will graduate in August of 2018. I am looking forward to learning more about the different jobs available to engineers. This division works directly with many different types of aircrafts and I am excited to learn more about this focus of engineering. The Aircraft Operations Division values team work greatly and I intend to improve my interpersonal skills by working with them this summer.

Sico, Mallory↗

Pioneer Odyssey: Encounter with a Giant

Ancient peoples, perhaps thousands of years ago, undoubtedly conceived the idea of "reaching out" to Jupiter, the largest and most brilliant of the "wandering stars." But for mankind to stretch across the half billion miles to the giant planet of the Solar System many advances in technical and organizational fields of human endeavor had to be made. Outreach to Jupiter did not become a serious possibility until the Pioneer F and G Project was formed by NASA early in 1968. And then man began to design an extension of his senses that would probe the environs of the giant of the Solar System, a truly pioneer odyssey into the virtually unknown regions beyond the orbit of Mars. In the ensuing year. a dedicated and cooperative effort of several thousand people in Govern­ment, university, and private industrial organiza­tions converted the idea into a reality. Less than twelve generations after Galileo first saw the banded disc of Jupiter and the flickering dots of its large satellites in the newly invented telescope, mankind sent a machine to make observations within that Jovian system. The two Pioneer spacecraft for the mission to Jupiter each weighed only about 570 pounds, yet carried eleven highly sophisticated instruments capable of operating unattended for many year in space. The spacecraft consumes less electrical power than a standard 100 watt lamp yet is able to accept instructions from Earth to control numerous operating modes of its scientific payload, process observations from these scientific instruments and format the observations into information usable on Earth. Even more remarkable. the space­craft transmits a radio signal of only 8 watts power - equal to a nightlight - yet the information carried by the radio signal is received back on Earth from a distance of several billion miles. The Pioneer mission could not have been a success without the special engineering, scientific and management organization created for its accomplishment. This organization was rather unique in that it first had to meet a launch date target relatively quickly and then had to function for an extremely long mission operational time, far longer than any previous mission to planets. The first task was thus to organize so that the mission could be planned and the spacecraft designed and fabricated to be ready for launch within a few weeks of a 30-month target for completion. The program also produced an organization that planned mission operations to such detail that more than 16,000 commands were transmitted flawlessly to the distant spacecraft during Jupiter encounter. And each command reached the spacecraft within one second of the planned time despite the more than 90 minutes required for the radio message to travel from Earth to the space­craft and for the spacecraft to return a confirma­tion to controllers back on Earth. The organization for Pioneer also determined the required flight path from Earth to Jupiter with such precision, and controlled the launch vehicle with such accuracy, that 21 months after launch the spacecraft was able to fly behind Jupiter's satellite lo, thereby providing the first measurement that indicated the possibility of a tenuous atmosphere about this large satellite. Finally, the Pioneer organization processed and analyzed each year sufficient information from the spacecraft to fill a book having about 3 million pages and reduced this avalanche of data from space into summaries of manageable size. And all this organization depended on people, consisted of people: the people who really made this whole mission possible. Pioneer has always depended on the dedication of many individuals from many organizations throughout the world to achieve its scientific objectives, and, as evidenced by the success of the Pioneer series, this dependence is completely justified. Relatively few individuals have an opportunity during their lives to participate in such a challenging, historic, pioneering effort; and still fewer are able to enjoy the rewards of such an activity. We who have worked on Pioneer 10 and its sister spacecraft, Pioneer 11, consider ourselves fortunate to be in both classes. For the opportunity we thank the people of the United States of America, who have supported our country's space effort and its spreading of human awareness of a vast and intriguing universe in which our own unique planet Earth is only one of myriads of worlds. This volume describing the mission to Jupiter and its results is one of the many rewards for our effort which we share with you, the reader.

Fimmel, Richard O.↗

Development of a Portable Stand-Alone 20 K Brayton Cycle Helium Refrigeration System

From 2012 to 2015, NASA funded development of the Ground Operations Demonstration Unit for Liquid Hydrogen (GODU-LH2) at Kennedy Space Center that scaled up and matured Integrated Refrigeration and Storage (IRAS) technology. IRAS involves the integration of an external helium refrigeration system with a cryogenic storage tank via an internal heat exchanger and allows advanced operations such as zero boiloff and densification of the liquid. The refrigeration system employed for GODU-LH2 was a Linde LR1620 piston-Brayton cycle machine with an RSX helium compressor. The GODU-LH2 system was installed in two separate shipping containers—one housing the cold-box, compressor, and gas management hardware, and the other the water chiller unit—with 480 VAC and 120 VAC electrical power fed from external hardware at the test site, and data capture and controls achieved using four different, independent software packages. From 2017 to 2019, in support of a densified hydrogen loading test program, the entire system was repackaged into a single, 40’ (12 m) shipping container, including the refrigeration system, water chiller, and electrical power distribution hardware, and controls were consolidated into a single Allen Bradley PanelView. Details regarding the design, build-out, and testing of the system will be presented and discussed.

W F Reaves↗

On-Command Force and Torque Impeding Devices (OC-FTID) Using ERF

Various machines have been developed to address the need for countermeasures of bone and muscle deterioration when humans operate over extended time in space. Even though these machines are in use, each of them has many limitations that need to be addressed in an effort to prepare for human missions to distant bodies in the solar system. An exercise exoskeleton was conceived that performs on-demand resistivity by inducing force and torque impedance via ElectroRheological Fluid (ERF). The resistive elements consist of pistons that are moving inside ERF-filled cylinders or a donut-shaped cavity, and the fluid flows through the piston when the piston is moved. Tests of the operation of ERF against load showed the feasibility of this approach. ERF properties of high yield stress, low current density, and fast response (less than one millisecond) offer essential characteristics for the construction of the exoskeleton. ERFs can apply very high electrically controlled resistive forces or torque while their size (weight and geometric parameters) can be very small. Their long life and ability to function in a wide temperature range (from -40 to 200 C) allows for their use in extreme environments. ERFs are also nonabrasive, non-toxic, and nonpolluting (meet health and safety regulations). The technology is applicable as a compact exercise machine for astronauts' countermeasure of microgravity, an exercise machine for sport, or as a device for rehabilitation of patients with limb issues.

Bar-Cohen, Yoseph↗

Sonoluminescence Bubble Measurements using Vision-Based Algorithms

Vision-based measurement methods were used to measure bubble sizes in this sonoluminescence experiment. Bubble imaging was accomplished by placing the bubble between a bright light source and a microscope-CCD camera system. A collimated light-emitting diode was operated in a pulsed model with an adjustable time delay with respect to the piezo-electric transducer drive signal. The light-emitting diode produced a bubble shadowgraph consisting of a multiple exposure made by numerous light pulses imaged onto a charge-couple device camera. Each image was transferred from the camera to a computer-controlled machine vision system via a frame grabber. The frame grabber was equipped with on-board memory to accomodate sequential image buffering while images were transferred to the host processor and analyzed. This configuration allowed the host computer to perform diameter measurements, centroid position measurements and shape estimation in "real-time" as the next image was being acquired. Bubble size measurement accuracy with an uncertainty of 3 microns was achieved using standard lenses and machine vision algorithms. Bubble centroid position accuracy was also within the 3 micron tolerance of the vision system. This uncertainty estimation accounted for the optical spatial resolution, digitization errors and the edge detection algorithm accuracy. The vision algorithms include camera calibration, thresholding, edge detection, edge position determination, distance between two edges computations and centroid position computations.

Hall, Nancy R.↗

Ni-Ti Alloys for Aerospace Bearing Applications

Nickel-rich Ni-Ti alloys are emerging candidate materials for aerospace bearing applications. These alloys exhibit a unique combination of physical, chemical, and tribological properties that are highly relevant to challenging aerospace bearings and other mechanical components. Despite being made solely from metals, Ni-Ti alloys are classified as intermetallics with properties akin to both metals and ceramics. For instance, like metals, they are electrically conductive but they tend to be brittle like ceramics. When properly processed, they have high hardness, low elastic modulus and an extensive elastic deformation range that imparts extraordinarily high resilience and resistance to denting. New alloy compositions enable simpler thermal processing and machining and intensive microstructural analyses have helped elucidate the materials science mechanisms governing hardness. In this paper, the application of state-of-art in NiTi alloys for aerospace bearings and mechanical components is explored. In addition to reviewing future trends and remaining challenges, the unique approaches and methods of tailoring bearing design to accommodate NiTis unique properties is discussed.

intermetallics↗

Control Demonstration of Multiple Doubly Fed Induction Motors for Hybrid Electric Propulsion

The Convergent Aeronautics Solutions (CAS) High Voltage Hybrid Electric Propulsion (HVHEP) activity was formulated to support the move into future hybrid-electric aircraft. The goal of this high-voltage activity is to develop a new alternating current (AC) power architecture to support the needs of higher efficiency and lower emissions aircraft. This proposed architecture will adopt the use of the doubly fed induction machine (DFIM) for propulsor drive motor application. The DFIMs are attractive for several reasons, including but not limited to, the ability to self-start, the ability to operate subsynchronously and supersynchronously, and the requirement for power converters rated at a fraction of those required in a corresponding direct current system, dependent on the range of operation. The focus of this report is based specifically on the presentation and analysis of a novel strategy, which allows for independent operation of multiple doubly fed induction motors from a common AC bus

David J Sadey↗

The Vibration Ring

The vibration ring was conceived as a driveline damping device to prevent structure-borne noise in machines. It has the appearance of a metal ring, and can be installed between any two driveline components like an ordinary mechanical spacer. Damping is achieved using a ring-shaped piezoelectric stack that is poled in the axial direction and connected to an electrical shunt circuit. Surrounding the stack is a metal structure, called the compression cage, which squeezes the stack along its poled axis when excited by radial driveline forces. The stack in turn generates electrical energy, which is either dissipated or harvested using the shunt circuit. Removing energy from the system creates a net damping effect. The vibration ring is much stiffer than traditional damping devices, which allows it to be used in a driveline without disrupting normal operation. In phase 1 of this NASA Seedling Fund project, a combination of design and analysis was used to examine the feasibility of this concept. Several designs were evaluated using solid modeling, finite element analysis, and by creating prototype hardware. Then an analytical model representing the coupled electromechanical response was formulated in closed form. The model was exercised parametrically to examine the stiffness and loss factor spectra of the vibration ring, as well as simulate its damping effect in the context of a simplified driveline model. The results of this work showed that this is a viable mechanism for driveline damping, and provided several lessons for continued development.

Asnani, Vivake M.↗

Knowledge representation in space flight operations

In space flight operations rapid understanding of the state of the space vehicle is essential. Representation of knowledge depicting space vehicle status in a dynamic environment presents a difficult challenge. The NASA Jet Propulsion Laboratory has pursued areas of technology associated with the advancement of spacecraft operations environment. This has led to the development of several advanced mission systems which incorporate enhanced graphics capabilities. These systems include: (1) Spacecraft Health Automated Reasoning Prototype (SHARP); (2) Spacecraft Monitoring Environment (SME); (3) Electrical Power Data Monitor (EPDM); (4) Generic Payload Operations Control Center (GPOCC); and (5) Telemetry System Monitor Prototype (TSM). Knowledge representation in these systems provides a direct representation of the intrinsic images associated with the instrument and satellite telemetry and telecommunications systems. The man-machine interface includes easily interpreted contextual graphic displays. These interactive video displays contain multiple display screens with pop-up windows and intelligent, high resolution graphics linked through context and mouse-sensitive icons and text.

Busse, Carl↗

Laser power transmission.

Description of studies which have led to the design of a conceptual device in which the limitation of transforming heat into coherent radiation can be examined. By exploring the basic thermodynamic relationships controlling the operation of this device, it is concluded that a closed-cycle gasdynamic laser is possible in which all of the shaft energy supplied can be turned into laser radiation. Hence, it is possible in principle to convert heat into coherent radiation with approximately the same efficiency with which heat may be converted into electricity. By modifying the closed-cycle-gasdynamic-laser system, this system can be operated in reverse and the incoming radiation may be used to pump the gas in the loop so that shaft power can be extracted. By carefully controlling the temperature distribution in this machine, laser energy can be converted into useful shaft energy with an efficiency approaching 1 .

Ahlstrom, H. G.↗

An electromagnetic noncontacting sensor for thickness measurement in a dispersive medium

This paper describes a general purpose imaging technology developed by the U.S. Bureau of Mines (USBM) that, when fully implemented, will solve the general problem of 'seeing into the earth.' A first-generation radar coal thickness sensor, the RCTS-1, has been developed and field-tested in both underground and highwall mines. The noncontacting electromagnetic technique uses spatial modulation created by moving a simple sensor antenna in a direction along each axis to be measured while the complex reflection coefficient is measured at multiple frequencies over a two-to-one bandwidth. The antenna motion imparts spatial modulation to the data that enables signal processing to solve the problems of media, target, and antenna dispersion. Knowledge of the dielectric constant of the media is not necessary because the electrical properties of the media are determined automatically along with the distance to the target and thickness of each layer of the target. The sensor was developed as a navigation guidance sensor to accurately detect the coal/noncoal interface required for the USBM computer-assisted mining machine program. Other mining applications include the location of rock fractures, water-filled voids, and abandoned gas wells. These hazards can be detected in advance of the mining operation. This initiating technology is being expanded into a full three-dimensional (3-D) imaging system that will have applications in both the underground and surface environment.

Chufo, Robert L.↗

Smart accelerometer

The invention discloses methods and apparatus for detecting vibrations from machines which indicate an impending malfunction for the purpose of preventing additional damage and allowing for an orderly shutdown or a change in mode of operation. The method and apparatus is especially suited for reliable operation in providing thruster control data concerning unstable vibration in an electrical environment which is typically noisy and in which unrecognized ground loops may exist.

Bozeman, Richard J., Jr.↗

It's a Clean Machine

Under an SBIR (Small Business Innovative Research) from Lewis Research Center, Precision Combustion, Inc. (PCI) developed the Advanced Technology Catalytic Combustor. The research proved the viability of efficient, cost-effective catalytic reduction of gas turbine nitrogen oxide emissions along with fuel efficiency. PCI has signed agreements with Westinghouse, other gas turbine manufacturers, including Capstone Turbine Corporation to develop a catalytic combustor for their hybrid electric vehicle.

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