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At least 487 records · Page 27
All sourcesNASA NTRSDOE OSTI
NASA NTRS2004

Resolving the Issues with Flywheel Position Sensors

For the past few years, the Advanced Electrical Systems Branch here at NASA Glenn has been pursuing research in the area of flywheels. The purpose of these pursuits has been t o explore the potential for flywheels to replace current battery-powered systems in space. So far it has been learned that flywheels offer large momentum storage capacity, comparatively small volume, high durability, and near- complete discharge capabilities, all of which are advancements over the existing nickel hydrogen and nickel cadmium batteries. Another significant advantage of flywheels is the potential they offer for combining the function of attitude control with energy storage. During the summer of 2004, I worked with Dr. Barbara Kenny in the Advanced Electrical Systems Branch, supporting the work she is doing by analyzing and testing some new components for the new Generation-2 flywheel. To monitor the speed and angular position of the flywheel rotor, a once-around (OAR) signal along with a sensorless algorithm is used. The OAR signal is used for the magnetic bearings that keep the flywheel suspended for frictionless operation. The sensorless algorithm is used for the flywheel motor/generator control. The OAR is generated from position sensors that monitor a circular plate. The plate has a cut down the middle such that one half of the circle is on a slightly lower level than the other. Every half-turn, or 180, the sensors detect the "cut" on the plate, and trigger the OAR, telling the computer that the rotor has made half a revolution. This, however, doesn't provide needed detailed information about the angular position of the rotor, since it only provides a signal alert every half- revolution. This is enough information for the magnetic bearing control but is insufficient for the motor/generator control. A new resolver was designed such that it would give continuous angle information rather than the 180 degree information of the OAR. The new resolver has two separate observable pieces: a flat middle section to monitor vertical motion, and an angled section around the circumference, which, when observed from above, produces a sine-wave displacement through the entire 360" revolution. My first job when I arrived this summer was to calibrate the sensors that would be mounted on the inside of the flywheel casing to monitor the position (angular and vertical) of the shaft. After calibration, I used the sensors to evaluate voltage outputs created by position differences between two pairs of sensors on the angled portion of the resolver for eight different angular positions, moving the resolver vertically and laterally through its entire potential range of motion. The results of these tests will be used to determine the rotor angular (and axial) position from the sensor readings once the new flywheel unit is assembled. The sensorless algorighm mentioned above consists of two operations: the signal injection method and the back electro-motive force (EMF). The signal injection is meant to work at low speeds, while the back EMF algorithm is meant to work at higher speeds. Both work together to determine the correct estimate of rotor position and speed based on the measured motor/generator current. It was determined that we wanted to know exactly how accurate our estimation methods were, and so a resolver (a commercially available mechanical sensor mounted to the motor/generator shaft to measure rotor position and speed) and a "Resolver to Digital" (R2D) circuit board was purchased to make the comparison to the existing estimation. My work related to the R2D board has included the following: creating two connector cables (one to power the circuit and one to get readable output off the board), writing Simulink code to process the board's output, and building a dSpace panel to control and monitor the circuit. The next step in the process will be to perform tests to compare the estimated rotor position and speed from the sensorless algorithm to the actual rotor and speed from the resolver signal.

Fehrmann, Elizabeth A.↗
NASA NTRS1978

Definition and analytical evaluation of a power management system for tilt-rotor aircraft

The paper reviews the special design criteria which apply to power management in a tilt-rotor aircraft. These include the need for accurate and fast control of rpm and thrust, while accounting for the dynamic interactions between rotor systems caused by cross-shafting and aircraft lateral/directional response. The power management system is also required to provide acceptable high speed sensitivity to longitudinal turbulence. It is shown that the criteria can best be met using a single governor adjusting the collective pitch by an amount proportional to a combination of the average rpm and the integral of the average rpm of the two rotors. This system is evaluated and compared with other candidate systems in hover and cruise flight.

Morris, J. J.↗
NASA NTRS2004

Future Issues and Approaches to Health Monitoring and Failure Prevention for Oil-Free Gas Turbines

Recent technology advances in foil air bearings, high temperature solid lubricants and computer based modeling has enabled the development of small Oil-Free gas turbines. These turbomachines are currently commercialized as small (<100 kW) microturbine generators and larger machines are being developed. Based upon these successes and the high potential payoffs offered by Oil-Free systems, NASA, industry, and other government entities are anticipating Oil-Free gas turbine propulsion systems to proliferate future markets. Since an Oil-Free engine has no oil system, traditional approaches to health monitoring and diagnostics, such as chip detection, oil analysis, and possibly vibration signature analyses (e.g., ball pass frequency) will be unavailable. As such, new approaches will need to be considered. These could include shaft orbit analyses, foil bearing temperature measurements, embedded wear sensors and start-up/coast down speed analysis. In addition, novel, as yet undeveloped techniques may emerge based upon concurrent developments in MEMS technology. This paper introduces Oil-Free technology, reviews the current state of the art and potential for future turbomachinery applications and discusses possible approaches to health monitoring, diagnostics and failure prevention.

DellaCorte, Christopher↗
NASA NTRS2007

Free-to-Roll Testing of Airplane Models in Wind Tunnels

A free-to-roll (FTR) test technique and test rig make it possible to evaluate both the transonic performance and the wingdrop/ rock behavior of a high-strength airplane model in a single wind-tunnel entry. The free-to-roll test technique is a single degree-of-motion method in which the model is free to roll about the longitudinal axis. The rolling motion is observed, recorded, and analyzed to gain insight into wing-drop/rock behavior. Wing-drop/rock is one of several phenomena symptomatic of abrupt wing stall. FTR testing was developed as part of the NASA/Navy Abrupt Wing Stall Program, which was established for the purposes of understanding and preventing significant unexpected and uncommanded (thus, highly undesirable) lateral-directional motions associated with wing-drop/rock, which have been observed mostly in fighter airplanes under high-subsonic and transonic maneuvering conditions. Before FTR testing became available, wingrock/ drop behavior of high-performance airplanes undergoing development was not recognized until flight testing. FTR testing is a reliable means of detecting, and evaluating design modifications for reducing or preventing, very complex abrupt wing stall phenomena in a ground facility prior to flight testing. The FTR test rig was designed to replace an older sting attachment butt, such that a model with its force balance and support sting could freely rotate about the longitudinal axis. The rig (see figure) includes a rotary head supported in a stationary head with a forward spherical roller bearing and an aft needle bearing. Rotation is amplified by a set of gears and measured by a shaft-angle resolver; the roll angle can be resolved to within 0.067 degrees at a rotational speed up to 1,000 degrees/s. An assembly of electrically actuated brakes between the rotary and stationary heads can be used to hold the model against a rolling torque at a commanded roll angle. When static testing is required, a locking bar is used to fix the rotating head rigidly to the stationary head. Switching between the static and FTR test modes takes only about 30 minutes. The FTR test rig was originally mounted in a 16-ft (approximately 4.0-m) transonic wind tunnel, but could just as well be adapted to use in any large wind tunnel. In one series of tests on the FTR rig, static and dynamic characteristics of models of four different fighter airplanes were measured. Two of the models exhibited uncommanded lateral motions; the other two did not. A figure of merit was developed to discern the severity of lateral motions. Using this figure of merit, it was shown that the FTR test technique enabled identification of conditions under which the uncommanded lateral motions occurred. The wind-tunnel conditions thus identified were found to be correlated with flight conditions under which the corresponding full-size airplanes exhibited uncommanded lateral motions.

Capone, Francis J.↗
NASA NTRS2011

Oil-Free Shaft Support System Rotordynamics: Past, Present, and Future Challenges and Opportunities

Recent breakthroughs in Oil-Free technologies have enabled new high-speed rotor systems and turbomachinery. Such technologies can include compliant-surface gas bearings, magnetic bearings, and advanced solid lubricants and tribo-materials. This presentation briefly reviews critical technology developments and the current state-of-the-art, emerging Oil-Free rotor systems and discusses obstacles preventing more widespread use. Key examples of "best practices" for deploying Oil-Free technologies will be presented and remaining major technical questions surrounding Oil-Free technologies will be brought forward.

DellaCorte, Christopher↗
NASA NTRS1991

Development of solid-lubricated ball-screws for use in space

Ball-screws lubricated by solid lubricant films containing molybdenum disulphide are developed. The ball-screws (shaft diameter: phi 25 mm, length: 667 mm) were operated under a load of 40 to 120 N at a speed of 1.5 to 200 rpm at 10(exp -5) Pa. First, ball-screws made of stainless steel SUS 440C were studied using test equipment originally designed for this study. To reduce weight, the next step taken was to develop a ball-screw made of 6Al-4V-titanium. Long wear-life of more than 1 x 10(exp 7) revolutions was achieved with solid lubricated ball-screws made of SUS 440C and 6Al-4V-titanium in a hard vacuum. According to the surface profile of the shaft measured after 1 x 10(exp 7) revolutions, more solid lubricant remained on the surface of 6Al-4V-titanium than that of stainless steel. Auger and EPMA analysis confirmed lubrication was maintained by solid lubricant on nuts and screws after the lubricant films on the balls were worn off.

Chiba, Masatoshi↗
NASA NTRS1949

Performance of J33 turbojet engine with shaft-power extraction III : turbine performance

The performance of the turbine component of a J33 turbojet engine was determined over a range of turbine speeds from 8000 to 11,500 rpm.Turbine-inlet temperature was varied from the minimum required to drive the compressor to a maximum of approximately 2000 degrees R at each of several intermediate turbine speeds. Data are presented that show the horsepower developed by the turbine per pound of gas flow. The relation between turbine-inlet stagnation pressure, turbine-outlet stagnation pressure, and turbine-outlet static pressure was established. The turbine-weight-flow parameter varied from 39.2 to 43.6. The maximum turbine efficiency measured was 0.86 at a pressure ratio of 3.5 and a ratio of blade speed to theoretical nozzle velocity of 0.39. A generalized performance map of the turbine-horsepower parameter plotted against the turbine-speed parameter indicated that the best turbine efficiency is obtained when the turbine power is 10 percent greater than the compressor horsepower. The variation of efficiency with the ratio of blade speed to nozzle velocity indicated that the turbine operates at a speed above that for maximum efficiency when the engine is operated normally with the 19-inch-diameter jet nozzle.

Huppert, M C↗
NASA NTRS1992

An exploratory investigation of the flight dynamics effects of rotor rpm variations and rotor state feedback in hover

This paper presents the results of an analytical study conducted to investigate airframe/engine interface dynamics, and the influence of rotor speed variations on the flight dynamics of the helicopter in hover, and to explore the potential benefits of using rotor states as additional feedback signals in the flight control system. The analytical investigation required the development of a parametric high-order helicopter hover model, which included heave/yaw body motion, the rotor speed degree of freedom, rotor blade motion in flapping and lead-lag, inflow dynamics, a drive train model with a flexible rotor shaft, and an engine/rpm governor. First, the model was used to gain insight into the engine/drive train/rotor system dynamics and to obtain an improved simple formula for easy estimation of the dominant first torsional mode, which is important in the dynamic integration of the engine and airframe system. Then, a linearized version of the model was used to investigate the effects of rotor speed variations and rotor state feedback on helicopter flight dynamics. Results show that, by including rotor speed variations, the effective vertical damping decreases significantly from that calculated with a constant speed assumption, thereby providing a better correlation with flight test data. Higher closed-loop bandwidths appear to be more readily achievable with rotor state feedback. The results also indicate that both aircraft and rotor flapping responses to gust disturbance are significantly attenuated when rotor state feedback is used.

Chen, Robert T. N.↗
NASA NTRS1992

An exploratory investigation of the flight dynamics effects of rotor rpm variations and rotor state feedback in hover

This paper presents the results of an analytical study conducted to investigate airframe/engine interface dynamics, and the influence of rotor speed variations on the flight dynamics of the helicopter in hover, and to explore the potential benefits of using rotor states as additional feedback signals in the flight control system. The analytical investigation required the development of a parametric high-order helicopter hover model, which included heave/yaw body motion, the rotor speed degree of freedom, rotor blade motion in flapping and lead-lag, inflow dynamics, a drive train model with a flexible rotor shaft, and an engine/rpm governor. First, the model was used to gain insight into the engine/drive train/rotor system dynamics and to obtain an improved simple formula for easy estimation of the dominant first torsional mode, which is important in the dynamic integration of the engine and airframe system. Then, a linearized version of the model was used to investigate the effects of rotor speed variations and rotor state feedback on helicopter flight dynamics. Results show that, by including rotor speed variations, the effective vertical damping decreases significantly from that calculated with a constant speed assumption, thereby providing a better correlation with flight test data. Higher closed-loop bandwidths appear to be more readily achievable with rotor state feedback. The results also indicate that both aircraft and rotor flapping responses to gust disturbance are significantly attenuated when rotor state feedback is used.

Chen, Robert T. N.↗
NASA NTRS1983

GSFC Flywheel Status

The assessment of flywheel energy storage for spacecraft power system is based on the conceptual flywheel design. This conceptual design of an integrated flywheel is based on the Mechanical Capacitor which evolved from development of magnetic bearings and permanent magnet ironless-brushless DC motors. The mechanical capacitor is based on three key technologies: (1) a composite rotor with a low ID to OD ratio for high energy density (weight and volume); (2) magnetic suspension close to the geometric center of the rotating mass to minimize loads normally encountered on the ends of a shaft, a no-wear mechanism in a vacuum environment, and to minimize losses at high rotational speeds; (3) permanent magnet ironless-brushless DC motor/generator for high efficiency of conversion and low losses at high rotational speeds. The complete system would include the necessary electronics for the motor/generator, containment, and counterrotating wheels for attitude control compatibility.

Rodriguez, G. E.↗
NASA NTRS1984

Integrated Power/Attitude Control System (IPACS) technology experiment

An experiment is proposed that will perform the tasks associated with the control and energy storage/power generation functions attendant to space operations. It was shown in past studies that the integration of these functions into one system can result in significant weight, volume, and cost savings. The Integrated Power/Attitude Control System (IPACS) concept is discussed. During orbit day, power is derived from the solar cell arrays and, after appropriate conditioning, is used to operate the spacecraft subsystems, including the control system. In conventional approaches, a part of the collected solar energy is stored in a bank of batteries to permit operation of the vehicle's systems during orbit night. In the IPACS concept, the solar energy is stored in the spinning flywheels of the control system in the form of kinetic energy. During orbit night, the wheels are despun and, through the use of a wheel-shaft mounted generator, power is generated for the onboard subsystems. Operating these flywheels over a 50-percent speed variation permits the extraction of 75 percent of the stored energy while at the same time preserving 50 percent of the momentum capacity for control of the vehicle. Batteries can therefore be eliminated and significant weight and volume savings realized.

Keckler, C. R.↗
NASA NTRS1984

Experimental study of bubble cavities attached to a rotating shaft in a reservoir

Bubble cavities formed by air entrainment and attached to a rotating shaft in an oil reservoir were studied. The cavities appear to the unaided eye as toroidal. High speed photography, however, reveals the individuality of the bubble cavities and their near solid body rotational characteristics. The cavities are distorted by the rotation effects but remain attached and tend to merge because of edge effects in the axial direction. The flow field within the reservoir is influenced by the unusual character of the two phase fluid found there; the vorticity is readily visualized. Other examples of vapor entrapment at the inlet of an eccentric rotor are also discussed. A simplified analytical method is provided, and a numerical analysis is being investigated. Vapor (void) entrainment and generation can significantly alter leakage rates and stability of seals, bearings, and dampers. Recognition of these effects in the component design systems will result only after detailed studies of the above phenomena.

Hendricks, R. C.↗
NASA NTRS1984

Twin tilt nacelle V/STOL aircraft

This paper describes the second government-conducted, piloted flight simulation of the Grumman Design 698 V/STOL (vertical and short takeoff and landing) aircraft. Emphasis is on the aircraft's handling qualities as rated by various NASA, Navy, and GAC pilots with flight experience ranging from CTOL (conventional take-off and landing) to V/STOL aircraft. The Design 698 had been modified to resolve the flight problems that were of most concern to the pilots in the first investigation (Phase I). Those problems included an adverse nonminimum phase (NMP) acceleration response in both the longitudinal and lateral axes, a large thrust-response lag, and adverse ground effects. The adverse NMP acceleration is an attribute of the vertical vanes (a Grumman patent) positioned in the fan exhaust flow. The primary modifications included using the vertical-vane deflection as a thrust spoiling method, the addition of the cross-shafted propulsion system, and the implementation of two velocity and attitude control modes (standard and precision) for speeds below 50 knots.

Eskey, M. A.↗
NASA NTRS1986

Structural dynamic measurement practices for turbomachinery at the NASA Lewis Research Center

Methods developed for measuring blade and rotor-shaft system response include optical systems, transient instruments, and special digital data processing equipment. Optical methods offer some distinct benefits for blade vibration measurement. Transient and steady state measurements of the response of rotor-shaft systems strongly affect analytical methods development. Digital computing systems allow processing of large volumes of high speed data from rotating blade sets. Also, digital systems develop useful vibration response signatures from randomly excited systems. Research facilities include the spin rig facility and the transient rotor response lab.

Kiraly, L. J.↗
NASA NTRS1982

Modification of Altitude Wind Tunnel for Icing and Propulsion Research Study, Part B

This report describes the results of an engineering study conducted for NASA-Lewis Research Center on Modifications to the Altitude Wind Tunnel (AWT) for Icing and Propulsion Research by DSW Engineering Corporation, Orlando, Florida and DSMA International Inc., Toronto, Canada. The engineering study referred to as study 'Part B' has been carried out under authorization of NASA Contract NAS 3-22933 (Ref. 1). The scope of work defined in the Statement of Work 3-169855 (Ref. 2) Revised 2/20/81 was discussed in detail with NASA on October 2, 1981 and covers the following areas: - Fan and Fan Housing. This includes assessment of circuit loss analyses, fan aerodynamics and mechanical conceptual design of variable and fixed pitch fans considering fixed and variable inlet guide vanes. - Fan Drive Systems - considering fixed and variable speed drives with continuous rating of 30,000 HP with overload capability of 45,000. The drive shaft between the motor and fan is to be considered and also the existing foundations for the main drive motor. - 20 ft.Test Section Arrangement - having slotted wall configurations suitable for testing at transonic velocities, with various model support systems required for the anticipated models and tests. A model handling concept aimed for high productivity testing and means for quick access to the model in the test section between test runs. - 45 ft. Test Section - feasible and practical approach for model installation and removal.

Leonard, H. Wayne↗
NASA NTRS2015

Relation Between Residual and Hoop Stresses and Rolling Bearing Fatigue Life

Rolling-element bearings operated at high speed or high vibration may require a tight interference fit between the bore of the bearing and shaft to prevent rotation of the bearing bore around the shaft and fretting damage at the interfaces. Previous work showed that the hoop stresses resulting from tight interference fits can reduce bearing lives by as much as 65 percent. Where tight interference fits are required, case-carburized steel such as AISI 9310 or M50 NiL is often used because the compressive residual stresses inhibit subsurface crack formation and the ductile core inhibits inner-ring fracture. The presence of compressive residual stress and its combination with hoop stress also modifies the Hertz stress-life relation. This paper analyzes the beneficial effect of residual stresses on rolling-element bearing fatigue life in the presence of high hoop stresses for three bearing steels. These additional stresses were superimposed on Hertzian principal stresses to calculate the inner-race maximum shearing stress and the resulting fatigue life of the bearing. The load-life exponent p and Hertz stress-life exponent n increase in the presence of compressive residual stress, which yields increased life, particularly at lower stress levels. The Zaretsky life equation is described and is shown to predict longer bearing lives and greater load- and stress-life exponents, which better predicts observed life of bearings made from vacuum-processed steel.

Fatigue↗
NASA NTRSDate not supplied

Preliminary Analysis of Moog SureFly Electric Motor Noise Measurements

The results of acoustics measurements on the installed and unloaded axial-flux electric motor used on the Moog SureFly® vehicle are presented and compared to previous ground run-up measurements for the vehicle. The directivity of the motor was found to be significantly different than that obtained for much smaller 2 – 4 kW radial flux motors tested previously in the Acoustic Test Laboratory at NASA Glenn. Significant radiation occurred at shaft orders between 17 and 20 and at order 30. Peak radiation levels occurred near the highest speeds expected for the vehicle. There was an indication that some of the tones appearing in the spectra obtained in the previous ground run-up test were associated with the motor.

Urban Air Mobility↗
NASA NTRS2005

Software Developed for Analyzing High- Speed Rolling-Element Bearings

COBRA-AHS (Computer Optimized Ball & Roller Bearing Analysis--Advanced High Speed, J.V. Poplawski & Associates, Bethlehem, PA) is used for the design and analysis of rolling element bearings operating at high speeds under complex mechanical and thermal loading. The code estimates bearing fatigue life by calculating three-dimensional subsurface stress fields developed within the bearing raceways. It provides a state-of-the-art interactive design environment for bearing engineers within a single easy-to-use design-analysis package. The code analyzes flexible or rigid shaft systems containing up to five bearings acted upon by radial, thrust, and moment loads in 5 degrees of freedom. Bearing types include high-speed ball, cylindrical roller, and tapered roller bearings. COBRA-AHS is the first major upgrade in 30 years of such commercially available bearing software. The upgrade was developed under a Small Business Innovation Research contract from the NASA Glenn Research Center, and incorporates the results of 30 years of NASA and industry bearing research and technology.

Fleming, David P.↗