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Plasma Activated Water for Crewed Transit and Planetary Habitation: A Study of Gas Type, Electrode Material, and Power Supply Selection and the Impact on the Final Frontier - FY21 CIF

An in-depth study of plasma activated water (PAW) generation was conducted to link changes in power supply, electrode material, input gas, and treatment time to the resulting reaction chemistry. These changes in chemistry can help tailor PAW for different space applications. An AC, DC, and nanosecond (ns) pulsed power supply were each used to generate PAW with stainless steel, copper, tungsten, or platinum (Pt) electrodes while utilizing air, nitrogen (N2), carbon dioxide (CO2), helium (He), or argon (Ar) as the feed gas. Tap or deionized (DI) water was treated for 1 to 15 minutes, and the generated PAW was tested for changes in pH, conductivity, oxidation reduction potential, nitrates (NO3-), ammonium (NH4+), and peroxide. Calculations showed that the production of reactive nitrogen species was the leading cause of pH and conductivity changes. The DC generated air plasma was able to reduce the pH of DI water and generate NO3‑. The pulsed supply, operating at 20% of the input power of the DC supply, lowered the pH generated NO3‑. When a simulated Martian gas mixture of 95% CO2 and 5% N2 was used as the feed gas, NO3‑ was generated with the DC and pulsed supplies, respectively. Mixing PAW with plasma generated ash from inedible biomass allowed pH control, thus enhancing PAW’s potential use for sanitation applications. The large shift in pH was used to study sanitation effects of Escherichia coli (E. coli) reduction and Staphylococcus aureus (S. aureus), in which log reductions were found to be negligible. Additionally, the plasma generated ash in combination with PAW was also implemented in 10-day microgreen growth trials, in which PAW and ash resulted in quicker emergence of the microgreens compared to the standard growth conditions and comparable dry masses to Hoagland’s nutrient solution treated samples.

plasma activated water (PAW)↗

Baltimore Energy & Infrastructure: Assessing Urban Heat Vulnerability in Baltimore Neighborhoods to Inform Transportation Resiliency Planning Efforts

Across the world, climate change is altering cities and their local climate systems. Following global trends of rising mean temperatures, Baltimore, Maryland is projected to experience more frequent extreme heat events. Exacerbated by Urban Heat Island (UHI) effects, residents of the city face high temperatures from limited tree canopy, highly paved and impervious surfaces, limited air flow, and high concentrations of localized emissions. Urban heat is dispersed asymmetrically, with historically marginalized populations experiencing disproportionately severe heat. Recognizing the impacts of extreme urban heat, the Maryland Transit Administration (MTA) collaborated with us, the Spring 2024 Goddard Energy and Infrastructure NASA DEVELOP team to assess urban impacts of MTA users and assets and explore opportunities to enhance resiliency planning. We evaluated the feasibility of NASA Earth observations (EOs) in visualizing heat vulnerability in Baltimore City and County. We mapped UHI and extreme heat using remote sensing observations, tailored a Heat Priority Score (HPS) to analyze heat data in tandem with socioeconomic data from American Community Survey (ACS), and utilized SOlar and LongWave Environmental Irradiance Geometry (SOLWEIG) model to estimate MTA riders’ thermal comfort. NASA EOs served to quantify the distribution and severity of extreme heat at the block group level, which was found to correlate with a lack of vegetation and presence of densely built-up surroundings. The HPS revealed that extreme heat events most negatively impact communities that exhibit social vulnerability through indicators such as age, race, and income. These findings will inform neighborhood resiliency plans for the MTA that can be incorporated into their Adaptation Resiliency Toolbox (ART).

Baltimore,↗

The Implementation of Satellite Control System Software Using Object Oriented Design

NASA established the Small Explorer (SMEX) program in 1988 to provide frequent opportunities for highly focused and relatively inexpensive space science missions that can be launched into low earth orbit by small expendable vehicles. The development schedule for each SMEX spacecraft was three years from start to launch. The SMEX program has produced five satellites; Solar Anomalous and Magnetospheric Particle Explorer (SAMPEX), Fast Auroral Snapshot Explorer (FAST), Submillimeter Wave Astronomy Satellite (SWAS), Transition Region and Coronal Explorer (TRACE) and Wide-Field Infrared Explorer (WIRE). SAMPEX and FAST are on-orbit, TRACE is scheduled to be launched in April of 1998, WIRE is scheduled to be launched in September of 1998, and SWAS is scheduled to be launched in January of 1999. In each of these missions, the Attitude Control System (ACS) software was written using a modular procedural design. Current program goals require complete spacecraft development within 18 months. This requirement has increased pressure to write reusable flight software. Object-Oriented Design (OOD) offers the constructs for developing an application that only needs modification for mission unique requirements. This paper describes the OOD that was used to develop the SMEX-Lite ACS software. The SMEX-Lite ACS is three-axis controlled, momentum stabilized, and is capable of performing sub-arc-minute pointing. The paper first describes the high level requirements which governed the architecture of the SMEX-Lite ACS software. Next, the context in which the software resides is explained. The paper describes the benefits of encapsulation, inheritance and polymorphism with respect to the implementation of an ACS software system. This paper will discuss the design of several software components that comprise the ACS software. Specifically, Object-Oriented designs are presented for sensor data processing, attitude control, attitude determination and failure detection. The paper addresses the benefits of the OOD versus a conventional procedural design. The final discussion in this paper will address the establishment of the ACS Foundation Class (AFC) Library. The AFC is a large software repository, requiring a minimal amount of code modifications to produce ACS software for future projects, saving production time and costs.

Anderson, Mark O.↗

Proposal and Development of a High Voltage Variable Frequency Alternating Current Power System for Hybrid Electric Aircraft

The development of ultra-efficient commercial vehicles and the transition to low-carbon emission propulsion are seen as thrust paths within NASA Aeronautics. A critical enabler to these paths comes in the form of hybrid-electric propulsion systems. For megawatt-class systems, the best power system topology for these hybrid-electric propulsion systems is debatable. Current proposals within NASA and the Aero community suggest using a combination of AC and DC for power transmission. This paper proposes an alternative to the current thought model through the use of a primarily high voltage AC power generation, transmission, and distribution systems, supported by the Convergent Aeronautics Solutions (CAS) Project. This system relies heavily on the use of dual-fed induction machines, which provide high power densities, minimal power conversion, and variable speed operation. The paper presents background on the project along with the system architecture, development status and preliminary results.

Propulsion↗

High Power Amplifier and Power Supply

A document discusses the creation of a high-voltage power supply (HVPS) that is able to contain voltages up to -20 kV, keep electrical field strengths to below 200 V/mil (approximately equal to 7.87 kV/mm), and can provide a 200-nanosecond rise/fall time focus modulator swinging between cathode potential of 16.3 kV and -19.3 kV. This HVPS can protect the 95-GHz, pulsed extended interaction klystron (EIK) from arcs/discharges from all sources, including those from within the EIK fs vacuum envelope. This innovation has a multi-winding pulse transformer design, which uses new winding techniques to provide the same delays and rise/fall times (less than 10 nanoseconds) at different potential levels ranging from -20 kV to -16 kV. Another feature involves a high-voltage printed-wiring board that was corona-free at -20 kV DC with a 3- kV AC swing. The corona-free multilayer high-voltage board is used to simulate fields of less than 200 V/mil (approximately equal to 7.87 kV/mm) at 20 kV DC. Drive techniques for the modulator FETs (field-effect transistors) (four to 10 in a series) were created to change states (3,000-V swing) without abrupt steps, while still maintaining required delays and transition times. The packing scheme includes a potting mold to house a ten-stage modulator in the space that, in the past, only housed a four-stage modulator. Problems keeping heat down were solved using aluminum oxide substrate in the high-voltage section to limit temperature rise to less than 10 while withstanding -20 kV DC voltage and remaining corona-free.

Duong, Johnny↗

Proposal and Development of a High Voltage Variable Frequency Alternating Current Power System for Hybrid Electric Aircraft

The development of ultra-efficient commercial vehicles and the transition to low-carbon emission propulsion are seen as strategic thrust paths within NASA Aeronautics. A critical enabler to these paths comes in the form of hybrid electric propulsion systems. For megawatt-class systems, the best power system topology for these hybrid electric propulsion systems is debatable. Current proposals within NASA and the Aero community suggest using a combination of alternating current (AC) and direct current (DC) for power generation, transmission, and distribution. This paper proposes an alternative to the current thought model through the use of a primarily high voltage AC power system, supported by the Convergent Aeronautics Solutions (CAS) Project. This system relies heavily on the use of doubly-fed induction machines (DFIMs), which provide high power densities, minimal power conversion, and variable speed operation. The paper presents background on the activity along with the system architecture, development status, and preliminary results.

Sadey, David J.↗

Nuclear Thermal Rocket/Vehicle Characteristics And Sensitivity Trades For NASA's Mars Design Reference Architecture (DRA) 5.0 Study

This paper summarizes Phase I and II analysis results from NASA's recent Mars DRA 5.0 study which re-examined mission, payload and transportation system requirements for a human Mars landing mission in the post-2030 timeframe. Nuclear thermal rocket (NTR) propulsion was again identified as the preferred in-space transportation system over chemical/aerobrake because of its higher specific impulse (I(sub sp)) capability, increased tolerance to payload mass growth and architecture changes, and lower total initial mass in low Earth orbit (IMLEO) which is important for reducing the number of Ares-V heavy lift launches and overall mission cost. DRA 5.0 features a long surface stay (approximately 500 days) split mission using separate cargo and crewed Mars transfer vehicles (MTVs). All vehicles utilize a common core propulsion stage with three 25 klbf composite fuel NERVA-derived NTR engines (T(sub ex) approximately 2650 - 2700 K, p(sub ch) approximately 1000 psia, epsilon approximately 300:1, I(sub sp) approximately 900 - 910 s, engine thrust-toweight ratio approximately 3.43) to perform all primary mission maneuvers. Two cargo flights, utilizing 1-way minimum energy trajectories, pre-deploy a cargo lander to the surface and a habitat lander into a 24-hour elliptical Mars parking orbit where it remains until the arrival of the crewed MTV during the next mission opportunity (approximately 26 months later). The cargo payload elements aerocapture (AC) into Mars orbit and are enclosed within a large triconicshaped aeroshell which functions as payload shroud during launch, then as an aerobrake and thermal protection system during Mars orbit capture and subsequent entry, descent and landing (EDL) on Mars. The all propulsive crewed MTV is a 0-gE vehicle design that utilizes a fast conjunction trajectory that allows approximately 6-7 month 1-way transit times to and from Mars. Four 12.5 kW(sub e) per 125 square meter rectangular photovoltaic arrays provide the crewed MTV with approximately 50 kW(sub e) of electrical power in Mars orbit for crew life support and spacecraft subsystem needs. Vehicle assembly involves autonomous Earth orbit rendezvous and docking between the propulsion stages, in-line propellant tanks and payload elements. Nine Ares-V launches -- five for the two cargo MTVs and four for the crewed MTV -- deliver the key components for the three MTVs. Details on mission, payload, engine and vehicle characteristics and requirements are presented and the results of key trade studies are discussed.

Borowski, Stanley K.↗

GASPS--A Herschel Survey of Gas and Dust in Protoplanetary Disks: Summary and Initial Statistics

We describe a large-scale far-infrared line and continuum survey of protoplanetary disk through to young debris disk systems carried out using the ACS instrument on the Herschel Space Observatory. This Open Time Key program, known as GASPS (Gas Survey of Protoplanetary Systems), targeted approx. 250 young stars in narrow wavelength regions covering the [OI] fine structure line at 63 micron the brightest far-infrared line in such objects. A subset of the brightest targets were also surveyed in [OI]145 micron, [CII] at 157 μm, as well as several transitions of H2O and high-excitation CO lines at selected wavelengths between 78 and 180 micron. Additionally, GASPS included continuum photometry at 70, 100 and 160 micron, around the peak of the dust emission. The targets were SED Class II– III T Tauri stars and debris disks from seven nearby young associations, along with a comparable sample of isolated Herbig AeBe stars. The aim was to study the global gas and dust content in a wide sample of circumstellar disks, combining the results with models in a systematic way. In this overview paper we review the scientific aims, target selection and observing strategy of the program. We summarize some of the initial results, showing line identifications, listing the detections, and giving a first statistical study of line detectability. The [OI] line at 63 micron was the brightest line seen in almost all objects, by a factor of ∼10. Overall [OI] 63 micron detection rates were 49%, with 100% of HAeBe stars and 43% of T Tauri stars detected. A comparison with published disk dust masses (derived mainly from sub-mm continuum, assuming standard values of the mm mass opacity) shows a dust mass threshold for [OI] 63 μm detection of approx.10(exp -5) Solar M.. Normalizing to a distance of 140 pc, 84% of objects with dust masses ≥10 (exp -5) Solar M can be detected in this line in the present survey; 32% of those of mass 10(exp -6) – 10 (exp -5) Solar M, and only a very small number of unusual objects with lower masses can be detected. This is consistent with models with a moderate UV excess and disk flaring. For a given disk mass, [OI] detectability is lower for M stars compared with earlier spectral types. Both the continuum and line emission was, in most systems, spatially and spectrally unresolved and centered on the star, suggesting that emission in most cases was from the disk. Approximately 10 objects showed resolved emission, most likely from outflows. In the GASPS sample, [OI] detection rates in T Tauri associations in the 0.3–4 Myr age range were approx. 50%. For each association in the 5–20 Myr age range, approx. 2 stars remain detectable in [OI] 63 micron, and no systems were detected in associations with age >20 Myr. Comparing with the total number of young stars in each association, and assuming a ISM-like gas/dust ratio, this indicates that approx. 18% of stars retain a gas-rich disk of total mass approx. Jupiter- M for 1–4 Myr, 1–7% keep such disks for 5–10 Myr, but none are detected beyond 10–20 Myr. The brightest [OI] objects from GASPS were also observed in [OI]145 micron, [CII]157 micron and CO J = 18- 17, with detection rates of 20–40%. Detection of the [CII] line was not correlated with disk mass, suggesting it arises more commonly from a compact remnant envelope.

Herschel Space Observatory↗

All-YBa2Cu3O(7-x) edge-geometry weak links

High quality YBa2Cu3O(7-x)/normal-metal/YBa2Cu3O(7-x) edge-geometry weak links are fabricated using nonsuperconducting Y-Ba-Cu-O barrier layers deposited by laser ablation at reduced growth temperatures. Devices incorporating 25-100-A-thick barrier layers exhibit current-voltage characteristics consistent with the resistively-shunted-junction model, as well as ac Josephson steps. Magnetic field modulation of the critical currents shows Fraunhofer-like behavior with a periodicity which scales with device area. The critical currents vary exponentially with barrier thickness indicating an effective normal metal coherence length of 20 A. The average resistances scale linearly with Y-Ba-Cu-O interlayer thickness and device area. The scaling behavior of the device parameters combined with the well-behaved magnetic field modulation of the critical currents demonstrates good barrier-layer uniformity with low pinhole densities. Near the transition temperature, the critical currents exhibit a temperature dependence proportional to (1 - T/Tc) squared.

Hunt, B. D.↗

Laboratory and theoretical models of planetary-scale instabilities and waves

The continuous low-g environment of the orbiting space shuttle provided a setting for conducting geophysical fluid model experiments with a completely consistent representation of sphericity and the resultant radial gravity found on astrogeophysical objects. This is possible because in zero gravity an experiment can be constructed that has its own radial buoyancy forces. The dielectric forces in a liquid, which are linearly dependent on fluid temperature, give rise to an effectively radial buoyancy force when a radial electrostatic field is applied. The Geophysical Fluid Flow Cell (GFFC) experiment is an implementation of this idea in which fluid is contained between two rotating hemispheres that are differentially heated and stressed with a large ac voltage. The GFFC flew on Spacelab 3 in May 1985. Data in the form of global Schlieren images of convective patterns were obtained for a large variety of configurations. These included situations of rapid rotation (large Taylor numbers), low rotation, large and small thermal forcing, and situations with applied meridional temperature gradients. The analysis and interpretation of the GFFC-85 data are being conducted. Improvements were developed to the GFFC instrument that will allow for real-time (TV) display of convection data and for near-real-time interactive experiments. These experiments, on the transition to global turbulence, the breakdown of rapidly rotating convective planforms and other phenomena, are scheduled to be carried out on the International Microgravity Laboratory (IML-1) aboard the shuttle in June 1990.

Hart, John E.↗

Novel Multiplexing Technique for Detector and Mixer Arrays

Future submillimeter and far-infrared space telescopes will require large-format (many 1000's of elements) imaging detector arrays to perform state-of-the-art astronomical observations. A crucial issue related to a focal plane array is a readout scheme which is compatible with large numbers of cryogenically-cooled (typically < 1 K) detectors elements. When the number of elements becomes of the order of thousands, the physical layout for individual readout amplifiers becomes nearly impossible to realize for practical systems. Another important concern is the large number of wires leading to a 0.1-0.3 K platform. In the case of superconducting transition edge sensors (TES), a scheme for time-division multiplexing of SQUID read-out amplifiers has been recently demonstrated. In this scheme the number of SQUIDs is equal to the number (N) of the detectors, but only one SQUID is turned on at a time. The SQUIDs are connected in series in each column of the array, so the number of wires leading to the amplifiers can be reduced, but it is still of the order of N. Another approach uses a frequency domain multiplexing scheme of the bolometer array. The bolometers are biased with ac currents whose frequencies are individual for each element and are much higher than the bolometer bandwidth. The output signals are connected in series in a summing loop which is coupled to a single SQUID amplifier. The total number of channels depends on the ratio between the SQUID bandwidth and the bolometer bandwidth and can be at least 100 according to the authors. An important concern about this technique is a contribution of the out-of-band Johnson noise which multiplies by factor N(exp 1/2) for each frequency channel. We propose a novel solution for large format arrays based on the Hadamard transform coding technique which requires only one amplifier to read out the entire array of potentially many 1000's of elements and uses approximately 10 wires between the cold stage and room temperature electronics. This can significantly reduce the complexity of the readout circuits.

Karasik, Boris S.↗

Hubble Space Telescope Fine Guidance Sensor and Two-Gyro Control Law Design, Implementation, and On-Orbit Performance

For fifteen years, the science mission of the Hubble Space Telescope (HST) required using at least three rate gyros for n Controlling with alternate sensors to replace failing gyros can extend the HST science mission. A two-gyro control law has been designed and implemented using magnetometers, star trackers, and Fine Guidance Sensors (FGSs) to control vehicle rate about the missing gyro axis. The three aforementioned sensors are used in succession to reduce HST boresight jitter to less than 7 milli-arcseconds rms prior to science imaging. The Magnetometer and 2-Gyro (M2G) control law is used for large angle maneuvers and attitude control during earth. occultation of star trackers and FGSs. The Tracker and 2-Gyro (T2G) control law dampens M2G rates and controls attitude in preparation for guide star acquisition with the FGSs. The Fine Guidance Sensor and 2-Gyro (F2G) control law dampens T2G rates and controls HST attitude during science imaging. This paper describes the F2G control law. Details of F2G algorithms are presented, including computation of the FGS-measured star vector using non-linear equations, optimal estimation of HST body rate, design of the F2G control laws and gyro bias observer, SISO and MIMO linear stability analyses, and design of the F2G intramode transition and guide star acquisition logic. Results from an FGS flight spare ground test are presented that define acceptable HST jitter levels for successful guide star acquisition under two-gyro control. HST-specific disturbance and noise models are described that are based upon flight telemetry; these models are used in HSTSIM, a high-fidelity non-linear time domain simulation, to predict HST on-orbit disturbance responses and FGS interferometer Loss of Lock (LOL) characteristics under F2G control. Additional HSTSIM results are presented predicting HST quiescent boresight jitter performance, science maneuver performance, and observer configuration performance during F2G operation. Simulation results are compared to on-orbit data b m F2G flight tests performed in February 2005. Science images and point spread functions from the Advanced Camera for Surveys (ACS) High Resolution Camera (HRC) are presented that compare HST science performance under F2G versus three-gyro control. Images and flight telemetry show that HST boresight jitter with the new F2G control law is usually less than jitter using the three-gyro law, and HST boresight jitter during F2G operation is dependent upon guide star magnitude.

Clapp, Brian R.↗

Solar Array Disturbances to Spacecraft Pointing During the Lunar Reconnaissance Orbiter (LRO) Mission

The Lunar Reconnaissance Orbiter (LRO), the first spacecraft to support NASA s return to the Moon, launched on June 18, 2009 from the Cape Canaveral Air Force Station aboard an Atlas V launch vehicle. It was initially inserted into a direct trans-lunar trajectory to the Moon. After a five day transit to the Moon, LRO was inserted into the Lunar orbit and successfully lowered to a low altitude elliptical polar orbit for spacecraft commissioning. Successful commissioning was completed in October 2009 when LRO was placed in its near circular mission orbit with an approximate altitude of 50km. LRO will spend at least one year orbiting the Moon, collecting lunar environment science and mapping data, utilizing a suite of seven instruments to enable future human exploration. The objective is to provide key science data necessary to facilitate human return to the Moon as well as identification of opportunities for future science missions. LRO's instrument suite will provide the high resolution imaging data with sub-meter accuracy, highly accurate lunar cartographic maps, mineralogy mapping, amongst other science data of interest. LRO employs a 3-axis stabilized attitude control system (ACS) whose primary control mode, the "Observing Mode", provides Lunar nadir, off-nadir, and inertial fine pointing for the science data collection and instrument calibration. This controller combines the capability of fine pointing with on-demand large angle full-sky attitude reorientation. It provides simplicity of spacecraft operation as well as additional flexibility for science data collection. A conventional suite of ACS components is employed in the Observing Mode to meet the pointing and control objectives. Actuation is provided by a set of four reaction wheels developed in-house at NASA Goddard Space Flight Center (GSFC). Attitude feedback is provided by a six state Kalman filter which utilizes two SELEX Galileo Star Trackers for attitude updates, and a single Honeywell Miniature Inertial Measurement Unit (MIMU) to provide body rates for attitude propagation. Rate is computed by differentiating accumulated angle provided by the MIMU. The Observing Mode controller is required to maintain fine pointing while a large fully-articulated solar array (SA) maintains its panel normal to the solar incidence. This paper describes the disturbances to the attitude control resulting from the SA articulation. Observing Mode performance in the presence of this disturbance was assessed while the spacecraft was in an initial elliptical low altitude orbit during the commissioning phase, which started about two weeks after launch and lasted for 90 days. LRO demonstrated excellent pointing performance during Observing Mode nadir and inertial attitude target operations during this phase. Transient LRO attitude errors observed during commissioning resulted primarily from three sources, Diviner instrument calibrations, RW zero crossings, and SA articulation. Even during times of considerable disturbance from SA articulation, the attitude errors were maintained below the statistical attitude error requirement level of 15 arc-sec (3 sigma).

Calhoun, Philip↗

Global Precipitation Measurement Mission Launch and Commissioning

During launch and early operation of the Global Precipitation Measurement (GPM) Mission, the Guidance, Navigation and Control (GNC) analysis team encountered four main on orbit anomalies. These include: (1) unexpected shock from Solar Array deployment, (2) momentum buildup from the Magnetic Torquer Bars (MTBs) phasing errors, (3) transition into Safehold due to albedo-induced Course Sun Sensor (CSS) anomaly, and (4) a flight software error that could cause a Safehold transition due to a Star Tracker occultation. This paper will discuss ways GNC engineers identified and tracked down the root causes. Flight data and GNC on board models will be shown to illustrate how each of these anomalies were investigated and mitigated before causing any harm to the spacecraft. On May 29, 2014, GPM was handed over to the Mission Flight Operations Team after a successful commissioning period. Currently, GPM is operating nominally on orbit, collecting meaningful scientific data that will significantly improve our understanding of the Earth's climate and water cycle.

Guidance Navigation and Control↗

Global Precipitation Measurement Mission Launch and Commissioning

During launch and early operation of the Global Precipitation Measurement (GPM) Mission, the Guidance, Navigation, and Control (GN&C) analysis team encountered four main on-orbit anomalies. These include: (1) unexpected shock from Solar Array deployment, (2) momentum buildup from the Magnetic Torquer Bars (MTBs) phasing errors, (3) transition into Safehold due to albedo induced Course Sun Sensor (CSS) anomaly, and (4) a flight software error that could cause a Safehold transition due to a Star Tracker occultation. This paper will discuss ways GN&C engineers identified the anomalies and tracked down the root causes. Flight data and GN&C on-board models will be shown to illustrate how each of these anomalies were investigated and mitigated before causing any harm to the spacecraft. On May 29, 2014, GPM was handed over to the Mission Flight Operations Team after a successful commissioning period. Currently, GPM is operating nominally on orbit, collecting meaningful scientific data that will significantly improve our understanding of the Earth's climate and water cycle.

Guidance Navigation and Control↗

Investigation of Spiral Bevel Gear Condition Indicator Validation Via AC-29-2C Using Damage Progression Tests

This report documents the results of spiral bevel gear rig tests performed under a NASA Space Act Agreement with the Federal Aviation Administration (FAA) to support validation and demonstration of rotorcraft Health and Usage Monitoring Systems (HUMS) for maintenance credits via FAA Advisory Circular (AC) 29-2C, Section MG-15, Airworthiness Approval of Rotorcraft (HUMS) (Ref. 1). The overarching goal of this work was to determine a method to validate condition indicators in the lab that better represent their response to faults in the field. Using existing in-service helicopter HUMS flight data from faulted spiral bevel gears as a "Case Study," to better understand the differences between both systems, and the availability of the NASA Glenn Spiral Bevel Gear Fatigue Rig, a plan was put in place to design, fabricate and test comparable gear sets with comparable failure modes within the constraints of the test rig. The research objectives of the rig tests were to evaluate the capability of detecting gear surface pitting fatigue and other generated failure modes on spiral bevel gear teeth using gear condition indicators currently used in fielded HUMS. Nineteen final design gear sets were tested. Tables were generated for each test, summarizing the failure modes observed on the gear teeth for each test during each inspection interval and color coded based on damage mode per inspection photos. Gear condition indicators (CI) Figure of Merit 4 (FM4), Root Mean Square (RMS), +/- 1 Sideband Index (SI1) and +/- 3 Sideband Index (SI3) were plotted along with rig operational parameters. Statistical tables of the means and standard deviations were calculated within inspection intervals for each CI. As testing progressed, it became clear that certain condition indicators were more sensitive to a specific component and failure mode. These tests were clustered together for further analysis. Maintenance actions during testing were also documented. Correlation coefficients were calculated between each CI, component, damage state and torque. Results found test rig and gear design, type of fault and data acquisition can affect CI performance. Results found FM4, SI1 and SI3 can be used to detect macro pitting on two more gear or pinion teeth as long as it is detected prior to progressing to other components or transitioning to another failure mode. The sensitivity of RMS to system and operational conditions limit its reliability for systems that are not maintained at steady state. Failure modes that occurred due to scuffing or fretting were challenging to detect with current gear diagnostic tools, since the damage is distributed across all the gear and pinion teeth, smearing the impacting signatures typically used to differentiate between a healthy and damaged tooth contact. This is one of three final reports published on the results of this project. In the second report, damage modes experienced in the field will be mapped to the failure modes created in the test rig. The helicopter CI data will then be re-processed with the same analysis techniques applied to spiral bevel rig test data. In the third report, results from the rig and helicopter data analysis will be correlated. Observations, findings and lessons learned using sub-scale rig failure progression tests to validate helicopter gear condition indicators will be presented.

gears↗