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NASA NTRS1994

Actuator Feasibility Study for Active Control of Ducted Axial Fan Noise

A feasibility study was performed to investigate actuator technology which is relevant for a particular application of active noise control for gas turbine stator vanes. This study investigated many different classes of actuators and ranked them on the order of applicability. The most difficult requirements the actuators had to meet were high frequency response, large amplitude deflections, and a thin profile. Based on this assessment, piezoelectric type actuators were selected as the most appropriate actuator class. Specifically, Rainbows (a new class of high performance piezoelectric actuators), and unimorphs (a ceramic/metal composite) appeared best suited to the requirements. A benchtop experimental study was conducted. The performance of a variety of different actuators was examined, including high polymer films, flextensional actuators, miniature speakers, unimorphs, and Rainbows. The displacement/frequency response and phase characteristics of the actuators were measured. Physical limitations of actuator operation were also examined. This report includes the first known, high displacement, dynamic data obtained for Rainbow actuators. A new "hard" ceramic Rainbow actuator which does not appear to be limited in operation by self heating as "soft" ceramic Rainbows was designed, constructed and tested. The study concludes that a suitable actuator for active noise control in gas turbine engines can be achieved with state of the art materials and processing.

Simonich, John C.↗

NASA NTRS2009

T-Slide Linear Actuators

T-slide linear actuators use gear bearing differential epicyclical transmissions (GBDETs) to directly drive a linear rack, which, in turn, performs the actuation. Conventional systems use a rotary power source in conjunction with a nut and screw to provide linear motion. Non-back-drive properties of GBDETs make the new actuator more direct and simpler. Versions of this approach will serve as a long-stroke, ultra-precision, position actuator for NASA science instruments, and as a rugged, linear actuator for NASA deployment duties. The T slide can operate effectively in the presence of side forces and torques. Versions of the actuator can perform ultra-precision positioning. A basic T-slide actuator is a long-stroke, rack-and-pinion linear actuator that, typically, consists of a T-slide, several idlers, a transmission to drive the slide (powered by an electric motor) and a housing that holds the entire assembly. The actuator is driven by gear action on its top surface, and is guided and constrained by gear-bearing idlers on its other two parallel surfaces. The geometry, implemented with gear-bearing technology, is particularly effective. An electronic motor operating through a GBDET can directly drive the T slide against large loads, as a rack and pinion linear actuator, with no break and no danger of back driving. The actuator drives the slide into position and stops. The slide holes position with power off and no brake, regardless of load. With the T slide configuration, this GBDET has an entire T-gear surface on which to operate. The GB idlers coupling the other two T slide parallel surfaces to their housing counterpart surfaces provide constraints in five degrees-of-freedom and rolling friction in the direction of actuation. Multiple GB idlers provide roller bearing strength sufficient to support efficient, rolling friction movement, even in the presence of large, resisting forces. T-slide actuators can be controlled using the combination of an off-the-shelf, electric servomotor, a motor angle resolution sensor (typically an encoder or resolver), and microprocessor-based intelligent software. In applications requiring precision positioning, it may be necessary to add strain gauges to the T-slide housing. Existing sensory- interactive motion control art will work for T slides. For open-loop positioning, a stepping motor emulation technique can be used.

Vranish, John↗

NASA NTRS2015

The Effects of Sweeping Jet Actuator Parameters on Flow Separation Control

A parametric experimental study was performed with sweeping jet actuators (fluidic oscillators) to determine their effectiveness in controlling flow separation on an adverse pressure gradient ramp. Actuator parameters that were investigated include blowing coefficients, operation mode, pitch and spreading angles, streamwise location, aspect ratio, and scale. Surface pressure measurements and surface oil flow visualization were used to characterize the effects of these parameters on the actuator performance. 2D Particle Image Velocimetry measurements of the flow field over the ramp and hot-wire measurements of the actuator's jet flow were also obtained for selective cases. In addition, the sweeping jet actuators were compared to other well-known flow control techniques such as micro-vortex generators, steady blowing, and steady vortex-generating jets. The results confirm that the sweeping jet actuators are more effective than steady blowing and steady vortex-generating jets. The results also suggest that an actuator with a larger spreading angle placed closer to the location where the flow separates provides better performance. For the cases tested, an actuator with an aspect ratio, which is the width/depth of the actuator throat, of 2 was found to be optimal. For a fixed momentum coefficient, decreasing the aspect ratio to 1 produced weaker vortices while increasing the aspect ratio to 4 reduced coverage area. Although scaling down the actuator (based on the throat dimensions) from 0.25 inch x 0.125 inch to 0.15 inch x 0.075 inch resulted in similar flow control performance, scaling down the actuator further to 0.075 inch x 0.0375 inch reduced the actuator efficiency by reducing the coverage area and the amount of mixing in the near-wall region. The results of this study provide insight that can be used to design and select the optimal sweeping jet actuator configuration for flow control applications.

Koklu, Mehti↗

NASA NTRS2016

Engineering Design Tools for Shape Memory Alloy Actuators: CASMART Collaborative Best Practices and Case Studies

The primary goal of the Consortium for the Advancement of Shape Memory Alloy Research and Technology (CASMART) is to enable the design of revolutionary applications based on shape memory alloy (SMA) technology. In order to help realize this goal and reduce the development time and required experience for the fabrication of SMA actuation systems, several modeling tools have been developed for common actuator types and are discussed herein along with case studies, which highlight the capabilities and limitations of these tools. Due to their ability to sustain high stresses and recover large deformations, SMAs have many potential applications as reliable, lightweight, solid-state actuators. Their advantage over classical actuators can also be further improved when the actuator geometry is modified to fit the specific application. In this paper, three common actuator designs are studied: wires, which are lightweight, low-profile, and easily implemented; springs, which offer actuation strokes upwards of 200 at reduced mechanical loads; and torque tubes, which can provide large actuation forces in small volumes and develop a repeatable zero-load actuation response (known as the two-way shape memory effect). The modeling frameworks, which have been implemented in the design tools, are developed for each of these frequently used SMA actuator types. In order to demonstrate the versatility and flexibility of the presented design tools, as well as validate their modeling framework, several design challenges were completed. These case studies include the design and development of an active hinge for the deployment of a solar array or foldable space structure, an adaptive solar array deployment and positioning system, a passive air temperature controller for regulation flow temperatures inside of a jet engine, and a redesign of the Corvette active hatch, which allows for pressure equalization of the car interior. For each of the presented case studies, a prototype or proof-of-concept was fabricated and the experimental results and lessons learned are discussed. This analysis presents a collection of CASMART collaborative best practices in order to allow readers to utilize the available design tools and understand their modeling principles. These design tools, which are based on engineering models, can provide first-order optimal designs and are a basic and efficient method for either demonstrating design feasibility or refining design parameters. Although the design and integration of an SMA-based actuation system always requires application- and environment-specific engineering considerations, common modeling tools can significantly reduce the investment required for actuation system development and provide valuable engineering insight.

Design tools↗

NASA NTRS1997

A Model of the THUNDER Actuator

A THUNDER actuator is a composite of three thin layers, a metal base, a piezoelectric wafer and a metal top cover, bonded together under pressure and at high temperature with the LaRC SI polyimid adhesive. When a voltage is applied between the metal layers across the PZT the actuator will bend and can generate a force. This document develops and describes an analytical model the transduction properties of THUNDER actuators. The model development is divided into three sections. First, a static model is described that relates internal stresses and strains and external displacements to the thermal pre-stress and applied voltage. Second, a dynamic energy based model is described that allows calculation of the resonance frequencies, developed force and electrical input impedance. Finally, a fully coupled electro-mechanical transducer model is described. The model development proceeds by assuming that both the thermal pre-stress and the piezoelectric actuation cause the actuator to deform in a pure bend in a single plane. It is useful to think of this as a two step process, the actuator is held flat, differential stresses induce a bending moment, the actuator is released and it bends. The thermal pre-stress is caused by the different amounts that the constituent layers shrink due to their different coefficients of thermal expansion. The adhesive between layers sets at a high temperature and as the actuator cools, the metal layers shrink more than the PZT. The PZT layer is put into compression while the metal layers are in tension. The piezoelectric actuation has a similar effect. An applied voltage causes the PZT layer to strain, which in turn strains the two metal layers. If the PZT layer expands it will put the metal layers into tension and PZT layer into compression. In both cases, if shear force effects are neglected, the actuator assembly will experience a uniform in-plane strain. As the materials each have a different elastic modulus, different stresses will develop in each layer and these stresses will induce a bending moment. When the actuator is released from its flat configuration, the differential stresses are relieved as the actuator bends.

Curtis, Alan R. D.↗

DOE OSTI2022

Nonlinear burn control in ITER using adaptive allocation of actuators with uncertain dynamics

Abstract ITER will be the first tokamak to sustain a fusion-producing, or burning, plasma. If the plasma temperature were to inadvertently rise in this burning regime, the positive correlation between temperature and the fusion reaction rate would establish a destabilizing positive feedback loop. Careful regulation of the plasma’s temperature and density, or burn control, is required to prevent these potentially reactor-damaging thermal excursions, neutralize disturbances and improve performance. In this work, a Lyapunov-based burn controller is designed using a full zero-dimensional nonlinear model. An adaptive estimator manages destabilizing uncertainties in the plasma confinement properties and the particle recycling conditions (caused by plasma–wall interactions). The controller regulates the plasma density with requests for deuterium and tritium particle injections. In ITER-like plasmas, the fusion-born alpha particles will primarily heat the plasma electrons, resulting in different electron and ion temperatures in the core. By considering separate response models for the electron and ion energies, the proposed controller can independently regulate the electron and ion temperatures by requesting that different amounts of auxiliary power be delivered to the electrons and ions. These two commands for a specific control effort (electron and ion heating) are sent to an actuator allocation module that optimally maps them to the heating actuators available to ITER: an electron cyclotron heating system (20 MW), an ion cyclotron heating system (20 MW), and two neutral beam injectors (16.5 MW each). Two different actuator allocators are presented in this work. The first actuator allocator finds the optimal mapping by solving a convex quadratic program that includes actuator saturation and rate limits. It is nonadaptive and assumes that the mapping between the commanded control efforts and the allocated actuators (i.e. the effector model) contains no uncertainties. The second actuator allocation module has an adaptive estimator to handle uncertainties in the effector model. This uncertainty includes actuator efficiencies, the fractions of neutral beam heating that are deposited into the plasma electrons and ions, and the tritium concentration of the fueling pellets. Furthermore, the adaptive allocator considers actuator dynamics (actuation lag) that contain uncertainty. This adaptive allocation algorithm is more computationally efficient than the aforementioned nonadaptive allocator because it is computed using dynamic update laws so that finding the solution to a static optimization problem is not required at every time step. A simulation study assesses the performance of the proposed adaptive burn controller augmented with each of the actuator allocation modules.

Physics↗

NASA NTRS1997

Performance of an Electro-Hydrostatic Actuator on the F-18 Systems Research Aircraft

An electro-hydrostatic actuator was evaluated at NASA Dryden Flight Research Center, Edwards, California. The primary goal of testing this actuator system was the flight demonstration of power-by-wire technology on a primary flight control surface. The electro-hydrostatic actuator uses an electric motor to drive a hydraulic pump and relies on local hydraulics for force transmission. This actuator replaced the F-18 standard left aileron actuator on the F-18 Systems Research Aircraft and was evaluated throughout the Systems Research Aircraft flight envelope. As of July 24, 1997 the electro-hydrostatic actuator had accumulated 23.5 hours of flight time. This paper presents the electro-hydrostatic actuator system configuration and component description, ground and flight test plans, ground and flight test results, and lessons learned. This actuator performs as well as the standard actuator and has more load capability than required by aileron actuator specifications of McDonnell- Douglas Aircraft, St. Louis, Missouri. The electro-hydrostatic actuator system passed all of its ground tests with the exception of one power-off test during unloaded dynamic cycling.

Robert Navarro↗

NASA NTRS2000

Flight Test Experience With an Electromechanical Actuator on the F-18 Systems Research Aircraft

Development of reliable power-by-wire actuation systems for both aeronautical and space applications has been sought recently to eliminate hydraulic systems from aircraft and spacecraft and thus improve safety, efficiency, reliability, and maintainability. The Electrically Powered Actuation Design (EPAD) program was a joint effort between the Air Force, Navy, and NASA to develop and fly a series of actuators validating power-by-wire actuation technology on a primary flight control surface of a tactical aircraft. To achieve this goal, each of the EPAD actuators was installed in place of the standard hydraulic actuator on the left aileron of the NASA F/A-18B Systems Research Aircraft (SRA) and flown throughout the SRA flight envelope. Numerous parameters were recorded, and overall actuator performance was compared with the performance of the standard hydraulic actuator on the opposite wing. This paper discusses the integration and testing of the EPAD electromechanical actuator (EMA) on the SRA. The architecture of the EMA system is discussed, as well as its integration with the F/A-18 Flight Control System. The flight test program is described, and actuator performance is shown to be very close to that of the standard hydraulic actuator it replaced. Lessons learned during this program are presented and discussed, as well as suggestions for future research.

Jensen, Stephen C.↗

NASA NTRS2000

Flight Test Experience with an Electromechanical Actuator on the F-18 Systems Research Aircraft

Jensen, Stephen C.↗

NASA NTRS2006

Flow and Noise Control in High Speed and High Reynolds Number Jets Using Plasma Actuators

The idea of manipulating flow to change its characteristics is over a century old. Manipulating instabilities of a jet to increase its mixing and to reduce its radiated noise started in the 1970s. While the effort has been successful in low-speed and low Reynolds number jets, available actuators capabilities in terms of their amplitude, bandwidth, and phasing have fallen short in control of high-speed and high Reynolds number jets of practical interest. Localized arc filament plasma actuators have recently been developed and extensively used at Gas Dynamics and Turbulence Laboratory (GDTL) for control of highspeed and high Reynolds number jets. While the technique has been quite successful and is very promising, all the work up to this point had been carried out using small high subsonic and low supersonic jets from a 2.54 cm diameter nozzle exit with a Reynolds number of about a million. The preliminary work reported in this paper is a first attempt to evaluate the scalability of the technique. The power supply/plasma generator was designed and built in-house at GDTL to operate 8 actuators simultaneously over a large frequency range (0 to 200 kHz) with independent control over phase and duty cycle of each actuator. This allowed forcing the small jet at GDTL with azimuthal modes m = 0, 1, 2, 3, plus or minus 1, plus or minus 2, and plus or minus 4 over a large range of frequencies. This power supply was taken to and used, with minor modifications, at the NASA Nozzle Acoustic Test Rig (NATR). At NATR, 32 actuators were distributed around the 7.5 in. nozzle (a linear increase with nozzle exit diameter would require 60 actuators). With this arrangement only 8 actuators could operate simultaneously, thus limiting the forcing of the jet at NATR to only three azimuthal modes m = plus or minus 1, 4, and 8. Very preliminary results at NATR indicate that the trends observed in the larger NASA facility in terms of the effects of actuation frequency and azimuthal modes are similar in both small GDTL and larger NASA jets. However, the actuation authority seems to fall short in the larger jet at higher Mach numbers, resulting in decreased amplitude response compared to the small jet, which is attributed at this point to the lack of sufficient number of actuators. The preliminary results seem also to suggest that amplitude of actuation tones is similar in both the small and larger jets.

Samimy, M.↗

NASA NTRS2010

Fast-Response-Time Shape-Memory-Effect Foam Actuators

Bulk shape memory alloys, such as Nitinol or CuAlZn, display strong recovery forces undergoing a phase transformation after being strained in their martensitic state. These recovery forces are used for actuation. As the phase transformation is thermally driven, the response time of the actuation can be slow, as the heat must be passively inserted or removed from the alloy. Shape memory alloy TiNi torque tubes have been investigated for at least 20 years and have demonstrated high actuation forces [3,000 in.-lb (approximately equal to 340 N-m) torques] and are very lightweight. However, they are not easy to attach to existing structures. Adhesives will fail in shear at low-torque loads and the TiNi is not weldable, so that mechanical crimp fits have been generally used. These are not reliable, especially in vibratory environments. The TiNi is also slow to heat up, as it can only be heated indirectly using heater and cooling must be done passively. This has restricted their use to on-off actuators where cycle times of approximately one minute is acceptable. Self-propagating high-temperature synthesis (SHS) has been used in the past to make porous TiNi metal foams. Shape Change Technologies has been able to train SHS derived TiNi to exhibit the shape memory effect. As it is an open-celled material, fast response times were observed when the material was heated using hot and cold fluids. A methodology was developed to make the open-celled porous TiNi foams as a tube with integrated hexagonal ends, which then becomes a torsional actuator with fast response times. Under processing developed independently, researchers were able to verify torques of 84 in.-lb (approximately equal to 9.5 Nm) using an actuator weighing 1.3 oz (approximately equal to 37 g) with very fast (less than 1/16th of a second) initial response times when hot and cold fluids were used to facilitate heat transfer. Integrated structural connections were added as part of the net shape process, eliminating the need for welding, adhesives, or mechanical crimping. Inexpensive net-shape processing was used, which reduces the cost of the actuator by over a factor of 10 over nonporous TiNi made by hot drawing of tube or electrical discharge machining. By forming the alloy as an open-celled foam, the surface area for heat transfer is dramatically increased, allowing for much faster response times. The technology also allows for netshape fabrication of the actuator, which allows for structural connections to be integrated into the actuator material, making these actuators significantly less expensive. Commercial applications include actuators for concepts such as the variable area chevron and nozzle in jet aircraft. Lightweight tube or rod components can be supplied to interested parties.

Jardine, Peter↗

NASA NTRS2011

DBD Plasma Actuators for Flow Control in Air Vehicles and Jet Engines - Simulation of Flight Conditions in Test Chambers by Density Matching

Dielectric Barrier Discharge (DBD) Plasma actuators for active flow control in aircraft and jet engines need to be tested in the laboratory to characterize their performance at flight operating conditions. DBD plasma actuators generate a wall-jet electronically by creating weakly ionized plasma, therefore their performance is affected by gas discharge properties, which, in turn, depend on the pressure and temperature at the actuator placement location. Characterization of actuators is initially performed in a laboratory chamber without external flow. The pressure and temperature at the actuator flight operation conditions need to be simultaneously set in the chamber. A simplified approach is desired. It is assumed that the plasma discharge depends only on the gas density, while other temperature effects are assumed to be negligible. Therefore, tests can be performed at room temperature with chamber pressure set to yield the same density as in operating flight conditions. The needed chamber pressures are shown for altitude flight of an air vehicle and for jet engines at sea-level takeoff and altitude cruise conditions. Atmospheric flight conditions are calculated from standard atmosphere with and without shock waves. The engine data was obtained from four generic engine models; 300-, 150-, and 50-passenger (PAX) aircraft engines, and a military jet-fighter engine. The static and total pressure, temperature, and density distributions along the engine were calculated for sea-level takeoff and for altitude cruise conditions. The corresponding chamber pressures needed to test the actuators were calculated. The results show that, to simulate engine component flows at in-flight conditions, plasma actuator should be tested over a wide range of pressures. For the four model engines the range is from 12.4 to 0.03 atm, depending on the placement of the actuator in the engine. For example, if a DBD plasma actuator is to be placed at the compressor exit of a 300 PAX engine, it has to be tested at 12.4 atm for takeoff, and 6 atm for cruise conditions. If it is to be placed at the low-pressure turbine, it has to be tested at 0.5 and 0.2 atm, respectively. These results have implications for the feasibility and design of DBD plasma actuators for jet engine flow control applications. In addition, the distributions of unit Reynolds number, Mach number, and velocity along the engine are provided. The engine models are non-proprietary and this information can be used for evaluation of other types of actuators and for other purposes.

Ashpis, David E.↗

NASA NTRS2003

Miniature Inchworm Actuators Fabricated by Use of LIGA

Miniature inchworm actuators that would have relatively simple designs have been proposed for applications in which there are requirements for displacements of the order of microns or tens of microns and for the ability to hold their positions when electric power is not applied. The proposed actuators would be members of the class of microelectromechanical systems (MEMS), but would be designed and fabricated following an approach that is somewhat unusual for MEMS. Like other MEMS actuators, the proposed inchworm actuators could utilize thermoplastic, bimetallic, shape-memory-alloy, or piezoelectric actuation principles. The figure depicts a piezoelectric inchworm actuator according to the proposal. As in other inchworm actuators, linear motion of an extensible member would be achieved by lengthening and shortening the extensible member in synchronism with alternately clamping and releasing one and then the other end of the member. In this case, the moving member would be the middle one; the member would be piezoelectric and would be shortened by applying a voltage to it. The two outer members would also be piezoelectric; the release of the clamps on the upper or lower end would be achieved by applying a voltage to the electrodes on the upper or lower ends, respectively, of these members. Usually, MEMS actuators cannot be fabricated directly on the side walls of silicon wafers, yet the geometry of this actuator necessitates such fabrication. The solution, according to the proposal, would be to use the microfabrication technique known by the German acronym LIGA - "lithographie, galvanoformung, abformung," which means lithography, electroforming, molding. LIGA involves x-ray lithography of a polymer film followed by selective removal of material to form a three-dimensional pattern from which a mold is made. Among the advantages of LIGA for this purpose are that it is applicable to a broad range of materials, can be used to implement a variety of designs, including those of structures >1 mm high, affords submicron precision, and is amenable to mass production at relatively low unit cost. Fabrication of the proposed actuators would involve some technological risks - in particular, in the integration of electrode connection lines and placement of actuator elements. It will also be necessary to perform an intensive study of the feasibility of growing piezoelectric crystals onto LIGA molds.

Yang, Eui-Hyeok↗

NASA NTRS2003

Mirrors Containing Biomimetic Shape-Control Actuators

Curved mirrors of a proposed type would comprise lightweight sheets or films containing integral, biologically inspired actuators for controlling their surface figures. These mirrors could be useful in such applications as collection of solar energy, focusing of radio beams, and (provided sufficient precision could be achieved) imaging. These mirrors were originally intended for use in outer space, but it should also be possible to develop terrestrial versions. Several prior NASA Tech Briefs articles have described a variety of approaches to the design of curved, lightweight mirrors containing integral shape-control actuators. The primary distinction between the present approach and the prior approaches lies in the actuator design concept, which involves shapes and movements reminiscent of those of a variety of small, multi-armed animals. The shape and movement of an actuator of this type can also be characterized as reminiscent of that of an umbrella. This concept can be further characterized as a derivative of that of multifinger grippers, the fingers of which are bimorph bending actuators (see Figure 1). The fingers of such actuators can be strips containing any of a variety of materials that have been investigated for use as actuators, including such electroactive polymers as ionomeric polymer/metal composites (IPMCs), ferroelectric polymers, and grafted elastomers. A mirror according to this proposal would be made from a sheet of one of the actuator composites mentioned above. The design would involve many variables, including the pre-curvature and stiffness of the mirror sheet, the required precision of figure control, the required range of variation in focal length (see Figure 2), the required precision of figure control for imaging or non-imaging use, the bending and twisting moments needed to effect the required deformations, and voltage-tomoment coefficients of the actuators, and the voltages accordingly required for actuation. A typical design would call for segmentation of the electrodes on the actuators so that voltages could be applied locally to effect local bending for fine adjustment of the surface figure.

Bar-Cohen, Yoseph↗

NASA NTRS2010

Mars Science Laboratory Rover Actuator Thermal Design

NASA will launch a 900 kg rover, part of the Mars Science Laboratory (MSL) mission, to Mars in October of 2011. The MSL rover is scheduled to land on Mars in August of 2012. The rover employs 31, electric-motor driven actuators to perform a variety of engineering and science functions including: mobility, camera pointing, telecommunications antenna steering, soil and rock sample acquisition and sample processing. This paper describes the MSL rover actuator thermal design. The actuators have stainless steel housings and planetary gearboxes that are lubricated with a "wet" lubricant. The lubricant viscosity increases with decreasing temperature. Warm-up heaters are required to bring the actuators up to temperature (above -55 C) prior to use in the cold wintertime environment of Mars (when ambient atmosphere temperatures are as cold as -113 C). Analytical thermal models of all 31 MSL actuators have been developed. The actuators have been analyzed and warm-up heaters have been designed to improve actuator performance in cold environments. Thermal hardware for the actuators has been specified, procured and installed. This paper presents actuator thermal analysis predicts, and describes the actuator thermal hardware and its operation. In addition, warm-up heater testing and thermal model correlation efforts for the Remote Sensing Mast (RSM) elevation actuator are discussed.

Novak, Keith S.↗

NASA NTRS2015

Space Shuttle Rudder Speed Brake Actuator-A Case Study Probabilistic Fatigue Life and Reliability Analysis

The U.S. Space Shuttle fleet was originally intended to have a life of 100 flights for each vehicle, lasting over a 10-year period, with minimal scheduled maintenance or inspection. The first space shuttle flight was that of the Space Shuttle Columbia (OV-102), launched April 12, 1981. The disaster that destroyed Columbia occurred on its 28th flight, February 1, 2003, nearly 22 years after its first launch. In order to minimize risk of losing another Space Shuttle, a probabilistic life and reliability analysis was conducted for the Space Shuttle rudder/speed brake actuators to determine the number of flights the actuators could sustain. A life and reliability assessment of the actuator gears was performed in two stages: a contact stress fatigue model and a gear tooth bending fatigue model. For the contact stress analysis, the Lundberg-Palmgren bearing life theory was expanded to include gear-surface pitting for the actuator as a system. The mission spectrum of the Space Shuttle rudder/speed brake actuator was combined into equivalent effective hinge moment loads including an actuator input preload for the contact stress fatigue and tooth bending fatigue models. Gear system reliabilities are reported for both models and their combination. Reliability of the actuator bearings was analyzed separately, based on data provided by the actuator manufacturer. As a result of the analysis, the reliability of one half of a single actuator was calculated to be 98.6 percent for 12 flights. Accordingly, each actuator was subsequently limited to 12 flights before removal from service in the Space Shuttle.

Rudder↗

NASA NTRS1993

RSRM nozzle actuator bracket/lug fracture mechanics qualification test

This is the final report for the actuator bracket/lug fracture mechanics qualification test. The test plan (CTP-0071) outlined a two-phase test program designed to answer questions about the fracture criticality of the redesigned solid rocket motor (RSRM) nozzle actuator bracket. An analysis conducted using the NASA/FLAGRO fracture mechanics computer program indicated that the actuator bracket might be a fracture critical component. In the NASA/FLAGRO analysis, a simple lug model was used to represent the actuator bracket. It was calculated that the bracket would fracture if subjected to an actuator stall load in the presence of a 0.10 in. corner crack at the actuator attachment hole. The 0.10 in. crack size corresponds to the nondestructive inspection detectability limit for the actuator bracket. The inspection method used is the dye penetrant method. The actuator stall load (103,424 lb) is the maximum load which the actuator bracket is required to withstand during motor operation. This testing was designed to establish the accuracy of the analytical model and to directly determine whether the actuator bracket is capable of meeting fracture mechanics safe-life requirements.

Kelley, Peggy↗

NASA NTRS1995

Actuator placement for active sound and vibration control of cylinders

Active structural acoustic control is a method in which the control inputs (used to reduce interior noise) are applied directly to a vibrating structural acoustic system. The control concept modeled in this work is the application of in-plane force inputs to piezoceramic patches bonded to the wall of a vibrating cylinder. The cylinder is excited by an exterior noise source -- an acoustic monopole -- located near the outside of the cylinder wall. The goal is to determine the force inputs and sites for the piezoelectric actuators so that (1) the interior noise is effectively damped; (2) the level of vibration of the cylinder shell is not increased; and (3) the power requirements needed to drive the actuators are not excessive. We studied external monopole excitations at two frequencies. A cylinder resonance of 100 Hz, where the interior acoustic field is driven in multiple, off-resonance cylinder cavity modes, and a cylinder resonance of 200 Hz are characterized by both near and off-resonance cylinder vibration modes which couple effectively with a single, dominant, low-order acoustic cavity mode at resonance. Previous work has focused almost exclusively on meeting objective (1) and solving a complex least-squares problem to arrive at an optimal force vector for a given set of actuator sites. In addition, it has been noted that when the cavity mode couples with cylinder vibration modes (our 200 Hz case) control spillover may occur in higher order cylinder shell vibrational modes. How to determine the best set of actuator sites to meet objectives (1)-(3) is the main contribution of our research effort. The selection of the best set of actuator sites from a set of potential sites is done via two metaheuristics -- simulated annealing and tabu search. Each of these metaheuristics partitions the set of potential actuator sites into two disjoint sets: those that are selected to control the noise (on) and those that are not (off). Next, each metaheuristic attempts to improve this initial solution by calculating the change in the objective value when one selected actuator site is turned off and one actuator site that previously was not selected is turned on. All such pairwise exchanges are performed and the exchange that improves the objective the most is made. Eventually the search is unable to improve the objective value and a local optimum (with respect to pairwise exchanges) is reached. Both simulated annealing and tabu search provide mechanisms to escape local optima and allow the search to continue until (hopefully) a global optimum is found. Our experiments with the 100 Hz and 200 Hz cases confirm that both metaheuristics are able to uncover better solutions than those selected based upon engineering judgement alone. In addition, the high quality solutions generated by these metaheuristics, when minimizing interior noise, do not further excite the cylinder shell. Thus, we are able to meet objective (2) without imposing an additional constraint or forming a multiobjective performance measure. An additional observation is that in many cases the amplitude and phase values for several chosen actuator sites were nearly identical. This natural grouping means that fewer control channels are needed and the resulting control system is simpler. Currently no power requirements have been set, so objective (3) cannot be addressed. A set of experiments is planned with a laboratory test article (a cylinder). For these experiments the transfer matrices will be generated experimentally. It is hoped that the predicted performance of the best actuator sites found by our metaheuristics will correlate well with the measured performance.

Kincaid, Rex K.↗