SEARCH · Engineering Papers

Results for “directed assembly”

Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

SourceResearch connectionFrom yearThrough year

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 541 records · Page 30

All sources NASA NTRS DOE OSTI

NASA NTRS2008

Evaluation of Perfluoropolyether Lubricant Lifetime in the High Stress and High Stress-Cycle Regime for Mars Applications

The successful operation of long-life, highly loaded mechanisms used for planetary exploration or autonomous structures assembly will depend upon the ability to effectively lubricate rolling-element bearings. As new tools are developed (i.e., drill, abraders, robotic manipulators, etc.) that interact with their environment in a more direct manner, lubricants will be pushed past the bounds that current scientific literature has published. This paper details results from bearing lubrication lifetime testing performed in support of Honeybee Robotics development of the Mars Science Laboratory (MSL) Surface Removal Tool (SRT). This testing was done due to the lack of available data in research literature that is applicable to the lubrication regime the SRT bearings are being designed for. Based on the test results, the chosen bearing arrangement can be used for the SRT Grind Shaft bearings with the use of a Braycote Micronic 601EF grease-plate with a 10 vol% grease slurry fill (50/50 wt% Braycote Micronic 601EF and Brayco 815Z). This arrangement showed no signs of detrimental degradation over the course of the 3x life test. The purely grease-plated bearing ran at a consistently higher torque and showed signs of failure beginning at approximately 2.2 x 10(exp 7) revs (approximately 6.3 x 10(exp 7) stress-cycles) with a torque over-limit failure at approximately 4.5 x 10(exp 7) revs (approximately 1.3 x 10(exp 8) stress-cycles). Barring cold-start torque margin limitations, it is recommended that any long-life bearing application include some vol% grease-pack in addition to a standard grease-plate to reduce parasitic torque and increase bearing life. While these results are specific to a particular environment and loading condition, they demonstrate the extended capabilities of a commonly used flight lubricant outside of the range that is published in current research literature.

Herman, Jason↗

NASA NTRS2018

Methodologies for Verification and Validation of Space Launch System (SLS) Structural Dynamic Models

Responses to challenges associated with verification and validation (V&V) of Space Launch System (SLS) structural dynamics models are presented in this paper. Four methodologies addressing specific requirements for V&V are discussed. (1) Residual Mode Augmentation (RMA), which has gained acceptance by various principals in the NASA community, defines efficient and accurate FEM modal sensitivity models that are useful in test-analysis correlation and reconciliation and parametric uncertainty studies. (2) Modified Guyan Reduction (MGR) and Harmonic Reduction (HR, introduced in 1976), developed to remedy difficulties encountered with the widely used Classical Guyan Reduction (CGR) method, are presented. MGR and HR are particularly relevant for estimation of "body dominant" target modes of shell-type SLS assemblies that have numerous "body", "breathing" and local component constituents. Realities associated with configuration features and "imperfections" cause "body" and "breathing" mode characteristics to mix resulting in a lack of clarity in the understanding and correlation of FEM- and test-derived modal data. (3) Mode Consolidation (MC) is a newly introduced procedure designed to effectively "de-feature" FEM and experimental modes of detailed structural shell assemblies for unambiguous estimation of "body" dominant target modes. Finally, (4) Experimental Mode Verification (EMV) is a procedure that addresses ambiguities associated with experimental modal analysis of complex structural systems. Specifically, EMV directly separates well-defined modal data from spurious and poorly excited modal data employing newly introduced graphical and coherence metrics.

Coppolino, Robert N.↗

NASA NTRS2016

High-Performance Reaction Wheel Optimization for Fine-Pointing Space Platforms: Minimizing Induced Vibration Effects on Jitter Performance plus Lessons Learned from Hubble Space Telescope for Current and Future Spacecraft Applications

The Hubble Space Telescope (HST) applies large-diameter optics (2.5-m primary mirror) for diffraction-limited resolution spanning an extended wavelength range (approx. 100-2500 nm). Its Pointing Control System (PCS) Reaction Wheel Assemblies (RWAs), in the Support Systems Module (SSM), acquired an unprecedented set of high-sensitivity Induced Vibration (IV) data for 5 flight-certified RWAs: dwelling at set rotation rates. Focused on 4 key ratios, force and moment harmonic values (in 3 local principal directions) are extracted in the RWA operating range (0-3000 RPM). The IV test data, obtained under ambient lab conditions, are investigated in detail, evaluated, compiled, and curve-fitted; variational trends, core causes, and unforeseen anomalies are addressed. In aggregate, these values constitute a statistically-valid basis to quantify ground test-to-test variations and facilitate extrapolations to on-orbit conditions. Accumulated knowledge of bearing-rotor vibrational sources, corresponding harmonic contributions, and salient elements of IV key variability factors are discussed. An evolved methodology is presented for absolute assessments and relative comparisons of macro-level IV signal magnitude due to micro-level construction-assembly geometric details/imperfections stemming from both electrical drive and primary bearing design parameters. Based upon studies of same-size/similar-design momentum wheels' IV changes, upper estimates due to transitions from ground tests to orbital conditions are derived. Recommended HST RWA choices are discussed relative to system optimization/tradeoffs of Line-Of-Sight (LOS) vector-pointing focal-plane error driven by higher IV transmissibilities through low-damped structural dynamics that stimulate optical elements. Unique analytical disturbance results for orbital HST accelerations are described applicable to microgravity efforts. Conclusions, lessons learned, historical context/insights, and perspectives on future applications are given; these previously unpublished data and findings represents a valuable resource for fine-pointing spacecraft or space-based platforms using RWAs, Control Moment Gyros (CMGs), Momentum Wheels, or other ball-bearing-based rotational units.

Hasha, Martin D.↗

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 NTRS2018

Thermal Protection Systems Technology Transfer from Apollo and Space Shuttle to the Orion Program

This paper describes how the Orion program is utilizing the Thermal Protection System (TPS) experience from the Apollo and Space Shuttle programs to reduce program risk and improve affordability to meet NASA's future manned exploration missions. The Orion program successfully completed the Exploration Flight Test (EFT-1) mission in 2014 and is currently assembling, integrating, and testing the next spacecraft for the Exploration Mission (EM-1) to meet the flight test objectives of an unmanned orbital mission to the moon and return to earth in 2019. The Orion spacecraft production operations are located in the Neil Armstrong Operations and Checkout (O&C) facility at the Kennedy Space Center (KSC) providing an affordable and seamless delivery approach of vehicles directly to the launch site eliminating spacecraft transportation and additional checkout testing. Innovative vehicle design, manufacturing and test operations approaches are maturing and evolving with each Orion vehicle build to support the challenging NASA exploration mission requirements beyond Low Earth Orbit (LEO) while reducing program cost and schedule impacts. An example of Orion's evolution is the incorporation of an improved heat shield design, assembly and testing approach to meet the higher re-entry velocities for a lunar return for the EM-1 mission. The EFT- 1 heat shield was based on the Apollo heat shield manufacturing processes and was assembled at a supplier location and then transported to KSC for final integration. The EM-1 heat shield is now manufactured, assembled, tested, and installed into the spacecraft at the O&C facility reducing program cost and production schedules. The transition of the Space Shuttle TPS capabilities has enabled Orion to provide a human rated capsule design using proven materials and processes established over years of orbiter re-entry missions. The Orion Crew Module (CM) TPS configuration is derived from the Apollo CM approach utilizing improved materials and processes developed from the Space Shuttle program. The Orion EFT-1 heat shield utilized the Avcoat ablative material from Apollo which was injected into a honeycomb substrate and has been updated for EM-1 incorporating a block configuration bonded to a composite shell structure. This approach utilizes the proven Avcoat material for the heat shield ablator and is utilizing derived bonding and inspection methods and techniques from the Space Shuttle tile experience. The Orion back shell TPS configuration is based on Space Shuttle tile designs using proven tile materials and coatings. The Orion forward bay cover utilizes the high temperature tiles similar to the back shell tiles and low temperature blankets derived from the Space Shuttle program reducing weight impacts. Space Shuttle Multi-Layer Insulation (MLI) is installed in the Orion capsule to control the interior temperature environment providing a light weight design. These TPS design approaches have performed successfully on the Orion first flight test on EFT-1 and are incorporated in the configuration for the next flight test for EM-1. Completion of these two flight tests will certify the TPS for the Orion program for human rated exploration missions and has reduced the development cost to the Orion program. In addition to transitioning the Space Shuttle TPS design configurations to Orion, the supporting manufacturing infrastructure, manufacturing processes, and inspection methods are also incorporated into the Orion assembly operations at KSC. This has avoided significant startup schedule and costs impacts of new capabilities and development of support operations necessary to fabricate, install, inspect, and validate the TPS installations for the Orion spacecraft. The Thermal Protection System Facility (TPSF) which supported the Space Shuttle program provides the heat shield Avcoat blocks and the back shell AETB-8 tiles for Orion program. Extending the existing Space Shuttle TPS operations at KSC provides onsite support to the Orion spacecraft assembly operations. A significant benefit to the Orion program is the transition of the Space Shuttle technician work force at KSC. This highly skilled workforce was able to transition to the Orion program and immediately support the TPS installation operations. They brought with them the human rated manufacturing and assembly operations culture that was critical to the Space Shuttle success avoiding the retraining cost and schedule impacts of a new workforce to Orion. The technician skills certification program from the Space Shuttle was found to be compatible with the Lockheed Martin technician certification programs enabling a seamless training process utilizing process similarity avoiding the cost of retraining the work force to Orion standards. The existing workforce is certificated for multiple processes enabling reassignment of technicians to other tasks in the Orion AI&P operations reducing the overall touch labor manpower requirements. Additional benefits of using the Space Shuttle workforce is the incorporation of the lessons learned from Space Shuttle processes to improve the Orion TPS processes. This has resulted in a continuous evolution of TPS processes to improve the producibility and reduce the program cost for the TPS for the Orion program. Transitioning the Apollo and Space Shuttle TPS designs, processes, and technician workforce has been instrumental in enabling Orion to successfully meet the program challenges for NASA's exploration missions of the future.

Stewart, Michael↗

NASA NTRS1974

Emergency descent device

Device includes cable wound on reel; special assembly enclosed in fluid medium controls unwinding speed of cable during descent. Device is compact and reliable. It can be rewound quickly because reel disengages from latches when it is turned in opposite direction.

Belew, R. R.↗

NASA NTRS1974

Status of 30 cm mercury ion thruster development

Two engineering model 30-cm ion thrusters were assembled, calibrated, and qualification tested. This paper discusses the thruster design, performance, and power system. Test results include documentation of thrust losses due to doubly charged mercury ions and beam divergence by both direct thrust measurements and beam probes. Diagnostic vibration tests have led to improved designs of the thruster backplate structure, feed system, and harness. Thruster durability is being demonstrated over a thrust range of 97 to 113 mN at a specific impulse of about 2900 seconds. As of August 15, 1974, the thruster has successfully operated for over 4000 hours.

Sovey, J. S.↗

NASA NTRS1974

Status of 30 cm mercury ion thruster development

Two engineering model 30-cm ion thrusters have been assembled, calibrated, and qualification tested. This paper discusses the thruster design, performance, and power system. Test results include documentation of thrust losses due to doubly charged mercury ions and beam divergence by both direct thrust measurements and beam probes. Diagnostic vibration tests have led to improved designs of the thruster backplate structure, feed system, and harness. Thruster durability is being demonstrated over a thrust range of 97 to 113 mN at a specific impulse of about 2900 seconds. As of August 15, 1974, the thruster has successfully operated for over 4000 hours.

Sovey, J. S.↗

NASA NTRS1977

Magnifying image intensifier

Coil assembly for zoom operation produces axial magnetic flux density that decreases in strength from photocathode to target. This results in magnification factor greater than unity. To extend magnification range, field is reversed in direction between object and image planes.

Vine, J.↗

NASA NTRS1982

The design and technology development for A 150 mlb resistojet for H2 or NH3

A 150 mlb thrust level hybrid resistojet which may operate on either H2 or NH3 is described whose design technique allows temperature distribution forecasting by means of a microcomputer-implemented mathematical model. The longer computer run times that accompany the exclusive use of BASIC, relative to assembled languages, are offset by the flexibility offered and the reduction of reprogramming and debugging efforts. The integration of a compact first-stage coiled heater with a concentric tubular gas heater offers direct matching of the 28 V terminal of the spacecraft system, while keeping maximum heater wall temperatures to less than 60 K over that of the gas temperature at the throat. Among the novel materials employed are grain-stabilized rhenium for heating elements and high purity aluminas for insulators.

Page, R. J.↗

NASA NTRS1989

A 17 degree of freedom anthropomorphic manipulator

A 17 axis anthropomorphic manipulator, providing coordinated control of two seven degree of freedom arms mounted on a three degree of freedom torso-waist assembly, is presented. This massively redundant telerobot, designated the Robotics Research K/B-2017 Dexterous Manipulator, employs a modular mechanism design with joint-mounted actuators based on brushless motors and harmonic drive gear reducers. Direct joint torque control at the servo level causes these high-output joint drives to behave like direct-drive actuators, facilitating the implementation of an effective impedance control scheme. The redundant, but conservative motion control system models the manipulator as a spring-loaded linkage with viscous damping and rotary inertia at each joint. This approach allows for real time, sensor-driven control of manipulator pose using a hierarchy of competing rules, or objective functions, to avoid unplanned collisions with objects in the workplace, to produce energy-efficient, graceful motion, to increase leverage, to control effective impedance at the tool or to favor overloaded joints.

Vold, Havard I.↗

NASA NTRS1993

Using computer graphics to design Space Station Freedom viewing

Viewing requirements were identified early in the Space Station Freedom program for both direct viewing via windows and indirect viewing via cameras and closed-circuit television (CCTV). These requirements reside in NASA Program Definition and Requirements Document (PDRD), Section 3: Space Station Systems Requirements. Currently, analyses are addressing the feasibility of direct and indirect viewing. The goal of these analyses is to determine the optimum locations for the windows, cameras, and CCTV's in order to meet established requirements, to adequately support space station assembly, and to operate on-board equipment. PLAID, a three-dimensional computer graphics program developed at NASA JSC, was selected for use as the major tool in these analyses. PLAID provides the capability to simulate the assembly of the station as well as to examine operations as the station evolves. This program has been used successfully as a tool to analyze general viewing conditions for many Space Shuttle elements and can be used for virtually all Space Station components. Additionally, PLAID provides the ability to integrate an anthropometric scale-modeled human (representing a crew member) with interior and exterior architecture.

Goldsberry, Betty S.↗

NASA NTRS1994

Terrestrial applications of NASA space telerobotics technologies

In 1985 the National Aeronautics and Space Administration (NASA) instituted a research program in telerobotics to develop and provide the technology for applications of telerobotics to the United States space program. The activities of the program are intended to most effectively utilize limited astronaut time by facilitating tasks such as inspection, assembly, repair, and servicing, as well as providing extended capability for remotely conducting planetary surface operations. As the program matured, it also developed a strong heritage of working with government and industry to directly transfer the developed technology into industrial applications.

Lavery, Dave↗

NASA NTRS2000

New Directions in NASA's Biological Crystal Growth Program on the International Space Station

NASA's Biological Crystal Growth Program (BCG) on the International Space Station (ISS) is changing direction from the study of crystallization to an emphasis on producing crystals for structure determination in leading problems in structural biology. The program will consist of two phases. The first phase is during assembly of the ISS and will primarily utilize payloads that currently fly in the orbiter middeck but can be adapted for ISS. The second phase begins after assembly of the ISS is complete and BCG payloads will occupy part of the Biotechnology Facility aboard the ISS. Two types of BCG payloads will be flown. One will emphasize the production of crystals for structure determination back on Earth. These types of payloads will allow hundreds of crystallization conditions to be tested. The second type of payload will be designed to study the crystallization process with the primary aim of assisting the structural biology efforts. Access to these facilities will be through the NASA BCG Guest Investigators program, the NASA Research Announcement, and other opportunities currently being formulated. Details of the crystallization hardware, the application procedures, and the operational aspects of the program will be described.

Kundrot, Craig E.↗

NASA NTRS2000

New Directions in NASA's Biological Crystal Growth Program on the International Space Station

Kundrot, Craig E.↗

NASA NTRS2007

Experimental Performance Evaluation of a High Speed Permanent Magnet Synchronous Motor and Drive for a Flywheel Application at Different Frequencies

This paper presents the results of an experimental performance characterization study of a high speed, permanent magnet motor/generator (M/G) and drive applied to a flywheel module. Unlike the conventional electric machine the flywheel M/G is not a separated unit; its stator and rotor are integrated into a flywheel assembly. The M/G rotor is mounted on a flywheel rotor, which is magnetically levitated and sealed within a vacuum chamber during the operation. Thus, it is not possible to test the M/G using direct load measurements with a dynamometer and torque transducer. Accordingly, a new in-situ testing method had to be developed. The paper describes a new flywheel M/G and drive performance evaluation technique, which allows the estimation of the losses, efficiency and power quality of the flywheel high speed permanent magnet M/G, while working in vacuum, over wide frequency and torque ranges. This method does not require any hardware modification nor any special addition to the test rig. This new measurement technique is useful for high-speed applications, when applying an external load is technically difficult.

Nagorny, Aleksandr S.↗

NASA NTRS2021

Demonstration of a 1-D Submillimeter-Wave Phased Array with MEMS Phase Shifters

At submillimeter-wave frequencies, due to the nonavailability of low-loss phase shifters, electronic antenna beam scanning is difficult to realize. Traditionally, power-hungry and bulky motors are used to mechanically scan the antenna beam. At lower-frequencies, phased array antennas are most commonly used where low-loss phase shifters are used with the array elements to accomplish beam steering. However, development of similar phased array antennas at submillimeter-waves has been challenging. Recently, we have developed a low-loss microelectromechanical systems (MEMS) based phased shifter in the 500-750 GHz band. In this work, we present a submillimeter-wave phased array antenna system with a cavity-backed double slot antenna architecture using the MEMS-based phase shifters. To demonstrate the concept, we developed two arrays: first one is a 8×1 linear antenna array with a fixed waveguide feeding network that achieved ±20◦ beam scanning, 18 dB directivity, and less than 1 dB scan loss over the design frequency of 500–570 GHz. The second one is a 4 × 1 linear antenna array with integrated MEMS-based phase shifters on each array element, achieving 15 dB directivity and capable of dynamic beam scanning over a range of ±9 ◦ . All the plots presented are simulated results since the parts are currently being fabricated. We hope to have access to our assembly and measurement facilities over the next few months and present measured performances at the conference.

Chattopadhyay, G.↗

NASA NTRS1980

Comparison of advanced engines for parabolic dish solar thermal power plants

A paraboloidal dish solar thermal power plant produces electrical energy by a two-step conversion process. The collector subsystem is composed of a two-axis tracking paraboloidal concentrator and a cavity receiver. The concentrator focuses intercepted sunlight (direct, normal insolation) into a cavity receiver whose aperture encircles the focal point of the concentrator. At the internal wall of the receiver the electromagnetic radiation is converted to thermal energy. A heat engine/generator assembly then converts the thermal energy captured by the receiver to electricity. Developmental activity has been concentrated on small power modules which employ 11- to 12-meter diameter dishes to generate nominal power levels of approximately 20 kWe. A comparison of advanced heat engines for the dish power module is presented in terms of the performance potential of each engine with its requirements for advanced technology development. Three advanced engine possibilities are the Brayton (gas turbine), Brayton/Rankine combined cycle, and Stirling engines.

Fujita, T.↗