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The design requirements, the design, development tests and problems, the qualification and life test and the findings of the strip examination of a dual wound DC brushed motor gearhead are described. It is the only space qualified dual wound dc brushed motor gearhead in Europe.
The parts of electric motors which should be duplicated in order to provide maximum reliability in spacecraft application are identified. Various common types of redundancy are described. The advantages and disadvantages of each are noted. The principal types are illustrated by reference to specific examples. For each example, constructional details, basic performance data and failure modes are described, together with a discussion of the suitability of particular redundancy techniques to motor types.
Small dc servomotor powered by simple constant-current source and with suitable gearing used to cancel effect of gravity upon load. Lead-screw positioning system has load counterbalanced by small supplementary motor powered by constant current source. Motor lighter and more compact alternative to counterbalance. Used in variety of mechanical systems where load positioned or accelerated in vertical plane.
Recent advances in the technology of infrared detectors have made possible a wide range of scientific measurements and investigations. One of the requirements for the use of sensitive IR detectors is that the entire instrument be cooled to temperatures approaching absolute zero. The cryogenic cooling system for these instruments is commonly designed as a large dewar containing liquid helium which completely surrounds the apparatus. Thus, there is a need for a remotely controlled, motorized cryovalve that is simple, reliable, and compact and can operate over extended periods of time in cryo-vac conditions. The design, development, and test of a motorized cryovalve with application to a variety of cryogenic systems currently under development is described.
Flow analyses have been performed to determine the nature of the three-dimensional flow field in the vicinity of the aft-most field joint of the Space Shuttle Redesigned Solid Rocket Motor (RSRM). Specific objectives included the quantification of the circumferential pressure and velocity gradients at the joint location which might be caused by the non-uniform erosion of the rubber inhibitor which protrudes from the wall into the flow field. Three-dimensional Navier-Stokes equations have been solved in conjunction with the conservation equation for the turbulence energy and the dissipation rate. The numerical predictions have been compared with the measurements from a 7.5 percent scale cold flow model of the redesigned solid rocket motor.
Segmented and monolithic Solid Rocket Motor (SRM) design concepts were evaluated with emphasis on joints and seals. Particular attention was directed to eliminating deficiencies in the SRM High Performance Motor (HPM). The selected conceptual design is described and discussed.
A number of computer codes are available for performing thermal analysis of solid rocket motor nozzles. Aerotherm Chemical Equilibrium (ACE) computer program can be used to perform one-dimensional gas expansion to determine the state of the gas at each location of a nozzle. The ACE outputs can be used as input to a computer program called Momentum/Energy Integral Technique (MEIT) for predicting boundary layer development development, shear, and heating on the surface of the nozzle. The output from MEIT can be used as input to another computer program called Aerotherm Charring Material Thermal Response and Ablation Program (CMA). This program is used to calculate oblation or decomposition response of the nozzle material. A code called Failure Analysis Nonlinear Thermal and Structural Integrated Code (FANTASTIC) is also likely to be used for performing thermal analysis of solid rocket motor nozzles after the program is duly verified. A part of the verification work on FANTASTIC was done by using one and two dimension heat transfer examples with known answers. An attempt was made to prepare input for performing thermal analysis of the CCT nozzle using the FANTASTIC computer code. The CCT nozzle problem will first be solved by using ACE, MEIT, and CMA. The same problem will then be solved using FANTASTIC. These results will then be compared for verification of FANTASTIC.
Induction motors are recognized for their simple rugged construction. To date, however, their application to variable speed or servo drives was hampered by limitations on their control. Induction motor drives tend to be complex and to display troublesome low speed characteristics due in part to nonsinusoidal driving voltages. A technique was developed which involves direct synthesis of sinusoidal driving voltages from a high frequency power bus and independent control of frequency and voltages. Separation of frequency and voltage allows independent control of rotor and stator flux, full four quadrant operation, and instantaneous torque control. Recent test results, current status of the technology, and proposed aerospace applications will be discussed.
As a part of the redesign of the Space Shuttle Solid Rocket Motor, the field and nozzle-to-case joints were redesigned to minimize the dynamic flexure caused by internal motor pressurization during ignition. The O-ring seals and glands for the joints were designed to accommodate both structural deflections and to promote pressure assistance. A test program was conducted to determine if a fluorocarbon elastomeric O-ring could meet this criteria in the redesigned gland. Resiliency tests were used to investigate the O-ring response to gap motion while static seal tests were used to verify design criteria of pressure assistance for sealing. All tests were conducted in face seal fixtures mounted in servo-hydraulic test machines. The resiliency of the O-ring was found to be extremely sensitive to the effects of temperature. The External Tank/Solid Rocket Booster attach strut loads had a negligible affect on the ability of the O-ring to track the simulated SRB field joint deflection. In the static pressure-assisted seal tests, as long as physical contact was maintained between the O-ring and the gland sealing surface, pressure assistance induced instantaneous sealing.
A computer program (referred to as UF-LRC-3D) was developed for studying the unsteady, three-dimensional flow field inside the combustion chambers of motored Wankel engines as a function of engine design and operating parameters. This paper presents the details of the governing equations and the numerical method used by UF-LRC-3D. Also presented are numerical solutions generated by UF-LRC-3D showing the velocity field inside a motored Wankel engine, the mixing of nonhomogeneous fuel-air mixtures that enter through the intake port, and the mixing that takes place when a gaseous fuel is injected into the combustion chamber during compression.
A comprehensive numerical analysis has been carried out to study the detailed physical and chemical processes involved in the combustion of homogeneous propellant in a rocket motor. The formulation is based on the time-dependent full Navier-Stokes equations, with special attention devoted to the chemical reactions in both gas and condensed phases. The turbulence closure is achieved using both the Baldwin-Lomax algebraic model and a modified k-epsilon two-equation scheme with a low Reynolds number and near-wall treatment. The effects of variable thermodynamic and transport properties are also included. The system of governing equations are solved using a multi-stage Runge-Kutta shceme with the source terms treated implicitly. Preliminary results clearly demonstrate the presence of various combustion regimes in the vicinity of propellant surface. The effects of propellant combustion on the motor internal flowfields are investigated in detail.
The Advanced Solid Rocket Motor (ASRM), a 150-in diameter segmented motor design that incorporates substantive design changes to improve the reliability and design safety margins of the Space Shuttle system, is discussed. The studies involved in the development of the ASRM are reviewed, and the ASRM design is summarized, including safety enhancement and performance improvement features. The ASRM program plan is briefly addressed.
The successful launching of Explorer I on an accelerated schedule was due in part to the extensive design and developmental testing effort accomplished in support of the U.S. Army's Sergeant missile system. The 1/5-scale solid rocket motor used in the missile development in conjunction with a modified Redstone rocket became the basis for the Jupiter-C launch vehicle, which launched the first U.S. satellite. A description of the solid rocket motor and its development for use as part of the upper stages of the Jupiter-C is presented.
A transient analysis was performed to correlate the predicted versus measured behavior of the Redesigned Solid Rocket Booster (RSRB) during Flight 360L001 (STS-26R) liftoff. Approximately 9 accelerometers, 152 strain gages, and 104 girth gages were bonded to the motors during this event. Prior to Flight 360L001, a finite element model of the RSRB was analyzed to predict the accelerations, strains, and displacements measured by this developmental flight instrumentation (DFI) within an order of magnitude. Subsequently, an analysis has been performed which uses actual Flight 360L001 liftoff loading conditions, and makes more precise predictions for the RSRB structural behavior. Essential information describing the analytical model, analytical techniques used, correlation of the predicted versus measured RSRB behavior, and conclusions, are presented. A detailed model of the RSRB was developed and correlated for use in analyzing the motor behavior during liftoff loading conditions. This finite element model, referred to as the RSRB global model, uses super-element techniques to model all components of the RSRB. The objective of the RSRB global model is to accurately predict deflections and gap openings in the field joints to an accuracy of approximately 0.001 inch. The model of the field joint component was correlated to Referee and Joint Environment Simulation (JES) tests. The accuracy of the assembled RSRB global model was validated by correlation to static-fire tests such DM-8, DM-9, QM-7, and QM-8. This validated RSRB global model was used to predict RSRB structural behavior and joint gap opening during Flight 360L001 liftoff. The results of a transient analysis of the RSRB global model with imposed liftoff loading conditions are presented. Rockwell used many gage measurements to reconstruct the load parameters which were imposed on the RSRB during the Flight 360L001 liftoff. Each load parameter, and its application, is described. Also presented are conclusions and recommendations based on the analysis of this load case and the resulting correlation between predicted and measured RSRB structural behavior.
The NASA space shuttle flight STS-26R, launched at 11:37.00.009 am, EDT on 29 Sep. 1988, used the redesigned solid rocket motors (RSRM) 360L001A and 360L001B. Evaluation of the ground environment instrumentation (GEI) data recorded prior to flight showed no launch commit criteria violations; that the field joint heater and aft skirt thermal conditioning systems performed adequately; and that the GEI data showed good agreement with thermal model predictions. Evaluation of the developmental flight instrumentation (DFI) revealed excellent agreement with both the predicted and required ballistic specifications. All parameters were well within the GEI specification requirements including propellant burn rates, specific impulse values, and thrust imbalance. Recorded strain values also indicated satisfactory radial growth and stress levels, as well as verification of adequate safety factors. Postflight inspection of the insulation, seals, case, and nozzles showed overall excellent performance. Some thermal DFI protective cork was missing, and inoperative field joint vent valves on the thermal protection cork allowed water entry into the field joints upon splashdown. Evaluation of these anomalies, as well as complete evaluation of all Redesigned Solid Rocket Motor components, is contained.
Robotics research has begun to address the modeling and implementation of a wide variety of unstructured tasks. Examples include automated navigation, platform servicing, custom fabrication and repair, deployment and recovery, and science exploration. Such tasks are poorly described at onset; the workspace layout is partially unfamiliar, and the task control sequence is only qualitatively characterized. The robot must model the workspace, plan detailed physical actions from qualitative goals, and adapt its instantaneous control regimes to unpredicted events. Developing robust representations and computational approaches for these sensing, planning, and control functions is a major challenge. The underlying domain constraints are very general, and seem to offer little guidance for well-bounded approximation of object shape and motion, manipulation postures and trajectories, and the like. This generalized modeling problem is discussed, with an emphasis on the role of sensing. It is also discussed that unstructured tasks often have, in fact, a high degree of underlying physical symmetry, and such implicit knowledge should be drawn on to model task performance strategies in a methodological fashion. A group-theoretic decomposition of the workspace organization, task goals, and their admissible interactions are proposed. This group-mechanical approach to task representation helps to clarify the functional interplay of perception and control, in essence, describing what perception is specifically for, versus how it is generically modeled. One also gains insight how perception might logically evolve in response to needs of more complex motor skills. It is discussed why, of the many solutions that are often mathematically admissible to a given sensory motor-coordination problem, one may be preferred over others.
A multidimensional implicit Navier-Stokes analysis that uses numerical solution of the ensemble-averaged Navier-Stokes equations in a nonorthogonal, body-fitted, cylindrical coordinate system has been applied to the simulation of the steady mean flow in solid propellant rocket motor chambers. The calculation procedure incorporates a two-equation (k-epsilon) turbulence model and utilizes a consistently split, linearized block-implicit algorithm for numerical solution of the governing equations. The code was validated by comparing computed results with the experimental data obtained in cylindrical-port cold-flow tests. The agreement between the computed and experimentally measured mean axial velocities is excellent. The axial location of transition to turbulent flow predicted by the two-equation (k-epsilon) turbulence model used in the computations also agrees well with the experimental data. Computations performed to simulate the axisymmetric flowfield in the vicinity of the aft field joint in the Space Shuttle solid rocket motor using 14,725 grid points show the presence of a region of reversed axial flow near the downstream edge of the slot.
A series of cold flow heat transfer tests was conducted with a 7.5-percent scale model of the Space Shuttle Rocket Motor (SRM) to measure the heat transfer coefficients in the separated flow region around the nose of the submerged nozzle. Modifications were made to an existing 7.5 percent scale model of the internal geometry of the aft end of the SRM, including the gimballed nozzle in order to accomplish the measurements. The model nozzle nose was fitted with a stainless steel shell with numerous thermocouples welded to the backside of the thin wall. A transient 'thin skin' experimental technique was used to measure the local heat transfer coefficients. The effects of Reynolds number, nozzle gimbal angle, and model location were correlated with a Stanton number versus Reynolds number correlation which may be used to determine the convective heating rates for the full scale Space Shuttle Solid Rocket Motor nozzle.