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At least 91 records · Page 5

All sources NASA NTRS DOE OSTI

NASA NTRS2007

High Specific Power Motors in LN2 and LH2

A switched reluctance motor has been operated in liquid nitrogen (LN2) with a power density as high as that reported for any motor or generator. The high performance stems from the low resistivity of Cu at LN2 temperature and from the geometry of the windings, the combination of which permits steady-state rms current density up to 7000 A/sq cm, about 10 times that possible in coils cooled by natural convection at room temperature. The Joule heating in the coils is conducted to the end turns for rejection to the LN2 bath. Minimal heat rejection occurs in the motor slots, preserving that region for conductor. In the end turns, the conductor layers are spaced to form a heat-exchanger-like structure that permits nucleate boiling over a large surface area. Although tests were performed in LN2 for convenience, this motor was designed as a prototype for use with liquid hydrogen (LH2) as the coolant. End-cooled coils would perform even better in LH2 because of further increases in copper electrical and thermal conductivities. Thermal analyses comparing LN2 and LH2 cooling are presented verifying that end-cooled coils in LH2 could be either much longer or could operate at higher current density without thermal runaway than in LN2.

Brown, Gerald V.↗

NASA NTRS2012

Low-Cost, Rugged High-Vacuum System

A need exists for miniaturized, rugged, low-cost high-vacuum systems. Recent advances in sensor technology have led to the development of very small mass spectrometer detectors as well as other analytical instruments such as scanning electron microscopes. However, the vacuum systems to support these sensors remain large, heavy, and power-hungry. To meet this need, a miniaturized vacuum system was developed based on a very small, rugged, and inexpensive-to-manufacture molecular drag pump (MDP). The MDP is enabled by a miniature, very-high-speed (200,000 rpm), rugged, low-power, brushless DC motor optimized for wide temperature operation and long life. The key advantages of the pump are reduced cost and improved ruggedness compared to other mechanical hig-hvacuum pumps. The machining of the rotor and stators is very simple compared to that necessary to fabricate rotor and stator blades for other pump designs. Also, the symmetry of the rotor is such that dynamic balancing of the rotor will likely not be necessary. Finally, the number of parts in the unit is cut by nearly a factor of three over competing designs. The new pump forms the heart of a complete vacuum system optimized to support analytical instruments in terrestrial applications and on spacecraft and planetary landers. The MDP achieves high vacuum coupled to a ruggedized diaphragm rough pump. Instead of the relatively complicated rotor and stator blades used in turbomolecular pumps, the rotor in the MDP consists of a simple, smooth cylinder of aluminum. This will turn at approximately 200,000 rpm inside an outer stator housing. The pump stator comprises a cylindrical aluminum housing with one or more specially designed grooves that serve as flow channels. To minimize the length of the pump, the gas is forced down the flow channels of the outer stator to the base of the pump. The gas is then turned and pulled toward the top through a second set of channels cut into an inner stator housing that surrounds the motor. The compressed gas then flows down channels in the motor housing to the exhaust port of the pump. The exhaust port of the pump is connected to a commercially available diaphragm or scroll pump.

Sorensen, Paul↗

NASA NTRS1991

SRB thermal curtain design support

The objective of the program during this time period was to evaluate candidate materials that could be used to design an improved Solid Rocket Motor (SRM) Aft Skirt Thermal Curtain (ASTC). The ASTC is a flexible, high temperature, cloth and insulation composite that is used to protect the hardware located inside the aft skirt of the shuttle solid rocket booster. The current ASTC consists of nine layers of insulating materials and is 2.58 inches thick. The ASTC is made up of twenty four segments. The segments are hand sewn together during installation on the aft skirt. The weight of the current ASTC is approximated at about six hundred pounds. This weight does not include the weight of the mounting hardware and ties required to install the twenty four ASTC segments (which is significant). The current effort entailed measuring the thermophysical properties of six candidate materials (quartz, S glass, and Kevlar woven into nominal 0.25 inch thick layers by angle interlock and polar-weave) and then using these properties in a computer program to predict the thermal performance of various curtain configurations subjected to an SRM heat flux.

Dixon, Carl A.↗

NASA NTRS2008

Modeling the Spin Motor Current of the International Space Station's Control Moment Gyroscopes

The International Space Station (ISS) attitude control is provided by two means: The Russian Segment uses thrusters and the U.S. Segment uses double-gimbaled control moment gyroscopes (CMG). CMGs are used as momentum exchange devices, providing non propulsive attitude control for the vehicle. The CMGs are very important for the ISS program because, first, they save propellant - which needs to be transferred to the Station in special cargo vehicles - and, second, they provide the microgravity environment on the Station - which is necessary for scientific experiments planned for the ISS mission. Since 2002, when one of the CMG on the ISS failed, all CMGs are closely monitored. High gimbal rates, vibration spikes, unusual variations of spin motor current and bearing temperatures are of great concern, since these parameters are the CMG health indicators. The telemetry analysis of these and some other CMG parameters is used to determine constrains and make changes to the CMGs operation on board. These CMG limitations, in turn, may limit the ISS attitude control capabilities and may be critical to ISS operation. Therefore, it is important to know whether the CMG parameter is nominal or out of family, and why. The goal of this project is to analyze an important CMG parameter - spin motor current. Some operational decisions are made now based on the spin motor current signatures. The spin motor current depends on gimbal rates, ISS rates, and spin bearing friction. The spin bearing friction in turn depends on the bearing temperatures, wheel rates, normal load - which is a function of gimbal and wheel rates - lubrication, etc. The first task of this project is to create a spin motor current mathematical model based on CMG dynamics model and the current knowledge on bearing friction in microgravity.

Pereira, Miguel A.↗

NASA NTRS2004

Evaluation of High Temperature Knitted Spring Tubes for Structural Seal Applications

Control surface seals are crucial to current and future space vehicles, as they are used to seal the gaps surrounding body flaps, elevons, and other actuated exterior surfaces. During reentry, leakage of high temperature gases through these gaps could damage underlying lower temperature structures such as rudder drive motors and mechanical actuators, resulting in impaired vehicle control. To be effective, control surface seals must shield lower temperature structures from heat transfer by maintaining sufficient resiliency to remain in contact with opposing sealing surfaces through multiple compression cycles. The current seal exhibits significant loss of resiliency after a few compression cycles at elevated temperatures (i.e., 1900 F) and therefore would be inadequate for advanced space vehicles. This seal utilizes a knitted Inconel X-750 spring tube as its primary resilient element. As part of a larger effort to enhance seal resiliency, researchers at the NASA Glenn Research Center performed high temperature compression testing (up to 2000 F) on candidate spring tube designs employing material substitutions and modified geometries. These tests demonstrated significant improvements in spring tube resiliency (5.5x better at 1750 F) through direct substitution of heat treated Rene 41 alloy in the baseline knit design. The impact of geometry modification was minor within the range of parameters tested, however trends did suggest that moderate resiliency improvements could be obtained by optimizing the current spring tube geometry.

Taylor, Shawn C.↗

DOE OSTI2024

All-digital Sensor System for Distributed Downhole Pressure Monitoring in Unconventional Fields

This project developed and validated (through field tests) a new low-cost all-digital pressure sensing technology for in situ distributed downhole pressure monitoring in unconventional oil and gas (UOG) fields. The all-digital sensing technology uses a built-in non-electric analog-to-digital converter (ADC) to transform the pressure information into a combination of binary (ON/OFF) states. As such, the system does not need downhole electronics for signal conditioning and telemetry. The all-digital sensors can be remotely logged over a long distance, and many sensors can be multiplexed for distributed sensing. Based on a review of unconventional wells in the Lower 48 states, the specification of the sensor is to measure pressure up to 69 MPa (10,000 psi) and temperature up to 250°C. A sensor with a helical bourdon sensing element and a digital signal decoder of 50 mm diameter and 109 mm length was constructed. The helical bourdon sensing element was made of 304L stainless steel and filled with motor oil. The digital converter was made up of 8 digital reading pads constructed of high-temperature epoxy with conductive inserts made of stainless steel. The sensor had a linear response to pressure with an accuracy of 0.14 MPa (20 psi). To withstand the high pressure, the sensor was enclosed in a stainless-steel pressure housing with a wall thickness of 5.5 mm, a diameter of 73 mm, and a length of 724 mm. In the laboratory tests, the sensor exhibited no temperature-related effects on the results. The sensor did not show drift over a 14-day test period at elevated pressure. A field test was conducted where the sensor was deployed in a test wellbore at the Quest drilling test facility to a depth of 0 feet over three weeks. The sensor was attached to the production rods, along with a downhole reference sensor of PPS27 type, which is a permanent downhole monitoring system. During the testing phase, the test well annular blow-out preventer was closed, and the well was pressurized at the surface to 11 MPa (1600 psi). The sensor read the elevated bottom hole pressure of 1500 psi. A multiplexing unit was created for the sensor to deploy multiple sensors on one data transmission line in a distributed approach. The multiplexing unit was tested in a simulated environment of 3048 m (10,000 ft) with five sensors distributed. The sensors were pressurized at different intervals. The multiplexed sensors recorded the correct pressure, and the multiplexing did not interfere with the readings. The proposed concept of an all-digital pressure sensor for harsh downhole environments was designed, manufactured, and tested in the laboratory and tested at the field to a up to 69 MPa and 250°C. This technology has high-temperature tolerance and has potential in downhole areas outside oil and gas, such as carbon capture and storage (CCS) and geothermal wells. The sensor concept has been proven in this project, but to create a commercially viable product, manufacturing a sensor with a smaller diameter needs to be performed.

02 PETROLEUM↗

NASA NTRS2001

Long-Term Durability of a Matrix for High-Temperature Composites Predicted

Polymer matrix composites (PMC's) are being increasingly used in applications where they are exposed for long durations to harsh environments such as elevated temperatures, moisture, oils and solvents, and thermal cycling. The exposure to these environments leads to the degradation of structures made from these materials. This also affects the useful lifetimes of these structures. Some of the more prominent aerospace applications of polymer matrix composites include engine supports and cowlings, reusable launch vehicle parts, radomes, thrust-vectoring flaps, and the thermal insulation of rocket motors. This demand has led to efforts to develop lightweight, high-strength, high-modulus materials that have upper-use temperatures over 316 C. A cooperative program involving two grants to the Massachusetts Institute of Technology and in-house work at the NASA Glenn Research Center was conducted to identify the mechanisms and the measurement of mechanical and physical properties that are necessary to formulate a mechanism-based model for predicting the lifetime of high-temperature polymer matrix composites. The polymer that was studied was PMR-15 polyimide, a leading matrix resin for use in high-temperature-resistant aerospace composite structures such as propulsion systems. The temperature range that was studied was from 125 to 316 C. The diffusion behavior of PMR-15 neat resin was characterized and modeled. Thermogravimetric analysis (TGA) was also conducted in nitrogen, oxygen, and air to provide quantitative information on thermal and oxidative degradation reactions. A new low-cost technique was developed to collect chemical degradation data for isothermal tests lasting up to 4000 hr in duration. In the temperature range studied, results indicate complex behavior that was not observed by previous TGA tests, including the presence of weight-gain reactions. These were found to be significant in the initial periods of aging from 125 to 225 C. Two types of weight loss reactions dominated at aging temperatures above 225 C. One was concentrated at the surface of the polymer and was very active at temperatures above 225 C. The second was observed to dominate in the latter stages of aging at temperatures below 260 C. This three-reaction model satisfactorily explains past findings that the degradation mechanism of PMR-15 appears to change around 316 C. It also indicates that the second weight gain mechanism is a significant factor at temperatures below 204 C. On the basis of these results, a predictive model was developed for the thermal degradation of PMR-15 at 316 C. A comparison of data generated by this model with actual experimental data is shown in the following figure.

Bowles, Kenneth J.↗

DOE OSTI2021

Improvements to the Powder Processing of near-Final Shape alnico Magnets

Alnico permanent magnets (PMs), a recent PM system of interest as an attractive rare earth-free PM alternative, have advantageous high operating temperature and magnetic saturation with the potential for utilization in electric machines, e.g. interior-PM motors found in electric vehicles, if current directional solidification methods can be replaced by a true mass production approach. Recently, two unique alnico compositions, termed Full-Co and Co-lean, with improved coercivity, were gas atomized, compression molded, and vacuum sintered (4h at 1240°C) to high densities of 97.8% and 99.3%, respectively. However, the Co-lean remained fine grained isotropic magnets and the Full-Co grains were not textured, lowering magnetic strength in spite of attempts to grow large textured grains by a stress-biased solid state grain alignment method to convert them to high energy anisotropic magnets. It was hypothesized that oxidation during de-binding in air left many prior particle boundary oxides within the sintered microstructure that hindered grain growth and texturing during the stress-biased texturing procedure and prevented the desired abnormal grain growth (AGG). Here we explored a vacuum de-binding step that was linked (in-place) to vacuum sintering and found that the Co-lean exhibited faster uniform grain growth that doubled the average grain size (40 μm to 80 μm). Linked vacuum de-binding and sintering of Full-Co produced some AGG after only 1 h of 1240°C sintering. A new direction for promoting AGG (and stress-biased texturing) in alnico is being explored that utilizes a fundamental analysis of systems with second phase particles that either inhibit or boost grain growth. This effort explores the influence of vacuum de-binding linked to a series of lower sintering temperatures at a fixed time (4h) to see if oxide particle size and volume fraction can be changed to promote AGG conditions in alnico. Surprising qualitative results indicate that AGG may be promoted for vacuum sintering at less than 1200°C.

Rinko, Emily↗

NASA NTRS1976

Test data from small solid propellant rocket motor plume measurements (FA-21)

A program is described for obtaining a reliable, parametric set of measurements in the exhaust plumes of solid propellant rocket motors. Plume measurements included pressures, temperatures, forces, heat transfer rates, particle sampling, and high-speed movies. Approximately 210,000 digital data points and 15,000 movie frames were acquired. Measurements were made at points in the plumes via rake-mounted probes, and on the surface of a large plate impinged by the exhaust plume. Parametric variations were made in pressure altitude, propellant aluminum loading, impinged plate incidence angle and distance from nozzle exit to plate or rake. Reliability was incorporated by continual use of repeat runs. The test setup of the various hardware items is described along with an account of test procedures. Test results and data accuracy are discussed. Format of the data presentation is detailed. Complete data are included in the appendix.

Hair, L. M.↗

NASA NTRS1985

Low frequency split cycle cryocooler

A split cycle Stirling cryocooler with two different drive motors and operating at a low drive frequency can have high thermodynamic efficiency. The temperature of the cold end of the cryocooler varies with drive frequency, voltage of the input electrical power and initial charge pressure values. The cryocooler operating at 8 Hz can provide 7 watts of refrigeration at 77 K for 230 watts of electrical input power.

Bian, S. X.↗

NASA NTRS1992

Comparison of high temperature, high frequency core loss and dynamic B-H loops of a 2V-49Fe-49Co and a grain oriented 3Si-Fe alloy

The design of power magnetic components such as transformers, inductors, motors, and generators, requires specific knowledge about the magnetic and electrical characteristics of the magnetic materials used in these components. Limited experimental data exists that characterizes the performance of soft magnetic materials for the combined conditions of high temperature and high frequency over a wide flux density range. An experimental investigation of a 2V-49-Fe-49Co (Supermendur) and a grain oriented 3 Si-Fe (Magnesil) alloy was conducted over the temperature range of 23 to 300 C and frequency range of 0.1 to 10 kHz. The effects of temperature, frequency, and maximum flux density on the core loss and dynamic B-H loops for sinusoidal voltage excitation conditions are examined for each of these materials. A comparison of the core loss of these two materials is also made over the temperature and frequency range investigated.

Wieserman, W. R.↗

NASA NTRS1992

Comparison of high temperature, high frequency core loss and dynamic B-H loops of a 2V-49Fe-49Co and a grain oriented 3Si-Fe alloy

Wieserman, W. R.↗

NASA NTRS2018

High Efficiency Megawatt Motor Conceptual Design

The High Efficiency Megawatt Motor (HEMM) is being designed to meet the needs of Electrified Aircraft Propulsion (EAP). The key objective of this work is to establish a motor technology which simultaneously attains high specific power (>16kW/kg ratio to electromagnetic weight) and high efficiency (>98%) by judicious application of high temperature superconducting wire and integrated thermal management. Another important feature is to achieve the performance goals with an eye to aircraft integration constraints. An electromagnetic analysis was performed which shows that the proposed HEMM design meets the performance objectives if key current capability and mechanical constraints are achieved. Sensitivity of motor power and performance to those parameters is illustrated. The HEMM technology could be applied to a range of aircraft types that require megawatt level electrical power.

Superconducting↗

NASA NTRS2018

High Efficiency Megawatt Motor Conceptual Design

Jansen, Ralph H.↗

NASA NTRS2018

Lunar Environment Simulation for a High Performance Motor

NASA and the Canadian Space Agency (CSA) through a CSA contractor, Argo Space/Robotics Division, partnered to perform environmental performance tests on a high torque producing motor. CSA provided the motor and NASA provided a thermal vacuum chamber capable of achieving high vacuum (P < 1 E-5 torr) and temperatures between 25 and 400 K. NASA also provided a dynamometer system capable of measuring and or applying break torque between 0 and 28 Nm. The two primary goals of the test were to simulate sun exposed and shadow condition expected on the lunar surface in order to determine survivability of the motor at extreme temperature conditions and to operate the motor under a constant break load of 6.8 Nm in the temperature range of 30K to 415K. A secondary objective of the test was to operate the motor for 15 km under 6.8 Nm of load. The primary goals of the test were fully achieved. The secondary goal was partially achieved.

O'Connell, Joe↗

NASA NTRS1991

Meissner-Effect Stepping Motor

Proposed stepping motor derives torque from diamagnetic repulsion produced by Meissner effect - exclusion of magnetic field from interior of superconductor. Design of motor takes advantage of silver-doped YB2Cu3O and other compounds superconductive at temperatures as high as that of liquid nitrogen. Skin of rotor cooled below its superconducting-transition temperature by liquid nitrogen. O-rings prevent leaks of liquid nitrogen from rotor. Weight, cost, and maintenance reduced.

Robertson, Glen A.↗

NASA NTRS1998

Effect of Bearing Cleaning on Long Term Bearing Life

For many years chlorofluorocarbon (CFC ) based solvents, such as Freon and 1,1,1, Trichloroethane (TCA), were used as bearing cleaning solvents for space mechanisms. The 1995 ban on the production of ozone depleting chemicals (ODC) such as CFCs caused a change to new ODC-free cleaners for the precision bearing cleaning. With this change the question arises what effect if any do these new cleaners have on long term bearing life. The purpose of this study was to evaluate this effect. A one year test using 60 small electrical motors (two bearings per motor) was conducted in a high vacuum environment (2.0* 10(exp -6) torr) at a temperature of 90C. Prior to testing the bearings were cleaned with one of four cleaners. These cleaners included two aqueous based cleaners, a CFC based cleaner and supercritical carbon dioxide. Three space compatible greases were tested. After testing the mass of each lubricated bearing was measured both pre and post test. Along with mass loss measurements a profilometer trace of each bearing was taken to measure post test wear of the bearings. In addition the bearings were visually examined and analyzed using an optical microscope.

Jett, Timothy Raymond↗

NASA NTRS2004

NASA Tech Briefs, October 2004

Topics include: Relative-Motion Sensors and Actuators for Two Optical Tables; Improved Position Sensor for Feedback Control of Levitation; Compact Tactile Sensors for Robot Fingers; Improved Ion-Channel Biosensors; Suspended-Patch Antenna With Inverted, EM-Coupled Feed; System Would Predictively Preempt Traffic Lights for Emergency Vehicles; Optical Position Encoders for High or Low Temperatures; Inter-Valence-Subband/Conduction-Band-Transport IR Detectors; Additional Drive Circuitry for Piezoelectric Screw Motors; Software for Use with Optoelectronic Measuring Tool; Coordinating Shared Activities; Software Reduces Radio-Interference Effects in Radar Data; Using Iron to Treat Chlorohydrocarbon-Contaminated Soil; Thermally Insulating, Kinematic Tensioned-Fiber Suspension; Back Actuators for Segmented Mirrors and Other Applications; Mechanism for Self-Reacted Friction Stir Welding; Lightweight Exoskeletons with Controllable Actuators; Miniature Robotic Submarine for Exploring Harsh Environments; Electron-Spin Filters Based on the Rashba Effect; Diffusion-Cooled Tantalum Hot-Electron Bolometer Mixers; Tunable Optical True-Time Delay Devices Would Exploit EIT; Fast Query-Optimized Kernel-Machine Classification; Indentured Parts List Maintenance and Part Assembly Capture Tool - IMPACT; An Architecture for Controlling Multiple Robots; Progress in Fabrication of Rocket Combustion Chambers by VPS; CHEM-Based Self-Deploying Spacecraft Radar Antennas; Scalable Multiprocessor for High-Speed Computing in Space; and Simple Systems for Detecting Spacecraft Meteoroid Punctures.

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