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At least 919 records · Page 51

Confessions of a robot lobotomist

Since its inception, numerically controlled (NC) machining methods have been used throughout the aerospace industry to mill, drill, and turn complex shapes by sequentially stepping through motion programs. However, the recent demand for more precision, faster feeds, exotic sensors, and branching execution have existing computer numerical control (CNC) and distributed numerical control (DNC) systems running at maximum controller capacity. Typical disadvantages of current CNC's include fixed memory capacities, limited communication ports, and the use of multiple control languages. The need to tailor CNC's to meet specific applications, whether it be expanded memory, additional communications, or integrated vision, often requires replacing the original controller supplied with the commercial machine tool with a more powerful and capable system. This paper briefly describes the process and equipment requirements for new controllers and their evolutionary implementation in an aerospace environment. The process of controller retrofit with currently available machines is examined, along with several case studies and their computational and architectural implications.

Gottshall, R. Marc↗

Task automation in a successful industrial telerobot

In this paper, we discuss cooperative work by Oak Ridge National Laboratory and Remotec, Inc., to automate components of the operator's workload using Remotec's Andros telerobot, thereby providing an enhanced user interface which can be retrofit to existing fielded units as well as being incorporated into new production units. Remotec's Andros robots are presently used by numerous electric utilities to perform tasks in reactors where substantial exposure to radiation exists, as well as by the armed forces and numerous law enforcement agencies. The automation of task components, as well as the video graphics display of the robot's position in the environment, will enhance all tasks performed by these users, as well as enabling performance in terrain where the robots cannot presently perform due to lack of knowledge about, for instance, the degree of tilt of the robot. Enhanced performance of a successful industrial mobile robot leads to increased safety and efficiency of performance in hazardous environments. The addition of these capabilities will greatly enhance the utility of the robot, as well as its marketability.

Spelt, Philip F.↗

Experimental evaluation of shape memory alloy actuation technique in adaptive antenna design concepts

Creation of an antenna system that could autonomously adapt contours of reflecting surfaces to compensate for structural loads induced by a variable environment would maximize performance of space-based communication systems. Design of such a system requires the comprehensive development and integration of advanced actuator, sensor, and control technologies. As an initial step in this process, a test has been performed to assess the use of a shape memory alloy as a potential actuation technique. For this test, an existing, offset, cassegrain antenna system was retrofit with a subreflector equipped with shape memory alloy actuators for surface contour control. The impacts that the actuators had on both the subreflector contour and the antenna system patterns were measured. The results of this study indicate the potential for using shape memory alloy actuation techniques to adaptively control antenna performance; both variations in gain and beam steering capabilities were demonstrated. Future development effort is required to evolve this potential into a useful technology for satellite applications.

Kefauver, W. Neill↗

Small UHV compatible hyperthermal oxygen atom generator

A high purity, hyperthermal, continuous beam atomic oxygen source capable of retrofitting to existing UHV systems has been developed. The instrument complements a general system capability, while its small size and simplicity of design permits tailoring the instrument for most experimental geometries. The flux level presently available is near 1 x 10 (exp 14) cm(exp -2)s(exp -1)(3P) but may be extended toward the theoretical limit of 3x10(exp 15 cm(exp -2)s(exp -1). The energy distribution of the emitted neutrals shows that the mean kinetic energy is about the same as observed for the ions or about 4 eV. The energy of the oxygen atoms may be substantially reduced for other applications by collision with a temperature controlled, non-reactive surface (with a concomitant spread in the energy distribution).

Outlaw, Ronald A.↗

Performance study of galactic cosmic ray shield materials

The space program is faced with two difficult radiation protection issues for future long-term operations. First, retrofit of shield material or conservatism in shield design is prohibitively expensive and often impossible. Second, shielding from the cosmic heavy ions is faced with limited knowledge on the physical properties and biological responses of these radiations. The current status of space shielding technology and its impact on radiation health is discussed herein in terms of conventional protection practice and a test biological response model. The impact of biological response on the selection of optimum materials for cosmic ray shielding is presented in terms of the transmission characteristics of the shield material. Although the systematics of nuclear cross sections are able to demonstrate the relation of exposure risk to shield-material composition, the current uncertainty in-nuclear cross sections will not allow an accurate evaluation of risk reduction. This paper presents a theoretical study of risk-related factors and a pilot experiment to study the effectiveness of choice of shield materials to reduce the risk in space operations.

Kim, Myung-Hee Y.↗

Adding intelligent services to an object oriented system

As today's software becomes increasingly complex, the need grows for intelligence of one sort or another to becomes part of the application, often an intelligence that does not readily fit the paradigm of one's software development. There are many methods of developing software, but at this time, the most promising is the object oriented (OO) method. This method involves an analysis to abstract the problem into separate 'objects' that are unique in the data that describe them and the behavior that they exhibit, and eventually to convert this analysis into computer code using a programming language that was designed (or retrofitted) for OO implementation. This paper discusses the creation of three different applications that are analyzed, designed, and programmed using the Shlaer/Mellor method of OO development and C++ as the programming language. All three, however, require the use of an expert system to provide an intelligence that C++ (or any other 'traditional' language) is not directly suited to supply. The flexibility of CLIPS permitted us to make modifications to it that allow seamless integration with any of our applications that require an expert system. We illustrate this integration with the following applications: (1) an after action review (AAR) station that assists a reviewer in watching a simulated tank battle and developing an AAR to critique the performance of the participants in the battle; (2) an embedded training system and over-the-shoulder coach for howitzer crewmen; and (3) a system to identify various chemical compounds from their infrared absorption spectra.

Robideaux, Bret R.↗

Environmentally compatible solid rocket propellants

Hercules' clean propellant development research is exploring three major types of clean propellant: (1) chloride-free formulations (no chlorine containing ingredients), being developed on the Clean Propellant Development and Demonstration (CPDD) contract sponsored by Phillips Laboratory, Edwards Air Force Base, CA; (2) low HCl scavenged formulations (HCl-scavenger added to propellant oxidized with ammonium perchlorate (AP)); and (3) low HCl formulations oxidized with a combination of AN and AP (with or without an HCl scavenger) to provide a significant reduction (relative to current solid rocket boosters) in exhaust HCl. These propellants provide performance approaching that of current systems, with less than 2 percent HCl in the exhaust, a significant reduction (greater than or equal to 70 percent) in exhaust HCl levels. Excellent processing, safety, and mechanical properties were achieved using only readily available, low cost ingredients. Two formulations, a sodium nitrate (NaNO3) scavenged HTPB and a chloride-free hydroxy terminated polyether (HTPE) propellant, were characterized for ballistic, mechanical, and rheological properties. In addition, the hazards properties were demonstrated to provide two families of class 1.3, 'zero-card' propellants. Further characterization is planned which includes demonstration of ballistic tailorability in subscale (one to 70 pound) motors over the range of burn rates required for retrofit into current Hercules space booster designs (Titan 4 SRMU and Delta 2 GEM).

Jacox, James L.↗

The Oak Ridge Refrigerant Management Program

For many years, chlorofluorocarbons (CFC's) have been used by the Department of Energy's (DOE) Oak Ridge Y-12 Plant in air conditioning and process refrigeration systems. However, Title 6 of the Clean Air Act Amendments (CAAA) and Executive Order 12843 (Procurement Requirements and Policies for Federal Agencies for Ozone Depleting Substances) signed by President Clinton require, as policy, that all federal agencies maximize their use of safe, alternate refrigerants and minimize, where economically practical, the use of Class 1 refrigerants. Unfortunately, many government facilities and industrial plants have no plan or strategy in place to make this changeover, even though their air conditioning and process refrigeration equipment may not be sustainable after CFC production ends December 31, 1995. The Y-12 Plant in Oak Ridge, Tennessee, has taken an aggressive approach to complying with the CAAA and is working with private industry and other government agencies to solve tough manufacturing and application problems associated with CFC and hydrochlorofluorocarbon (HCFC) alternatives. Y-12 was the first DOE Defense Program (DP) facility to develop a long-range Stratospheric Ozone Protection Plan for refrigerant management for compliance with the CAAA. It was also the first DOE DP facility to complete detailed engineering studies on retrofitting and replacing all air conditioning and process refrigeration equipment to enable operation with alternate refrigerants. The management plan and engineering studies are models for use by other government agencies, manufacturing plants, and private industry. This presentation identifies some of the hidden pitfalls to be encountered in the accelerated phaseout schedule of CFC's and explains how to overcome and prevent these problems. In addition, it outlines the general issues that must be considered when addressing the phase-out of ozone depleting substances and gives some 'lessons learned' by Y-12 from its Refrigerant Management Program. Discussion topics include requirements for developing a refrigerant management plan and establishing priorities for cost-effective compliance with the CAAA, as well as ways in which employees can be empowered to develop a comprehensive refrigerant management plan. The result of this employee empowerment was a cooperative labor-management effort that is beneficial for Y-12, DOE, and the environment.

Kevil, Thomas H.↗

Alternatives to ozone depleting refrigerants in test equipment

This paper describes the initial results of a refrigerant retrofit project at the Aerospace Guidance and Metrology Center (AGMC) at Newark Air Force Base, Ohio. The objective is to convert selected types of test equipment to properly operate on hydrofluorocarbon (HFC) alternative refrigerants, having no ozone depleting potential, without compromising system reliability or durability. This paper discusses the primary technical issues and summarizes the test results for 17 different types of test equipment: ten environmental chambers, two ultralow temperature freezers, two coolant recirculators, one temperature control unit, one vapor degreaser, and one refrigerant recovery system. The postconversion performance test results have been very encouraging: system capacity and input power remained virtually unchanged. In some cases, the minimum operating temperature increased by a few degrees as a result of the conversion, but never beyond AGMC's functional requirements.

Hall, Richard L.↗

Display-And-Alarm Circuit For Accelerometer

Compact accelerometer assembly consists of commercial accelerometer retrofit with display-and-alarm circuit. Provides simple means for technician attending machine to monitor vibrations. Also simpifies automatic safety shutdown by providing local alarm or shutdown signal when vibration exceeds preset level.

Bozeman, Richard J., Jr.↗

Marshall Space Flight Center Electromagnetic Compatibility Design and Interference Control (MEDIC) handbook

The purpose of the MEDIC Handbook is to provide practical and helpful information in the design of electrical equipment for electromagnetic compatibility (EMS). Included is the definition of electromagnetic interference (EMI) terms and units as well as an explanation of the basic EMI interactions. An overview of typical NASA EMI test requirements and associated test setups is given. General design techniques to minimize the risk of EMI and EMI suppression techniques at the board and equipment interface levels are presented. The Handbook contains specific EMI test compliance design techniques and retrofit fixes for noncompliant equipment. Also presented are special tests that are useful in the design process or in instances of specification noncompliance.

Clark, T. L.↗

Mir Cooperative Solar Array Flight Performance Data and Computational Analysis

The Mir Cooperative Solar Array (MCSA) was developed jointly by the United States (US) and Russia to provide approximately 6 kW of photovoltaic power to the Russian space station Mir. The MCSA was launched to Mir in November 1995 and installed on the Kvant-1 module in May 1996. Since the MCSA photovoltaic panel modules (PPMs) are nearly identical to those of the International Space Station (ISS) photovoltaic arrays, MCSA operation offered an opportunity to gather multi-year performance data on this technology prior to its implementation on ISS. Two specially designed test sequences were executed in June and December 1996 to measure MCSA performance. Each test period encompassed 3 orbital revolutions whereby the current produced by the MCSA channels was measured. The temperature of MCSA PPMs was also measured. To better interpret the MCSA flight data, a dedicated FORTRAN computer code was developed to predict the detailed thermal-electrical performance of the MCSA. Flight data compared very favorably with computational performance predictions. This indicated that the MCSA electrical performance was fully meeting pre-flight expectations. There were no measurable indications of unexpected or precipitous MCSA performance degradation due to contamination or other causes after 7 months of operation on orbit. Power delivered to the Mir bus was lower than desired as a consequence of the retrofitted power distribution cabling. The strong correlation of experimental and computational results further bolsters the confidence level of performance codes used in critical ISS electric power forecasting. In this paper, MCSA flight performance tests are described as well as the computational modeling behind the performance predictions.

Kerslake, Thomas W.↗

Numerical Study of Boundary-Layer in Aerodynamics

The accomplishments made in the following three tasks are described: (1) The first task was to study shock-wave boundary-layer interactions with bleed - this study is relevant to boundary-layer control in external and mixed-compression inlets of supersonic aircraft; (2) The second task was to test RAAKE, a code developed for computing turbulence quantities; and (3) The third task was to compute flow around the Ames ER-2 aircraft that has been retrofitted with containers over its wings and fuselage. The appendices include two reports submitted to AIAA for publication.

Shih, Tom I-P.↗

Tip Fence for Reduction of Lift-Generated Airframe Noise

The present invention is directed toward a unique lift-generated noise reduction apparatus. This apparatus includes a plurality of tip fences that are secured to the trailing and leading assemblies of the high-lift system, as close as possible to the discontinuities where the vortices are most likely to form. In one embodiment, these tip fences are secured to some or all of the outboard and inboard tips of the wing slats and flaps. The tip fence includes a generally flat, or an aerodynamically shaped plate or device that could be formed of almost any rigid material, such as metal, wood, plastic, fiber glass, aluminum, etc. In a preferred embodiment, the tip fences extend below and perpendicularly to flaps and the slats to which they are attached, such that these tip fences are aligned with the nominal free stream velocity of the aircraft. In addition to reducing airframe noise, the tip fence tends to decrease drag and to increase lift, thus improving the overall aerodynamic performance of the aircraft. Another advantage presented by the tip fence lies in the simplicity of its design, its elegance, and its ready ability to fit on the wing components, such as the flaps and the slats. Furthermore, it does not require non-standard materials or fabrication techniques, and it can be readily, easily and inexpensively retrofited on most of the existing aircraft, with minimal design changes.

Ross, James C.↗

Refurbishment and Automation of the Thermal/Vacuum Facilities at the Goddard Space Flight Center

The thermal/vacuum facilities located at the Goddard Space Flight Center (GSFC) have supported both manned and unmanned space flight since the 1960s. Of the 11 facilities, currently 10 of the systems are scheduled for refurbishment and/or replacement as part of a 5-year implementation. Expected return on investment includes the reduction in test schedules, improvements in the safety of facility operations, reduction in the complexity of a test and the reduction in personnel support required for a test. Additionally, GSFC will become a global resource renowned for expertise in thermal engineering, mechanical engineering and for the automation of thermal/vacuum facilities and thermal/vacuum tests. Automation of the thermal/vacuum facilities includes the utilization of Programmable Logic Controllers (PLCs) and the use of Supervisory Control and Data Acquisition (SCADA) systems. These components allow the computer control and automation of mechanical components such as valves and pumps. In some cases, the chamber and chamber shroud require complete replacement while others require only mechanical component retrofit or replacement. The project of refurbishment and automation began in 1996 and has resulted in the computer control of one Facility (Facility #225) and the integration of electronically controlled devices and PLCs within several other facilities. Facility 225 has been successfully controlled by PLC and SCADA for over one year. Insignificant anomalies have occurred and were resolved with minimal impact to testing and operations. The amount of work remaining to be performed will occur over the next four to five years. Fiscal year 1998 includes the complete refurbishment of one facility, computer control of the thermal systems in two facilities, implementation of SCADA and PLC systems to support multiple facilities and the implementation of a Database server to allow efficient test management and data analysis.

Donohue, John T.↗

Friction-Stir Welding of Large Scale Cryogenic Fuel Tanks for Aerospace Applications

The Marshall Space Flight Center has established a facility for the joining of large-scale aluminum-lithium alloy 2195 cryogenic fuel tanks using the friction-stir welding process. Longitudinal welds, approximately five meters in length, were made possible by retrofitting an existing vertical fusion weld system, designed to fabricate tank barrel sections ranging from two to ten meters in diameter. The structural design requirements of the tooling, clamping and the spindle travel system will be described in this paper. Process controls and real-time data acquisition will also be described, and were critical elements contributing to successful weld operation.

Jones, Clyde S., III↗

SSME HPFTP/AT Turbine Blade Platform Featherseal Damper Design

During the Space Shuttle Main Engines (SSM) HPFtP/AT development program, engine hot fire testing resulted in turbine blade fatigue cracks. The cracks were noted after only a few tests and a several hundred seconds versus the design goal of 60 tests and >30,000 seconds. Subsequent investigation attributed the distress to excessive steady and dynamic loads. To address these excessive turbine blade loads, Pratt & Whitney Liquid Space Propulsion engineers designed and developed retrofitable turbine blade to blade platform featherseal dampers. Since incorporation of these dampers, along with other turbine blade system improvements, there has been no observed SSME HPFTP/AT turbine blade fatigue cracking. The high time HPFTP/AT blade now has accumulated 32 starts and 19,200 seconds hot fire test time. Figure #1 illustrates the HPFTP/AT turbine blade platform featherseal dampers. The approached selected was to improve the turbine blade structural capability while simultaneously reducing loads. To achieve this goal, the featherseal dampers were designed to seal the blade to blade platform gap and damp the dynamic motions. Sealing improves the steady stress margins by increasing turbine efficiency and improving turbine blade attachment thermal conditioning. Load reduction was achieved through damping. Thin Haynes 188 sheet metal was selected based on its material properties (hydrogen resistance, elongation, tensile strengths, etc.). The 36,000 rpm wheel speed of the rotor result in a normal load of 120#/blade. The featherseals then act as micro-slip dampers during actual SSME operation. After initial design and analysis (prior to full engine testing), the featherseal dampers were tested in P&W's spin rig facility in West Palm Beach, Florida. Both dynamic strain gages and turbine blade tip displacement measurements were utilized to quantify the featherseal damper effectiveness. Full speed (36,000 rpm), room temperature rig testing verified the elimination of fundamental mode (i.e, modes 1 & 2) resonant response. The reduction in turbine blade dynamic response is shown for a typical turbine blade. This paper discusses the design and verification of these dampers. The numerous benefits associated with this design concept warrants consideration in existing and future turbomachinery applications.

Montgomery, S. K.↗

Engineered Solutions to Reduce Occupational Noise Exposure at the NASA Glenn Research Center: A Five-Year Progress Summary (1994-1999)

At the NASA John H. Glenn Research Center at Lewis Field (formerly the Lewis Research Center), experimental research in aircraft and space propulsion systems is conducted in more than 100 test cells and laboratories. These facilities are supported by a central process air system that supplies high-volume, high-pressure compressed air and vacuum at various conditions that simulate altitude flight. Nearly 100,000 square feet of metalworking and specialized fabrication shops located on-site produce prototypes, models, and test hardware in support of experimental research operations. These activities, comprising numerous individual noise sources and operational scenarios, result in a varied and complex noise exposure environment, which is the responsibility of the Glenn Research Center Noise Exposure Management Program. Hearing conservation, community noise complaint response and noise control engineering services are included under the umbrella of this Program, which encompasses the Occupational Safety and Health Administration (OSHA) standard on occupational noise exposure, Sec. 29CFR 1910.95, as well as the more stringent NASA Health Standard on Hearing Conservation. Prior to 1994, in the absence of feasible engineering controls, strong emphasis had been placed on personal hearing protection as the primary mechanism for assuring compliance with Sec. 29CFR 1910.95 as well as NASA's more conservative policy, which prohibits unprotected exposure to noise levels above 85 dB(A). Center policy and prudent engineering practice required, however, that these efforts be extended to engineered noise controls in order to bring existing work areas into compliance with Sec. 29CFR 1910.95 and NASA's own policies and to ensure compliance for new installations. Coincident with the establishment in 1995 of a NASA wide multi-year commitment of funding for environmental abatement projects, the Noise Exposure Management Program was established, with its focus on engineering approaches to reducing occupational and community noise exposure. The organization and mission of this Program were documented shortly after its inception, and individual programmatic components have been the subject of subsequent papers. This paper summarizes the status and accomplishments of the engineering aspects of the Program from a five-year retrospective viewpoint and includes a review of retrofit noise control solution strategies, which have not been previously documented.

Cooper, Beth A.↗