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At least 127 records · Page 7
All sourcesNASA NTRSDOE OSTI
NASA NTRS2011

Fiber Optic Strain Sensor for Planetary Gear Diagnostics

This paper presents a new sensing approach for helicopter damage detection in the planetary stage of a helicopter transmission based on a fiber optic strain sensor array. Complete helicopter transmission damage detection has proven itself a difficult task due to the complex geometry of the planetary reduction stage. The crowded and complex nature of the gearbox interior does not allow for attachment of sensors within the rotating frame. Hence, traditional vibration-based diagnostics are instead based on measurements from externally mounted sensors, typically accelerometers, fixed to the gearbox exterior. However, this type of sensor is susceptible to a number of external disturbances that can corrupt the data, leading to false positives or missed detection of potentially catastrophic faults. Fiber optic strain sensors represent an appealing alternative to the accelerometer. Their small size and multiplexibility allows for potentially greater sensing resolution and accuracy, as well as redundancy, when employed as an array of sensors. The work presented in this paper is focused on the detection of gear damage in the planetary stage of a helicopter transmission using a fiber optic strain sensor band. The sensor band includes an array of 13 strain sensors, and is mounted on the ring gear of a Bell Helicopter OH-58C transmission. Data collected from the sensor array is compared to accelerometer data, and the damage detection results are presented

Kiddy, Jason S.↗
NASA NTRS2014

Investigation of Spiral Bevel Gear Condition Indicator Validation via AC-29-2C Using Fielded Rotorcraft HUMS Data

This report presents the analysis of gear condition indicator data collected on a helicopter when damage occurred in spiral bevel gears. The purpose of the data analysis was to use existing in-service helicopter HUMS flight data from faulted spiral bevel gears as a Case Study, to better understand the differences between HUMS data response in a helicopter and a component test rig, the NASA Glenn Spiral Bevel Gear Fatigue Rig. The reason spiral bevel gear sets were chosen to demonstrate differences in response between both systems was the availability of the helicopter data and the availability of a test rig that was capable of testing spiral bevel gear sets to failure. The objective of the analysis presented in this paper was to re-process helicopter HUMS data with the same analysis techniques applied to the spiral bevel rig test data. The damage modes experienced in the field were mapped to the failure modes created in the test rig. A total of forty helicopters were evaluated. Twenty helicopters, or tails, experienced damage to the spiral bevel gears in the nose gearbox. Vibration based gear condition indicators data was available before and after replacement. The other twenty tails had no known anomalies in the nose gearbox within the time frame of the datasets. These twenty tails were considered the baseline dataset. The HUMS gear condition indicators evaluated included gear condition indicators (CI) Figure of Merit 4 (FM4), Root Mean Square (RMS) or Diagnostic Algorithm 1 (DA1) and +/- 3 Sideband Index (SI3). Three additional condition indicators, not currently calculated on-board, were calculated from the archived data. These three indicators were +/- 1 Sideband Index (SI1), the DA1 of the difference signal (DiffDA1) and the peak-to-peak of the difference signal (DP2P). Results found the CI DP2P, not currently available in the on-board HUMS, performed the best, responding to varying levels of damage on thirteen of the fourteen helicopters evaluated. Two additional CIs also not in the on-board system, DiffDA1and SI1, also performed well responding to twelve and ten of the fourteen helicopters evaluated respectively. Of the three CIs currently available in the MSPU, DA1, FM4 and SI3, SI3, responded to eight, DA1 responded to six and FM4 responded to four of the fourteen helicopters evaluated. FM4, the poorest performing CI, was not as responsive to damage as the other five CIs. Conversely, when compared to the other two, it was the only CI that responded to damage on two helicopters. CI response could not be correlated to specific failure modes due to limited pictures and subjective descriptions found within the TDA. Flight regime did affect CI response to some gear faults. Due to the range of operating conditions for each regime, more studies are required to determine their sensitivity to regimes.

rotorcraft↗
NASA NTRS2016

Rolling Bearing Life Prediction, Theory, and Application

A tutorial is presented outlining the evolution, theory, and application of rolling-element bearing life prediction from that of A. Palmgren, 1924; W. Weibull, 1939; G. Lundberg and A. Palmgren, 1947 and 1952; E. Ioannides and T. Harris, 1985; and E. Zaretsky, 1987. Comparisons are made between these life models. The Ioannides-Harris model without a fatigue limit is identical to the Lundberg-Palmgren model. The Weibull model is similar to that of Zaretsky if the exponents are chosen to be identical. Both the load-life and Hertz stress-life relations of Weibull, Lundberg and Palmgren, and Ioannides and Harris reflect a strong dependence on the Weibull slope. The Zaretsky model decouples the dependence of the critical shear stress-life relation from the Weibull slope. This results in a nominal variation of the Hertz stress-life exponent. For 9th- and 8th-power Hertz stress-life exponents for ball and roller bearings, respectively, the Lundberg-Palmgren model best predicts life. However, for 12th- and 10th-power relations reflected by modern bearing steels, the Zaretsky model based on the Weibull equation is superior. Under the range of stresses examined, the use of a fatigue limit would suggest that (for most operating conditions under which a rolling-element bearing will operate) the bearing will not fail from classical rolling-element fatigue. Realistically, this is not the case. The use of a fatigue limit will significantly overpredict life over a range of normal operating Hertz stresses. (The use of ISO 281:2007 with a fatigue limit in these calculations would result in a bearing life approaching infinity.) Since the predicted lives of rolling-element bearings are high, the problem can become one of undersizing a bearing for a particular application. Rules had been developed to distinguish and compare predicted lives with those actually obtained. Based upon field and test results of 51 ball and roller bearing sets, 98 percent of these bearing sets had acceptable life results using the Lundberg- Palmgren equations with life adjustment factors to predict bearing life. That is, they had lives equal to or greater than that predicted. The Lundberg-Palmgren model was used to predict the life of a commercial turboprop gearbox. The life prediction was compared with the field lives of 64 gearboxes. From these results, the roller bearing lives exhibited a load-life exponent of 5.2, which correlated with the Zaretsky model. The use of the ANSI/ABMA and ISO standards load-life exponent of 10/3 to predict roller bearing life is not reflective of modern roller bearings and will underpredict bearing lives.

Life prediction↗
NASA NTRS2022

Environmental Testing of the OVEN System for Lunar Water Extraction and Prospecting

Introduction: The presence of water ice in permanently shadowed regions on the lunar surface [1] may enable a sustained human presence on the Moon with minimal need for consumables. However, in order to develop a long term utilization plan that includes the usage of in-situ water we must first understand the abundance, stratigraphy and distribution of this re-source. Multiple space agencies currently have plans for lunar water prospecting missions. The Optimized Volatile Extraction Node (OVEN) was designed for water prospecting missions that require samples to be weighed, sealed, and heated as the means of determining water concentration. This method of water quantification necessitates a fair amount of automation, so a rigorous environmental test program was performed in order to build confidence in the performance of the OVEN design. The work presented here describes the OVEN environmental test program as well as ongoing efforts to improve on the design. Vibration: The OVEN participated in two rounds of random vibration tests. The first test was a stand-alone test performed at the Energy Systems Test Area of the Johnson Space Center. The second test was an integrated test with the mobile platform developed for the Resource Prospector project. The OVEN survived both tests without damage, but the tests did provide valuable lessons learned with regards to specific operations. Thermal Vacuum: The OVEN was successfully demonstrated at a temperature range of -50 to 75 C in a thermal vacuum chamber. The need to heat motor gearboxes at lower temperatures was predetermined so this test program was completed by implementing a method of gearbox heating that used the existing circuitry within the motors. Dust: A custom dynamometer was built in order to determine the torque required to move the various mechanisms within the OVEN at a range of temperatures. The OVEN system was coated with lunar dust simulant in order to determine mechanism torques under a worst-case operating condition. Sublimation: Sublimation losses within the OVEN were quantified through a series of test configurations, including an integrated test in a thermal vacuum chamber at Glenn Research Center [2]. Current Work: The OVEN subsystem is currently not a component of any existing prospecting missions, but work continues that will take the lessons learned from previous environmental tests and improve on the design in order to be considered for future prospecting opportunities. References: [1] Colaprete, A., Schultz, P., Heldmann, J., Wooden, D., Shirley, M., Ennico, K., ... & Sollitt, L. (2010). Detection of water in the LCROSS ejecta plume. science, 330(6003), 463-468. [2] Kleinhenz, J., Smith, J., Roush, T., Colaprete, A., Zacny, K., Paulsen, G., ... & Paz, A. (2018). Volatiles Loss from water bearing regolith simulant at Lunar Environments. In Earth and Space 2018: Engineering for Extreme Environments (pp. 454-466). Reston, VA: American Society of Civil Engineers.

A Paz↗
NASA NTRSDate not supplied

Design Concepts to Meet EASA SC-VTOL-01 Single Failure Criteria

The objective of the current work is to discuss European Union Aviation Safety Agency (EASA) SC-VTOL-01 single failure criteria, VTOL.2250(c). Prior studies have developed concept distributed propulsion and flight control (DPFC) system architectures and found they comply with EASA SC-VTOL-01 probabilistic failure criteria, VTOL.2510(a). Prior work developed two all-electric DPFC systems utilized in a quadrotor concept aircraft developed by the National Aeronautics and Space Administration (NASA); one uses interconnecting shafts and gearboxes to interconnect redundant motors with each rotor system and the other uses gearboxes to connect redundant motors locally, near each rotor. Common between the two electric DPFC systems were rotor shafts, epicyclic systems, and motors. The current work explores Category I failures in drive systems, relevant research to support fail-safe design practices for gear systems, research and adjacent industry trends in motor fail-safety and reliability, and proposed design concepts to comply with VTOL.2250(c). Continued research in fail-safe design concepts and design guidance will benefit eVTOL and conventional rotorcraft, alike. Continued research in these areas will benefit eVTOL certification against SC-VTOL-01, and could optimistically translate to more widespread adoption of similar fail-safe design concepts into new rotorcraft designs certified against CS-29.

Rotorcraft↗
NASA NTRSDate not supplied

Assessment of ProgPy - An Open-Source Condition Monitoring and Diagnostics Tool

Traditional maintenance programs, such as corrective and preventive strategies, may lead to high costs and operational inefficiencies. Condition Monitoring and Diagnostics (CM&D) aims to improve these maintenance strategies by enabling timely insights into equipment health and performance. However, implementation of CM&D can be challenging without a robust framework that manages data efficiently, supports interoperability and simplifies integration. To address these challenges ProgPy, an open-source Python-based prognostics tool developed by NASA Ames Research Center, offers a structured solution for broader Prognostics and Health Management (PHM) applications. Ongoing research is assessing the feasibility of implementing ProgPy as a Condition Monitoring and Diagnostics (CM&D) solution by comparing its framework to the guidelines for open CM&D systems recommended in the ISO 13374-2 standard. This evaluation aims to highlight ProgPy’s strengths and identify opportunities for improvement, thereby, contributing to its advancement as an effective tool for Prognostics and Health Management (PHM). This paper presents the results of an initial assessment of the ProgPy toolbox through a gearbox case study using open-source datasets.

Condition-Monitoring, Diagnostics, Failure, Gearbo↗
NASA NTRS1972

Preliminary design of an auxiliary power unit for the space shuttle. Volume 1: Summary

Numerous candidate APU concepts are considered, each meeting the space shuttle APU problem statement. Evaluation of these concepts indicates that the optimum concept is a hydrogen-oxygen APU incorporating a recuperator to utilize the exhaust energy and using the cycle hydrogen flow as a means of cooling the component heat loads. A preliminary design of the selected APU concept is presented, placing primary emphasis on the cycle thermal management and the controls. Results for both steady state and transient APU performance are also included, based on digital computer programs developed during the study. The selected APU provides up to 400 hp out of the gearbox, has a fixed weight of about 277 lb, and requires about 2 lb/shp-hr of propellants.

Hamilton, M. L.↗
NASA NTRS1972

Preliminary design of an auxiliary power unit for the space shuttle. Volume 4: Selected system supporting studies

Selected system supporting analyses in conjunction with the preliminary design of an auxiliary power unit (APU) for the space shuttle are presented. Both steady state and transient auxiliary power unit performance, based on digital computer programs, were examined. The selected APU provides up to 400 horsepower out of the gearbox, weighs 227 pounds, and requires 2 pounds per shaft horsepower hour of propellants.

Hamilton, M. L.↗
NASA NTRS1972

Rotor systems research aircraft predesign study. Volume 2: Conceptual study report

The overall feasibility of the technical requirements and concepts for a rotor system research aircraft (RSRA) was determined. The designs of two aircraft were then compared against the RSRA requirements. One of these is an all new aircraft specifically designed as an RSRA vehicle. A new main rotor, transmission, wings, and fuselage are included in this design. The second aircraft uses an existing Sikorsky S-61 main rotor, an S-61 roller gearbox, and a highly modified Sikorsky S-67 airframe. The wing for this aircraft is a new design. Both aircraft employ a fan-in-fin anti-torque/yaw control system, T58-GE-16 engines for rotor power, and TF34-GE-2 turbofans for auxiliary thrust. Each aircraft meets the basic requirements and goals of the program. The all new aircraft has inflight variable main rotor shaft tilt, a side-by-side cockpit seating arrangement, and is slightly faster in the compound mode. It is also somewhat lighter since it uses new dynamic components specifically designed for the RSRA. Preliminary development plans, including schedules and costs, were prepared for both of these aircraft.

Schmidt, S. A.↗
NASA NTRS1973

Study of design and control of remote manipulators. Part 2: Vibration considerations in manipulator design

An investigation is reported involving a mathematical procedure using 4 x 4 transformation matrices for analyzing the vibrations of flexible manipulators. Previous studies with the procedure are summarized and the method is extended to include flexible joints as well as links, and to account for the effects of various power transmission schemes. A systematic study of the allocation of structural material and the placement of components such as motors and gearboxes was undertaken using the analytical tools developed. As one step in this direction the variables which relate the vibration parameters of the arm to the task and environment of the arm were isolated and nondimensionalized. The 4 x 4 transformation matrices were also used to develop analytical expressions for the terms of the complete 6 x 6 compliance matrix for the case of two flexible links joined by a rotating joint, flexible about its axis of rotation.

Book, W. J.↗
NASA NTRS1972

Integrated engine-generator for aircraft secondary power.

The integrated engine-generator concept consists of an electric generator located inside a turbojet or turbofan engine and both concentric with and driven by one of the main engine shafts. The electric power-conversion equipment and generator controls are conveniently located in the aircraft. When properly rated, the generator serves as an engine starter as well as a source of electric power. The available generating capacity permits use of electrically driven engine accessories. This reduces or eliminates the need for an external gearbox on the engine, thereby simplifying the engine and nacelle assembly and increasing aircraft design flexibility. The nacelle diameter can then be decreased, resulting in less aerodynamic drag and reduced takeoff gross weight.

Secunde, R. R.↗
NASA NTRS1974

Design of H2-O2 space shuttle APU. Volume 1: APU design

The H2-O2 space shuttle auxiliary power unit (APU) program is a NASA-Lewis effort aimed at hardware demonstration of the technology required for potential use on the space shuttle. It has been shown that a hydrogen-oxygen power unit (APU) system is an attractive alternate to the space shuttle baseline hydrazine APU system for minimum weight. It has the capability for meeting many of the heat sink requirements for the space shuttle vehicle, thereby reducing the amount of expendable evaporants required for cooling in the baseline APU. Volume 1 of this report covers preliminary design and analysis of the current reference system and detail design of the test version of this reference system. Combustor test results are also included. Volume 2 contains the results of the analysis of an initial version of the reference system and the computer printouts of system performance. The APU consists of subsystems for propellant feed and conditioning, turbopower, and control. Propellant feed and conditioning contains all heat exchangers, valves, and the combustor. The turbopower subsystem contains a two-stage partial-admission pressure-modulated, 400-hp, 63,000-rpm turbine, a 0-to 4-g lubrication system, and a gearbox with output pads for two hydraulic pumps and an alternator (alternator not included on test unit). The electronic control functions include regulation of speed and system temperatures; and start-and-stop sequences, overspeed (rpm) and temperature limits, failsafe provisions, and automatic shutdown provisions.

Harris, E.↗
NASA NTRS1973

French wind generator systems

The experimental design of a wind driven generator with a rated power of 800 kilovolt amperes and capable of being connected to the main electrical network is reported. The rotor is a three bladed propeller; each blade is twisted but the fixed pitch is adjustable. The asynchronous 800-kilovolt ampere generator is driven by the propeller through a gearbox. A dissipating resistor regulates the machine under no-load conditions. The first propeller on the machine lasted 18 months; replacement of the rigid propeller with a flexible structure resulted in breakdown due to flutter effects.

Noel, J. M.↗
NASA NTRS1974

Design guide for helicopter transmission seals

A detailed approach for the selection and design of seals for helicopter transmissions is presented. There are two major types of seals presently being used and they are lip type seals and mechanical type seals. Lip type seals can be divided in conventional lip seals and hydrodynamic lip seals. Conventional lip seals can be used for slow-speed, low-pressure, low-temperature sealing. Hydrodynamic lip seals although they are as pressure and temperature limited as conventional lip seals, can operate at a higher speed. Mechanical types seals are comprised of face seals and circumferential seals. Face seals are capable of high speed, high pressure, and high temperature. Circumferential seals can be used in high-speed and high-temperature applications, but will leak excessively at moderate pressures. The performance goals of transmission seals are a life that is at least equal to the scheduled overhaul interval of the gearbox component and a leakage rate of near zero.

Hayden, T. S.↗
NASA NTRS1975

H2O2 space shuttle APU

A cryogenic H2-O2 auxiliary power unit (APU) was developed and successfully demonstrated. It has potential application as a minimum weight alternate to the space shuttle baseline APU because of its (1) low specific propellant consumption and (2) heat sink capabilities that reduce the amount of expendable evaporants. A reference system was designed with the necessary heat exchangers, combustor, turbine-gearbox, valves, and electronic controls to provide 400 shp to two aircraft hydraulic pumps. Development testing was carried out first on the combustor and control valves. This was followed by development of the control subsystem including the controller, the hydrogen and oxygen control valves, the combustor, and a turbine simulator. The complete APU system was hot tested for 10 hr with ambient and cryogenic propellants. Demonstrated at 95 percent of design power was 2.25 lb/hp-hr. At 10 percent design power, specific propellant consumption was 4 lb/hp-hr with space simulated exhaust and 5.2 lb/hp-hr with ambient exhaust. A 10 percent specific propellant consumption improvement is possible with some seal modifications. It was demonstrated that APU power levels could be changed by several hundred horsepower in less than 100 msec without exceeding allowable turbine inlet temperatures or turbine speed.

Source record↗
NASA NTRS1977

Powered wheel for aircraft

Single integral unit includes motor, gearbox, and clutch. Device has two-speed capability, fits within aerodynamic contours of aircraft, operates with onboard power source, does not interfere with normal landing gear functions, reduces use of regular brakes in congested areas, and provides locomotion and supplementary braking capability.

Long, M. J.↗
NASA NTRS1975

100-kW hingeless metal wind turbine blade design, analysis and fabrication

The design, fabrication and analysis of aluminum wind turbine rotor blades is discussed. The blades are designed to meet criteria established for a 100-kilowatt wind turbine generator operating between 8 and 60-mile-per-hour speeds at 40 revolutions per minute. The design wind speed is 18 miles per hour. Two rotor blades are used on a new facility which includes a hingeless hub and its shaft, gearbox, generator and tower. Experience shows that, for stopped rotors, safe wind speeds are strongly dependent on blade torsional and bending rigidities which the basic D spar structural blade design provides. The 0.25-inch-thick nose skin is brake/bump formed to provide the basic 'D' spar structure for the tapered, twisted blades. Adequate margins for flutter and divergence are predicted from the use of existing, correlated stopped rotor and helicopter rotor analysis programs.

Donham, R. E.↗
NASA NTRS1976

Energy consumption characteristics of transports using the prop-fan concept

The fuel saving and economic potentials of the prop-fan high-speed propeller concept were evaluated for twin-engine commercial transport airplanes designed for 3333.6 km range, 180 passengers, and Mach 0.8 cruise. A fuel saving of 9.7% at the design range was estimated for a prop-fan airplane having wing-mounted engines, while a 5.8% saving was estimated for a design having the engines mounted on the aft body. The fuel savings and cost were found to be sensitive to the propeller noise level and to aerodynamic drag effects due to wing-slipstream interaction. Uncertainties in these effects could change the fuel savings as much as + or - 50%. A modest improvement in direct operating cost (DOC) was estimated for the wing-mounted prop-fan at current fuel prices. This improvement could become substantial in the event of further relative increases in the price of oil. The improvement in DOC requires the achievement of the nominal fuel saving and reductions in propeller and gearbox maintenance costs relative to current experience.

Source record↗