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NASA NTRS2016

Hybrid Gear

A hybrid gear consisting of metallic outer rim with gear teeth and metallic hub in combination with a composite lay up between the shaft interface (hub) and gear tooth rim is described. The composite lay-up lightens the gear member while having similar torque carrying capability and it attenuates the impact loading driven noise/vibration that is typical in gear systems. The gear has the same operational capability with respect to shaft speed, torque, and temperature as an all-metallic gear as used in aerospace gear design.

Handschuh, Robert F.↗

NASA NTRS2015

Braided Composite Technologies for Rotorcraft Structures

A&P Technology has developed a braided material approach for fabricating lightweight, high-strength hybrid gears for aerospace drive systems. The conventional metallic web was replaced with a composite element made from A&P's quasi-isotropic braid. The 0deg, +/-60deg braid architecture was chosen so that inplane stiffness properties and strength would be nearly equal in all directions. The test results from the Phase I Small Spur Gear program demonstrated satisfactory endurance and strength while providing a 20 percent weight savings. (Greater weight savings is anticipated with structural optimization.) The hybrid gears were subjected to a proof-of-concept test of 1 billion cycles in a gearbox at 10,000 revolutions per minute and 490 in-lb torque with no detectable damage to the gears. After this test the maximum torque capability was also tested, and the static strength capability of the gears was 7x the maximum operating condition. Additional proof-of-concept tests are in progress using a higher oil temperature, and a loss-of-oil test is planned. The success of Phase I led to a Phase II program to develop, fabricate, and optimize full-scale gears, specifically Bull Gears. The design of these Bull Gears will be refined using topology optimization, and the full-scale Bull Gears will be tested in a full-scale gear rig. The testing will quantify benefits of weight savings, as well as noise and vibration reduction. The expectation is that vibration and noise will be reduced through the introduction of composite material in the vibration transmission path between the contacting gear teeth and the shaft-and-bearing system.

Jessie, Nathan↗

NASA NTRS2013

Measurements of Cyclotron Features and Pulse Periods in the High-Mass X-Ray Binaries 4U 1538-522 and 4U 1907+09 with the International Gamma-Ray Astrophysics Laboratory

We present a spectral and timing analysis of International Gamma-Ray Astrophysics Laboratory (INTEGRAL) observations of two high-mass X-ray binaries, 4U 1538−522 and 4U 1907+09. Our timing measurements for 4U 1538−522 find the pulse period to have exhibited a spin-up trend until approximately 2009, after which there is evidence for a torque reversal, with the source beginning to spin down to the most recently measured period of 525.407 plus or minus 0.001 seconds. The most recent INTEGRAL observations of 4U 1907+09 are not found to yield statistically significant pulse periods due to the significantly lower flux from the source compared with 4U 1538−522. A spectral model consisting of a power-law continuum with an exponential cutoff and modified by two cyclotron resonance scattering features is found to fit both sources well, with the cyclotron scattering features detected at approximately 22 and approximately 49 kiloelectronvolts for 4U 1538−522 and at approximately 18 and approximately 36 kiloelectronvolts for 4U 1907+09. The spectral parameters of 4U 1538−522 are generally not found to vary significantly with flux and there is little to no variation across the torque reversal. Examining our results in conjunction with previous work, we find no evidence for a correlation between cyclotron line energy and luminosity for 4U 1538−522. 4U 1907+09 shows evidence for a positive correlation between cyclotron line energy and luminosity, which would make it the fourth, and lowest luminosity, cyclotron line source to exhibit this relationship.

stars: magnetic field↗

NASA NTRS2015

Design, Fabrication, and Testing of a Composite Rack Prototype in Support of the Deep Space Habitat Program

In support of the Deep Space Habitat project a number of composite rack prototypes were developed, designed, fabricated and tested to various extents ( with the International Standard Payload Rack configuration, or crew quarters, as a baseline). This paper focuses specifically on a composite rack prototype with a direct tie in to Space Station hardware. The outlined prototype is an all composite construction, excluding metallic fasteners, washers, and their associated inserts. The rack utilizes braided carbon composite tubing for the frame with the sidewalls, backwall and flooring sections utilizing aircraft grade composite honeycomb sandwich panels. Novel additively manufactured thermoplastic joints and tube inserts were also developed in support of this effort. Joint and tube insert screening tests were conducted at a preliminary level. The screening tests allowed for modification, and enhancement, of the fabrication and design approaches, which will be outlined. The initial joint tests did not include mechanical fasteners. Adhesives were utilized at the joint to composite tube interfaces, along with mechanical fasteners during final fabrication (thus creating a stronger joint than the adhesive only variant). In general the prototype was focused on a potential in-space assembly approach, or kit-of-parts construction concept, which would not necessarily require the inclusion of an adhesive in the joint regions. However, given the tie in to legacy Station hardware (and potential flight loads with imbedded hardware mass loadings), the rack was built as stiff and strong as possible. Preliminary torque down tests were also conducted to determine the feasibility of mounting the composite honeycomb panels to the composite tubing sections via the additively manufactured tube inserts. Additional fastener torque down tests were also conducted with inserts (helicoils) imbedded within the joints. Lessons learned are also included and discussed.

Smith, Russ↗

NASA NTRS2016

Magnetospheric Multiscale Mission Attitude Dynamics: Observations from Flight Data

The NASA Magnetospheric Multiscale mission, launched on Mar. 12, 2015, is flying four spinning spacecraft in highly elliptical orbits to study the magnetosphere of the Earth. Extensive attitude data is being collected, including spin rate, spin axis orientation, and nutation rate. The paper will discuss the various environmental disturbance torques that act on the spacecraft, and will describe the observed results of these torques. In addition, a slow decay in spin rate has been observed for all four spacecraft in the extended periods between maneuvers. It is shown that this despin is consistent with the effects of an additional disturbance mechanism, namely that produced by the Active Spacecraft Potential Control devices. Finally, attitude dynamics data is used to analyze a micrometeoroid/orbital debris impact event with MMS4 that occurred on Feb. 2, 2016.

Conjunction↗

NASA NTRS2016

Magnetospheric Multiscale Mission Attitude Dynamics: Observations from Flight Data

Extensive flight data is being collected throughout the MMS mission that includes quantities that are of interest for attitude dynamics studies such as spin rate, spin axis orientation nutation rate, etc. One example of such data is the long-term evolution of the spin rates of the four spacecraft. Spikes in these rates are observed that are separated by the MMS orbital period (just under 24 hr) and occur around perigee due to gravity-gradient torque. Periodic discontinuities in spin rate are caused by the controller resetting the spin rate approximately to the nominal 3.1 RPM value at the time of each maneuver. In between, a slow decay in spin rate can be seen to occur. The paper will discuss various disturbance torque mechanisms that could potentially be responsible for this behavior: these include magnetic hysteresis, eddy currents, solar radiation pressure, and a possible interaction between gravity-gradient and wire boom flexibility effects. One additional disturbance mechanism is produced by the Active Spacecraft Potential Control (ASPOC) devices: these emit positive indium ions to keep the MMS spacecraft electrically neutral, so as not to corrupt the electric field observations that are made by some of the on-board instruments. The spin rate decays that could be produced by these various mechanisms will be quantified in the paper, and their signatures described. Comparing these with the observations from flight data then allow the most likely candidate to be determined.

DYNAMICS↗

NASA NTRS2016

NDARC NASA Design and Analysis of Rotorcraft - Input, Appendix 4

The NDARC code performs design and analysis tasks. The design task involves sizing the rotorcraft to satisfy specified design conditions and missions. The analysis tasks can include off-design mission performance analysis, flight performance calculation for point operating conditions, and generation of subsystem or component performance maps. The principal tasks (sizing, mission analysis, flight performance analysis) are shown in the figure as boxes with heavy borders. Heavy arrows show control of subordinate tasks. The aircraft description consists of all the information, input and derived, that denes the aircraft. The aircraft consists of a set of components, including fuselage, rotors, wings, tails, and propulsion. This information can be the result of the sizing task; can come entirely from input, for a fixed model; or can come from the sizing task in a previous case or previous job. The aircraft description information is available to all tasks and all solutions. The sizing task determines the dimensions, power, and weight of a rotorcraft that can perform a specified set of design conditions and missions. The aircraft size is characterized by parameters such as design gross weight, weight empty, rotor radius, and engine power available. The relations between dimensions, power, and weight generally require an iterative solution. From the design flight conditions and missions, the task can determine the total engine power or the rotor radius (or both power and radius can be fixed), as well as the design gross weight, maximum takeoff weight, drive system torque limit, and fuel tank capacity. For each propulsion group, the engine power or the rotor radius can be sized. Missions are defined for the sizing task, and for the mission performance analysis. A mission consists of a number of mission segments, for which time, distance, and fuel burn are evaluated. For the sizing task, certain missions are designated to be used for design gross weight calculations; for transmission sizing; and for fuel tank sizing. The mission parameters include mission takeoff gross weight and useful load. For specified takeoff fuel weight with adjustable segments, the mission time or distance is adjusted so the fuel required for the mission equals the takeoff fuel weight. The mission iteration is on fuel weight or energy. Flight conditions are specified for the sizing task, and for the flight performance analysis. For the sizing task, certain flight conditions are designated to be used for design gross weight calculations; for transmission sizing; for maximum takeoff weight calculations; and for anti-torque or auxiliary thrust rotor sizing. The flight condition parameters include gross weight and useful load. For flight conditions and mission takeoff, the gross weight can be maximized, such that the power required equals the power available. A flight state is defined for each mission segment and each flight condition. The aircraft performance can be analyzed for the specified state, or a maximum effort performance can be identified. The maximum effort is specified in terms of a quantity such as best endurance or best range, and a variable such as speed, rate of climb, or altitude.

Rotorcraft Input↗

NASA NTRS2017

Flex Dynamics Avoidance Control of the NEA Scout Solar Sail Spacecraft's Reaction Control System

The Attitude Control System (ACS) is developed for a Near Earth Asteroid (NEA) Scout mission using a solar sail. The NEA-Scout spacecraft is a 6U cubesat with an 86 square-meter solar sail. NEA Scout will launch on Space Launch System (SLS) Exploration Mission 1 (EM-1), currently scheduled to launch in 2018. The spacecraft will rendezvous with a target asteroid after a two year journey, and will conduct science imagery. The solar sail spacecraft ACS consists of three major actuating subsystems: a Reaction Wheel (RW) control system, a Reaction Control System (RCS), and an Adjustable Mass Translator (AMT) system. The three subsystems allow for a wide range of spacecraft attitude control capabilities, needed for the different phases of the NEA-Scout mission. Because the sail is a flexible structure, care must be taken in designing a control system to avoid exciting the structural modes of the sail. This is especially true for the RCS, which uses pulse actuated, cold-gas jets to control the spacecraft's attitude. While the reaction wheels can be commanded smoothly, the RCS jets are simple on-off actuators. Long duration firing of the RCS jets - firings greater than one second - can be thought of as step inputs to the spacecraft's torque. On the other hand, short duration firings - pulses on the order of 0.1 seconds - can be thought of as impulses in the spacecraft's torque. These types of inputs will excite the structural modes of the spacecraft, causing the sail to oscillate. Sail oscillations are undesirable for many reasons. Mainly, these oscillations will feed into the spacecraft attitude sensors and pointing accuracy, and long term oscillations may be undesirable over the lifetime of the solar sail. In order to limit the sail oscillations, an RCS control scheme is being developed to minimize sail excitations. Specifically, an input shaping scheme similar to the method described in Reference 1 will be employed. A detailed description of the RCS control scheme will be provided with particular emphasis on flexible body excitation. The RCS performance will be provided to show that sail and boom excitation is minimized.

Heaton Andrew↗

NASA NTRS2017

Momentum Management for the NASA Near Earth Asteroid Scout Solar Sail Mission

The Momentum Management (MM) system is described for the NASA Near Earth Asteroid Scout (NEA Scout) cubesat solar sail mission. Unlike many solar sail mission proposals that used solar torque as the primary or only attitude control system, NEA Scout uses small reaction wheels (RW) and a reaction control system (RCS) with cold gas thrusters, as described in the abstract "Solar Sail Attitude Control System for Near Earth Asteroid Scout Cubesat Mission." The reaction wheels allow fine pointing and higher rates with low mass actuators to meet the science, communication, and trajectory guidance requirements. The MM system keeps the speed of the wheels within their operating margins using a combination of solar torque and the RCS.

Heaton, Andrew↗

NASA NTRS2016

Cooling of Electric Motors Used for Propulsion on SCEPTOR

Benefits of Electric Power: Reduced energy consumption, Lower emissions, Less noise. Traction motors: Permanent magnet, Synchronous, High torque at low rotational speeds, High power density, (High concentration of heat). Annular inlet: Very compatible with PM motors, (Provides cooling where needed, No need for complicated ducting, Leads to a larger motor diameter which is beneficial for motor torque) Effect of prop wash on heat transfer coefficients: Assumed propeller induced turbulence would increase heat transfer coefficients, Holmes, Obara Yip reported 'propeller slipstream showed little if any apparent effect of the slip stream', Derlaga @ LaRC also found little change in heat transfer in the wake of the propeller.

Aircraft↗

NASA NTRS2017

Biomechanical Modeling Analysis of Loads Configuration for Squat Exercise

INTRODUCTION: Long duration space travel will expose astronauts to extended periods of reduced gravity. Since gravity is not present to assist loading, astronauts will use resistive and aerobic exercise regimes for the duration of the space flight to minimize loss of bone density, muscle mass and aerobic capacity that occurs during exposure to a reduced gravity environment. Unlike the International Space Station (ISS), the area available for an exercise device in the next generation of spacecraft for travel to the Moon or to Mars is limited and therefore compact resistance exercise device prototypes are being developed. The Advanced Resistive Exercise Device (ARED) currently on the ISS is being used as a benchmark for the functional performance of these new devices. Biomechanical data collection and computational modeling aid the device design process by quantifying the joint torques and the musculoskeletal forces that occur during exercises performed on the prototype devices. METHODS The computational models currently under development utilize the OpenSim [1] software platform, consisting of open source code for musculoskeletal modeling, using biomechanical input data from test subjects for estimation of muscle and joint loads. The OpenSim Full Body Model [2] is used for all analyses. The model incorporates simplified wrap surfaces, a new knee model and updated lower body muscle parameters derived from cadaver measurements and magnetic resonance imaging of young adults. The upper body uses torque actuators at the lumbar and extremity joints. The test subjects who volunteer for this study are instrumented with reflective markers for motion capture data collection while performing squat exercising on the Hybrid Ultimate Lifting Kit (HULK) prototype device (ZIN Technologies, Middleburg Heights, OH). Ground reaction force data is collected with force plates under the feet, and device loading is recorded through load cells internal to the HULK. Test variables include the applied device load and the dual cable long bar or single cable T-bar interface between the test subject and the device. Data is also obtained using free weights with the identical loading for a comparison to the resistively loaded exercise device trials. The data drives the OpenSim biomechanical model, which has been scaled to match the anthropometrics of the test subject, to calculate the body loads. RESULTS Lower body kinematics, joint moments, joint forces and muscle forces are obtained from the OpenSim biomechanical analysis of the squat exercises under different loading conditions. Preliminary results from the model for the loading conditions will be presented as will hypotheses developed for follow on work.

Human Factors Engineering↗

NASA NTRS2017

Two-Pendulum Model of Propellant Slosh in Europa Clipper PMD Tank

Model propellant slosh for Europa Clipper using two pendulums such that controls engineers can predict slosh behavior during the mission. Importance of predicting propellant slosh; (1) Sloshing changes CM (center of mass) of spacecraft and exerts forces and torques on spacecraft. (2) Avoid natural frequencies of structures. (3) Size ACS (Attitude Control Systems) thrusters to counteract forces and torques. Can model sloshing fluid as two pendulums with specific parameters (mass, length, damping),

Two-Pendulum Model of Propellant Slosh in Europa C↗

NASA NTRS2016

Wire Rope Failure on the Guppy Winch

On January 6, 2016 at El Paso, the Guppy winch motor was changed. After completion of the operational checks, the load bar was being reinstalled on the cargo pallet when the motor control FORWARD relay failed in the energized position. The pallet was pinned at all locations (each pin has a load capacity of 16,000 lbs.) while the winch was running. The wire rope snapped before aircraft power could be removed. After disassembly, the fractured wire rope was shipped to ES4 lab for further characterization of the wire rope portion of the failure. The system was being operated without a clear understanding of the system capability and function. The proximate cause was the failure of the K48 -Forward Winch Control Relay in the energized position, which allowed the motor to continuously run without command from the hand controller, and operation of the winch system with both controllers connected to the system. This prevented the emergency stop feature on the hand controller from functioning as designed. An electrical checkout engineering work instruction was completed and identified the failed relay and confirmed the emergency stop only paused the system when the STOP button on both connected hand controllers were depressed simultaneously. The winch system incorporates a torque limiting clutch. It is suspected that the clutch did not slip and the motor did not stall or overload the current limiter. Aircraft Engineering is looking at how to change the procedures to provide a checkout of the clutch and set to a slip torque limit appropriate to support operations.

Figert, John↗

NASA NTRS2017

Lessons for Interstellar Travel from the Guidance and Control Design of the Near Earth Asteroid Scout Solar Sail Mission

NASA is developing the Near Earth Asteroid (NEA) Scout mission that will use a solar sail to travel to an asteroid where it will perform a slow flyby to acquire science imagery. A guidance and control system was developed to meet the science and trajectory requirements. The NEA Scout design process can be applied to an interstellar or precursor mission that uses a beam propelled sail. The scientific objectives are met by accurately targeting the destination trajectory position and velocity. The destination is targeted by understanding the force on the sail from the beam (or sunlight in the case of NEA Scout) over the duration of the thrust maneuver. The propulsive maneuver is maintained by accurate understanding of the torque on the sail, which is a function of sail shape, optical properties, and mass properties, all of which apply to NEA Scout and beam propelled sails. NEA Scout uses active control of the sail attitude while trimming the solar torque, which could be used on a beamed propulsion sail if necessary. The biggest difference is that NEA Scout can correct for uncertainties in sail thrust modeling, spacecraft orbit, and target orbit throughout the flight to the target, while beamed propulsion needs accurate operation for the short duration of the beamed propulsion maneuver, making accurate understanding of the sail thrust and orbits much more critical.

Diedrich, Benjamin↗

NASA NTRS2017

Lessons for Interstellar Travel from the G&C Design of the NEA Scout Solar Sail Mission

NASA is developing the Near Earth Asteroid (NEA) Scout mission that will use a solar sail to travel to an asteroid where it will perform a slow flyby to acquire science imagery. A guidance and control system was developed to meet the science and trajectory requirements. The NEA Scout design process can be applied to an interstellar or precursor mission that uses a beam-propelled sail. The scientific objectives are met by accurately targeting the destination trajectory position and velocity. The destination is targeted by understanding the force on the sail from the beam (or sunlight in the case of NEA Scout) over the duration of the thrust maneuver. The propulsive maneuver is maintained by accurate understanding of the torque on the sail, which is a function of sail shape, optical properties, and mass properties, all of which apply to NEA Scout and beam propelled sails. NEA Scout uses active control of the sail attitude while trimming the solar torque, which could be used on a beamed propulsion sail if necessary. The biggest difference is that NEA Scout can correct for uncertainties in sail thrust modeling, spacecraft orbit, and target orbit throughout the flight to the target, while beamed propulsion needs accurate operation for the short duration of the beamed propulsion maneuver, making accurate understanding of the sail thrust and orbits much more critical.

Heaton, Andrew↗

NASA NTRS2011

The Effects of Propellant Slosh Dynamics on the Solar Dynamics Observatory

The Solar Dynamics Observatory (SDO) mission, which is part of the Living With a Star program, was successfully launched and deployed from its Atlas V launch vehicle on February 11, 2010. SDO is an Explorer-class mission now operating in a geosynchronous orbit (GEO). The basic mission is to observe the Sun for a very high percentage of the 5-year mission (10-year goal) with long stretches of uninterrupted observations and with constant, high-data-rate transmission to a dedicated ground station located in White Sands, New Mexico. A significant portion of SDO's launch mass was propellant, contained in two large tanks. To ensure performance with this level of propellant, a slosh analysis was performed. This paper provides an overview of the SDO slosh analysis, the on-orbit experience, and the lessons learned. SDO is a three-axis controlled, single fault tolerant spacecraft. The attitude sensor complement includes sixteen coarse Sun sensors, a digital Sun sensor, three two-axis inertial reference units, two star trackers, and four guide telescopes. Attitude actuation is performed either using four reaction wheels or eight thrusters, depending on the control mode, along with single main engine which nominally provides velocity-change thrust. The attitude control software has five nominal control modes: three wheel-based modes and two thruster-based modes. A wheel-based Safehold running in the Attitude Control Electronics (ACE) box improves the robustness of the system as a whole. All six modes are designed on the same basic proportional-integral-derivative attitude error structure, with more robust modes setting their integral gains to zero. To achieve and maintain a geosynchronous orbit for a 2974-kilogram spacecraft in a cost effective manner, the SDO team designed a high-efficiency propulsive system. This bi-propellant design includes a 100-pound-force main engine and eight 5-pound-force attitude control thrusters. The main engine provides high specific impulse for the maneuvers to attain GEO, while the smaller Attitude Control System (ACS) thrusters manage the disturbance torques of the larger main engine and provide the capability for much smaller orbit adjustment burns. SDO's large solar profile produces a large solar torque disturbance and momentum buildup. This buildup drives the frequency of momentum unloads via ACS thrusters. SDO requires 1409 kilograms (which is approximately half the launch mass) of propellant to achieve and maintain the GEO orbit while performing the momentum unloads for 10 years.

Mason, Paul↗

NASA NTRS2018

The Design & Development of the Ocean Color Instrument Precision Superduplex Hybrid Bearing Cartridge

A high precision, high-resolution Ocean Color Imaging (OCI) instrument is under development for the Plankton, Aerosol, Cloud, ocean Ecosystem (PACE) mission which requires a pair of medium speed mechanisms to scan the ocean surface continuously. The design of the rotating telescope (RT) mechanism operating at 360 RPM and the half-angle mirror (HAM) mechanism synchronized at 180 RPM was concern for maintaining pointing precision over the required life and continuous operations. An effort was undertaken with the manufacturer to design and analyze a special bearing configuration to minimize axial and radial runout, minimize torque, and maintain nominal contact stresses and stiffness over the operating temperature range and to maximize life. The bearing design, development effort, analysis and testing will be discussed as will the technical challenges that this specific design imposed upon the mechanism engineers. Bearing performance, runout as achieved and verified during encoder installation and operating torque will be described.

mechanism↗

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↗