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At least 163 records · Page 9

All sources NASA NTRS DOE OSTI

NASA NTRS2012

Preliminary Assessment of Variable Speed Power Turbine Technology on Civil Tiltrotor Size and Performance

A Large Civil Tiltrotor (LCTR) conceptual design was developed as part of the NASA Heavy Lift Rotorcraft Systems Investigation in order to establish a consistent basis for evaluating the benefits of advanced technology for large tiltrotors. The concept has since evolved into the second-generation LCTR2, designed to carry 90 passengers for 1,000 nm at 300 knots, with vertical takeoff and landing capability. This paper performs a preliminary assessment of variable-speed power turbine technology on LCTR2 sizing, while maintaining the same, advanced technology engine core. Six concepts were studied; an advanced, single-speed engine with a conventional power turbine layout (Advanced Conventional Engine, or ACE) using a multi-speed (shifting) gearbox. There were five variable-speed power turbine (VSPT) engine concepts, comprising a matrix of either three or four turbine stages, and fixed or variable guide vanes; plus a minimum weight, twostage, fixed-geometry VSPT. The ACE is the lightest engine, but requires a multi-speed (shifting) gearbox to maximize its fuel efficiency, whereas the VSPT concepts use a lighter, fixed-ratio gearbox. The NASA Design and Analysis of Rotorcraft (NDARC) design code was used to study the trades between rotor and engine efficiency and weight. Rotor performance was determined by Comprehensive Analytical Model of Rotorcraft Aerodynamics and Dynamics (CAMRAD II), and engine performance was estimated with the Numerical Propulsion System Simulation (NPSS). Design trades for the ACE vs. VSPT are presented in terms of vehicle gross and empty weight, propulsion system weight and mission fuel burn for the civil mission. Because of its strong effect on gearbox weight and on both rotor and engine efficiency, rotor speed was chosen as the reference design variable for comparing design trades. Major study assumptions are presented and discussed. Impressive engine power-to-weight and fuel efficiency reduced vehicle sensitivity to propulsion system choice. The 10% weight penalty for multi-speed gearbox was more significant than most engine technology weight penalties to the vehicle design because drive system weight is more than two times engine weight. Based on study assumptions, fixed-geometry VSPT concept options performed better than their variable-geometry counterparts. Optimum design gross weights varied 1% or less and empty weights less than 2% among the concepts studied, while optimum fuel burns varied up to 5%. The outcome for some optimum configurations was so unexpected as to recommend a deeper look at the underlying technology assumptions.

Snyder, Christopher A.↗

DOE OSTI2020

Control of Vibration Systems with Mechanical Motion Rectifier and their Applications to Vehicle Suspension and Ocean Energy Harvester

Vibration control is a large branch in control research, because all moving systems may induce desired or undesired vibration. Due to the limitation of passive system’s adaptability and changing excitation input, vibration control brings the solution to change system dynamic with desired behavior to fulfill control targets. According to preference, vibration control can be separated into two categories: vibration reduction and vibration amplification. Lots of research papers only examine one aspect in vibration control. The thesis investigates the control development for both control targets with two different control applications: vehicle suspension and ocean wave energy converter. It develops control methods for both systems with simplified modeling setup, then followed by the application of a novel mechanical motion rectifier (MMR) gearbox that uses mechanical one-way clutches in both systems. The flow is from the control for common system to the control design for a specifically designed system. In the thesis, active (model predictive control: MPC), semi-active (Skyhook, skyhook-power driven damper: SHPDD, hybrid model predictive control: HMPC), and passive control (Latching Control) methods are developed for different applications or control performance comparison on single system. The thesis also studies about new type of system with switching mechanism, in which other papers do not talk too much and possible control research direction to deal with such complicated system in vibration control. The state-space modeling for both systems are provided in the thesis with detailed model of the MMR gearbox. From the simulation, it can be shown that in the vehicle suspension application, the controlled MMR gearbox can be effective in improving vehicle ride comfort by 29.2% compared to that of the traditional hydraulic suspension. In the ocean wave energy converter, the controlled MMR WEC with simple latching control can improve the power generation by 57% compared to the passive MMR WEC. Besides, the passive MMR WEC also shows its advantage on the passive direct drive WEC in power generation improvement. From the control development flow for the MMR system, the limitation of the MMR gearbox is also identified, which introduces the future work in developing active-MMR gearbox by using an electromagnetic clutch. Some possible control development directions on the active-MMR is also mentioned at the end of the thesis to provide reference for future works.

16 TIDAL AND WAVE POWER↗

DOE OSTI2020

Validation of a Generalized Formulation for Load-Sharing Behavior in Epicyclic Gears for Wind Turbines: Preprint

In an ideal epicyclic gear set every parallel gear path transmits the same amount of torque. However, it is well known that certain manufacturing variations result in unequal load sharing between the parallel gear paths. Previous works have developed and validated a general closed-form analytical model of this phenomenon that describes the load sharing characteristics of epicyclic gear sets from three to six planets at any torque level. More recently, this analytical model has been reformulated to include the effects of gravity, carrier bearing clearance, and external applied moments, all of which are relevant to most gearboxes and their mounting configuration in horizontal-axis wind turbines. In this paper, the reformulated model is compared to load measurements collected from two similar wind turbine gearboxes with three-planet epicyclic gear sets. The resulting load sharing values are also compared to the mesh load factor requirements in the AGMA 6006 and IEC 61400-4 wind turbine gearbox design standards. Load sharing factors as high as 1.16 at extreme rotor moments and 1.08 with no moment were measured for the gearbox with cylindrical roller bearings, but the load sharing factor remained below 1.10 for the gearbox with tapered roller bearings The results show that in the wind turbine application, load sharing is not equal - even for three-planet systems with a floating central member because of the effects of gravity, rotor moments, and the resulting relative motions among the epicyclic gear components within the carrier bearing clearance.

closed-form analytical model↗

DOE OSTI2020

Validation of a Generalized Formulation for Load Sharing Behavior in Epicyclic Gears for Wind Turbines

closed-form analytical model↗

DOE OSTI2022

Highly mobile robot for remote inspection

A robotic vehicle can include a plurality of motors coupled to a plurality of gearboxes, each gearbox of the plurality of gearboxes configured to be rotated, a plurality of nested driveshafts coupled to the plurality of gearboxes and including at least a first driveshaft and a second driveshaft, and a plurality of appendages operably coupled to the plurality of gearboxes. A particular appendage of the plurality of appendages can be configured to be rotated in response to a rotational motion of the first driveshaft. The robotic vehicle can include a plurality of wheels coupled to the plurality of appendages and configured to rotate about a plurality of wheel axles. Each wheel of the plurality of wheels can be configured to cause the robotic vehicle to be transported across a contacting surface in response to the rotational motion of the second driveshaft.

Crane, Carl D.↗

DOE OSTI2017

Investigation of Bearing Axial Cracking: Benchtop and Full-Scale Test Results

The most common failure mode in wind turbine gearboxes is axial cracking in intermediate and high-speed-stage bearings, also commonly called white-etching cracks (WECs). Although these types of cracks have been reported for over a decade, the conditions leading to WECs, the process by which this failure culminates, and the reasons for their apparent prevalence in wind turbine gearboxes are all highly debated. This paper summarizes the state of a multipronged research effort to examine the causes of WECs in wind turbine gearbox bearings. Recent efforts have recreated WECs on a benchtop test rig in highly loaded sliding conditions, wherein it was found that the formation of a dark etching microstructure precedes the formation of a crack, and a crack precedes the formation of white-etching microstructure. A cumulative frictional sliding energy criterion has been postulated to predict the presence of WECs. Bearing loads have also been measured and predicted in steady state and transient drivetrain operations in dynamometer testing. In addition, both loads and sliding at full scale will be measured in planned uptower drivetrain testing. If the cumulative frictional sliding energy is the dominant mechanism that causes WECs, understanding the amount of frictional sliding energy that wind turbine bearings are subjected to in typical operations is the next step in the investigation. If highly loaded sliding conditions are found uptower, similar to the examined benchtop levels, appropriate mitigation solutions can be examined, ranging from new bearing coatings and improved lubricants to changes in gearbox designs and turbine operations.

17 WIND ENERGY↗

DOE OSTI2018

Electromagnetic and Mechanical Design of a Hermetically Sealed Magnetic Gear for a Marine Hydrokinetic Generator

This article presents a new type of hermetically sealed magnetically geared generator typology for a marine hydrokinetic application. The proposed magnetically geared generator is composed of two series connected magnetic gearbox stages with the second stage having an integrated stator. This paper focuses only on presenting the electromagnetic design for the first stage magnetic gearbox with a 5kW (at 40RPM) rating. A volumetric and mass torque density tradeoff analysis is utilized in order to arrive at a high torque density design. The designed magnetic gearbox uses a unique laminated flux concentration inner rotor and Halbach array outer rotor typology with a 6.67:1 gear ratio. Furthermore, a mechanical deflection analysis is performed to verify that the proposed magnetic gearbox is mechanically robust.

16 TIDAL AND WAVE POWER↗

DOE OSTI2019

A Prognostics and Health Management Framework for Wind

Operation and maintenance costs are a major driver for levelized cost of energy of wind power plants and can be reduced through optimized operation and maintenance practices accomplishable by various prognostics and health management (PHM) technologies. In recent years, the wind industry has become more open to adopting PHM solutions, especially those focusing on diagnostics. However, prognostics activities are, in general, still at the research and development stage. On the other hand, the industry has a request to estimate a component's remaining useful life (RUL) when it has faulted, and this is a key output of prognostics. Systematically presenting PHM technologies to the wind industry by highlighting the RUL prediction need potentially helps speed up its acceptance and provides more benefits from PHM to the industry. In this paper, we introduce a PHM for wind framework. It highlights specifics unique to wind turbines and features integration of data and physics domain information and models. The output of the framework focuses on RUL prediction. To demonstrate its application, a data domain method for wind turbine gearbox fault diagnostics is presented. It uses supervisory control and data acquisition system time series data, normalizes gearbox temperature measurements with reference to environmental temperature and turbine power, and leverages big data analytics and machine-learning techniques to make the model scalable and the diagnostics process automatic. Another physics-domain modeling method for RUL prediction of wind turbine gearbox high-speed-stage bearings failed by axial cracks is also discussed. Bearing axial cracking has been shown to be the prevalent wind turbine gearbox failure mode experienced in the field and is different from rolling contact fatigue, which is targeted during the bearing design stage. The method uses probability of failure as a component reliability assessment and RUL prediction metric, which can be expanded to other drivetrain components or failure modes. The presented PHM for wind framework is generic and applicable to both land-based and offshore wind turbines.

17 WIND ENERGY↗

DOE OSTI2020

Gear Test Assembly - Report on Experimental Testing (FY2020)

The Gear Test Assembly (GTA) has completed Campaign #2 of in-sodium testing at the Mechanisms Engineering Test Loop (METL). Campaign #1 was conducted in 2019 and completed 19,600 cycles, correlating to 9,800 fuel assembly maneuvers. Campaign #1 was terminated following a shaft seizure caused by a failed bearing in the sodium gearbox. Campaign #2 was conducted in the spring of 2020 and completed 2,768 cycles, correlating to 1,384 fuel assembly maneuvers. Campaign #2 was terminated following elevated vibration measurements coming from the sodium gearbox. Following cleaning and disassembly, a bearing was found to have failed in the sodium gearbox. Campaign #1 used tapered roller bearings made of 52100 steel with a heat treatment from the manufacturer that allows for operation to 350°C. Campaign #2 used the same tapered roller bearings, but with no heat treatment. A new dynamic shaft seal design was used in Campaign #2 that led to significant reductions in argon consumption and graphite debris generation. A modified external gearbox system led to no external bearing failures and allowed for higher torque output. Finally, modifications to the Carbonation System led to a more effective carbonation process and all-around reduction in turnaround time.

42 ENGINEERING↗

NASA NTRS1991

Analytical and experimental study of vibrations in a gear transmission

An analytical simulation of the dynamics of a gear transmission system is presented and compared to experimental results from a gear noise test rig at the NASA Lewis Research Center. The analytical procedure developed couples the dynamic behaviors of the rotor-bearing-gear system with the response of the gearbox structure. The modal synthesis method is used in solving the overall dynamics of the system. Locally each rotor-gear stage is modeled as an individual rotor-bearing system using the matrix transfer technique. The dynamics of each individual rotor are coupled with other rotor stages through the nonlinear gear mesh forces and with the gearbox structure through bearing support systems. The modal characteristics of the gearbox structure are evaluated using the finite element procedure. A variable time steping integration routine is used to calculate the overall time transient behavior of the system in modal coordinates. The global dynamic behavior of the system is expressed in a generalized coordinate system. Transient and steady state vibrations of the gearbox system are presented in the time and frequency domains. The vibration characteristics of a simple single mesh gear noise test rig is modeled. The numerical simulations are compared to experimental data measured under typical operating conditions. The comparison of system natural frequencies, peak vibration amplitudes, and gear mesh frequencies are generally in good agreement.

Choy, F. K.↗

NASA NTRS1992

Parameter and configuration study of the DSS-13 antenna drives

The effects of different elevation and azimuth drive configurations on DSS-13 antenna performance are presented as well as a study of gearbox stiffness and motor inertia. Small motor inertia and rigid gearboxes would improve the pointing accuracy up to a certain limit. The limit is imposed by critical values of gearbox stiffness and motor inertia introduced in the article. The critical values depend on the lowest structural frequency of the rate-loop model. The tracking performance can be improved by raising gearbox stiffness to the critical stiffness and reducing motor inertia to the critical inertia. An azimuth drive configuration with four driven wheels was also investigated. For the four-wheel drive configuration in azimuth, the cross-coupling effects are reduced and wind disturbance rejection properties improved. Pointing is improved substantially in the cross-elevation but is relatively unaffected in the elevation direction. More significant improvements can be achieved through either structural redesign (stiffening the structure) or new control algorithms or control concepts, which would eliminate the effect of flexible deformations on the antenna pointing accuracy. Although the study is performed for the DSS-13 antenna, the results can be extended for other DSN antennas.

Gawronski, W.↗

NASA NTRS1993

Vibration and noise analysis of a gear transmission system

This paper presents a comprehensive procedure to predict both the vibration and noise generated by a gear transmission system under normal operating conditions. The gearbox vibrations were obtained from both numerical simulation and experimental studies using a gear noise test rig. In addition, the noise generated by the gearbox vibrations was recorded during the experimental testing. A numerical method was used to develop linear relationships between the gearbox vibration and the generated noise. The hypercoherence function is introduced to correlate the nonlinear relationship between the fundamental noise frequency and its harmonics. A numerical procedure was developed using both the linear and nonlinear relationships generated from the experimental data to predict noise resulting from the gearbox vibrations. The application of this methodology is demonstrated by comparing the numerical and experimental results from the gear noise test rig.

Choy, F. K.↗

NASA NTRS1993

Vibration and noise analysis of a gear transmission system

Choy, F. K.↗

NASA NTRS2013

Design Study of Propulsion and Drive Systems for the Large Civil TiltRotor (LCTR2) Rotorcraft

Boeing, Rolls Royce, and NASA have worked together to complete a parametric sizing study for NASA's Large Civil Tilt Rotor (LCTR2) concept 2nd iteration. Vehicle gross weight and fuel usage were evaluated as propulsion and drive system characteristics were varied to maximize the benefit of reduced rotor tip speed during cruise conditions. The study examined different combinations of engine and gearbox variability to achieve rotor cruise tip speed reductions down to 54% of the hover tip speed. Previous NASA studies identified that a 54% rotor speed reduction in cruise minimizes vehicle gross weight and fuel burn. The LCTR2 was the study baseline for initial sizing. This study included rotor tip speed ratios (cruise to hover) of 100%, 77% and 54% at different combinations of engine RPM and gearbox speed reductions, which were analyzed to achieve the lightest overall vehicle gross weight (GW) at the chosen rotor tip speed ratio. Different engine and gearbox technology levels are applied ranging from commercial off-the-shelf (COTS) engines and gearbox technology to entry-in-service (EIS) dates of 2025 and 2035 to assess the benefits of advanced technology on vehicle gross weight and fuel burn. Interim results were previously reported1. This technical paper extends that work and summarizes the final study results including additional engine and drive system study accomplishments. New vehicle sizing data is presented for engine performance at a single operating speed with a multispeed drive system. Modeling details for LCTR2 vehicle sizing and subject engine and drive sub-systems are presented as well. This study was conducted in support of NASA's Fundamental Aeronautics Program, Subsonic Rotary Wing Project.

Robuck, Mark↗

NASA NTRS2017

Experimental Investigation of Shrouding on Meshed Spur Gear Windage Power Loss

Windage power loss in high-speed gearboxes results in efficiency losses and increased heating due to drag on the gear teeth. Test results for meshed spur gear windage power loss are presented at ambient oil inlet temperatures, both with and without shrouding. The rate of windage power loss is observed to increase above a gear surface speed of 10,000 feet per minute (51 meters per second), similar to results presented in the literature. Shrouding is observed to become more effective above 15,000 feet per minute (76 meters per second), decreasing power loss by 10 percent at 25,000 feet per minute (127 meters per second). The need for gearbox oil drain slots limits the effectiveness of shrouding in reducing windage power loss. Windage power loss is observed to decrease with increasing gearbox temperatures and to increase with oil flow. Windage power losses for unshrouded meshed spur gears are 7 times greater than losses determined from unshrouded single spur gear tests. A 6- to 12-times increase in windage power loss is observed in the shrouded meshed spur gear data compared with shrouded single spur gear data. Based on this preliminary study, additional research is suggested to determine the effect of oil drain slot configurations, axial and radial shroud clearances, and higher gear surface speeds on windage power loss. Additional work is also suggested to determine the sensitivity of windage power loss to oil temperature and oil flow. Windage power loss for meshed spur gears tested in both the shrouded and unshrouded configurations is shown to be more than double versus windage power loss for the same spur gears run individually in the same shroud configurations. Further study of the physical processes behind these results is needed to optimize gearbox shrouds for minimum windage power loss.

drag↗

NASA NTRS2017

Experimental Investigation of Shrouding on Meshed Spur Gear Windage Power Loss

Windage power loss in high-speed gearboxes result in efficiency losses and increased heating due to drag on the gear teeth. Meshed spur gear windage power loss test results are presented at ambient oil inlet temperatures both with and without shrouding. The rate of windage power loss is observed to increase above 10,000 ft.min., gear surface speed, similar to results presented in the literature. Shrouding is observed to become more effective above 15,000 ft.min., decreasing power loss by 10 at 25,000 ft.min. The need for gearbox oil drain slots limits the effectiveness of shrouding on reducing windage power loss. Also, windage power loss is observed to decrease with increasing gearbox temperatures and to increase with oil flow. Windage power losses for the unshrouded meshed spur gears are 7x more than losses determined from unshrouded single spur gear tests. A 6x to 12x increase in windage power is observed comparing shrouded single spur gear data with shrouded meshed spur gear data. Based on this preliminary study additional research is suggested to determine the effect of oil drain slot configurations, axial and radial shroud clearances, and higher gear surface speeds on windage power loss. Additional work is also suggested to determine the sensitivity of windage power loss to oil temperature and oil flow. Windage power loss of meshed spur gears tested in both the shrouded and unshrouded configurations is shown to be more than double versus the same spur gears run individually in the same shroud configurations. Further study of the physical processes behind these results is needed for optimizing gearbox shrouds for minimum windage power loss.

gear↗

NASA NTRS2017

The Effectiveness of Shrouding on Reducing Meshed Spur Gear Power Loss - Test Results

Gearbox efficiency is reduced at high rotational speeds due to windage drag and viscous effects on rotating, meshed gear components. A goal of NASA aeronautics rotorcraft research is aimed at propulsion technologies that improve efficiency while minimizing vehicle weight. Specifically, reducing power losses to rotorcraft gearboxes would allow gains in areas such as vehicle payload, range, mission type, and fuel consumption. To that end, a gear windage rig has been commissioned at NASA Glenn Research Center to measure windage drag on gears and to test methodologies to mitigate windage power losses. One method used in rotorcraft gearbox design attempts to reduce gear windage power loss by utilizing close clearance walls to enclose the gears in both the axial and radial directions. The close clearance shrouds result in reduced drag on the gear teeth, and reduced power loss. For meshed spur gears, the shrouding takes the form of metal side plates and circumferential metal sectors. Variably positioned axial and radial shrouds are incorporated in the NASA rig to study the effect of shroud clearance on gearbox power loss. A number of researchers have given experimental and analytical results for single spur gears, with and without shrouding. Shrouded meshed spur gear test results are sparse in the literature. Windage tests were run at NASA Glenn using meshed spur gears at four shroud configurations: unshrouded, shrouded (max. axial, max radial), and two intermediate shrouding conditions. Results are compared to available meshed spur gear power loss data analyses as well as single spur gear data/analyses. Recommendations are made for future work.

power loss↗

NASA NTRS2017

The Effectiveness of Shrouding on Reducing Meshed Spur Gear Power Loss Test Results

Gearbox efficiency is reduced at high rotational speeds due to windage drag and viscous effects on rotating, meshed gear components. A goal of NASA aeronautics rotorcraft research is aimed at propulsion technologies that improve efficiency while minimizing vehicle weight. Specifically, reducing power losses to rotorcraft gearboxes would allow gains in areas such as vehicle payload, range, mission type, and fuel consumption. To that end, a gear windage rig has been commissioned at NASA Glenn Research Center to measure windage drag on gears and to test methodologies to mitigate windage power losses. One method used in rotorcraft gearbox design attempts to reduce gear windage power loss by utilizing close clearance walls to enclose the gears in both the axial and radial directions. The close clearance shrouds result in reduced drag on the gear teeth and reduced power loss. For meshed spur gears, the shrouding takes the form of metal side plates and circumferential metal sectors. Variably positioned axial and radial shrouds are incorporated in the NASA rig to study the effect of shroud clearance on gearbox power loss. A number of researchers have given experimental and analytical results for single spur gears, with and without shrouding. Shrouded meshed spur gear test results are sparse in the literature. Windage tests were run at NASA Glenn using meshed spur gears at four shroud configurations: unshrouded, shrouded (max. axial, max. radial), and two intermediate shrouding conditions. Results are compared to available meshed spur gear power loss data analyses as well as single spur gear data analyses.

windage↗