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Precision electromechanical power wrench applies a given amount of torque to a series of fasteners. It uses a commercially available dc permanent magnet torque motor with a current-controllable torque output and torque value indicator designed to the principles of human engineering.
Permanent magnet torque generator reaction torque effect in precision gyros and accelerometers
The GEOS-1 general circulation model has been used to compute atmospheric torques on the oceans and solid Earth for the period 1980-1995. The time series for the various torque components have been analyzed by means of Fourier transform techniques. It was determined that the wind stress torque over land is more powerful than the wind stress torque over water by 55%, 42%, and 80% for the x, y, and z components respectively. This is mainly the result of power in the high frequency range. The pressure torques due to polar flattening, equatorial ellipticity, marine geoid, and continental orography were computed. The orographic or "mountain torque" components are more powerful than their wind stress counterparts (land plus ocean) by 231% (x), 191% (y), and 77% (z). The marine pressure torques due to geoidal undulations are much smaller than the orographic ones, as expected. They are only 3% (x), 4% (y), and 5% (z) of the corresponding mountain torques. The geoidal pressure torques are approximately equal in magnitude to those produced by the equatorial ellipticity of the Earth. The pressure torque due to polar flattening makes the largest contributions to the atmospheric torque budget. It has no zonal component, only equatorial ones. Most of the power of the latter, between 68% and 69%, is found in modes with periods under 15 days. The single most powerful mode has a period of 361 days. The gravitational torque ranks second in power only to the polar flattening pressure torque. Unlike the former, it does produce a zonal component, albeit much smaller (1%) than the equatorial ones. The gravitational and pressure torques have opposite signs, therefore, the gravitational torque nullifies 42% of the total pressure torque. Zonally, however, the gravitational torque amounts to only 6% of the total pressure torque. The power budget for the total atmospheric torque yields 7595 and 7120 Hadleys for the equatorial components and 966 Hadleys for the zonal. The x-component exhibits a large mean value (1811 H), mainly the result of polar flattening pressure torque acting on the ocean surfaces. Atmospheric torque modes with periods of 408, 440, and 476 days appear in the spectrum of the equatorial components.
The GEOS-1 general circulation model has been used to compute atmospheric torques on the oceans and solid Earth for the period 1980-1995. The time series for the various torque components have been analyzed by means of Fourier transform techniques. It was determined that the wind stress torque over land is more powerful than the wind stress torque over water by 55\%, 42\%, and 80\t for the x, y, and z components respectively. This is mainly the result of power in the high frequency range. The pressure torques due to polar flattening, equatorial ellipticity, marine geoid, and continental orography were computed. The orographic or "mountain torque" components are more powerful than their wind stress counterparts (land plus ocean) by 231\% (x), 191\% (y), and 77\% (z). The marine pressure torques due to geoidal undulations are much smaller than the orographic ones, as expected. They are only 3\% (x), 4\% (y), and 5\% (z) of the corresponding mountain torques. The geoidal pressure torques are approximately equal in magnitude to those produced by the equatorial ellipticity of the Earth. The pressure torque due to polar flattening makes the largest contributions to the atmospheric'torque budget. It has no zonal component, only equatorial ones. Most of the power of the latter, between 68\% and 69 %, is found in modes with periods under 15 days. The single most powerful mode has a period of 361 days. The gravitational torque ranks second in power only to the polar flattening pressure torque. Unlike the former, it does produce a zonal component, albeit much smaller (1\ ) than the equatorial ones. The gravitational and pressure torques have opposite signs, therefore, the gravitational torque nullifies 42\% of the total pressure torque. Zonally, however, the gravitational torque amounts to only 6\% of the total pressure torque. The power budget for the total atmospheric torque yields 7595 and 7120 Hadleys for the equatorial components and 966 Hadleys for the zonal. The x-component exhibits a large mean value (1811 H), mainly the result of polar flattening pressure torque acting on the ocean surfaces. Atmospheric torque modes with periods of 408, 440, and 476 days appear in the spectrum of the equatorial components.
During design of the SDO Science and Inertial mode PID controllers, the decision was made to disable the integral torque whenever system stability was in question. Three different schemes were developed to determine when to disable or enable the integral torque, and a trade study was performed to determine which scheme to implement. The trade study compared complexity of the control logic, risk of not reenabling the integral gain in time to reject steady-state error, and the amount of integral torque space used. The first scheme calculated a simplified Routh criterion to determine when to disable the integral torque. The second scheme calculates the PD part of the torque and looked to see if that torque would cause actuator saturation. If so, only the PD torque is used. If not, the integral torque is added. Finally, the third scheme compares the attitude and rate errors to limits and disables the integral torque if either of the errors is greater than the limit. Based on the trade study results, the third scheme was selected. Once it was decided when to disable the integral torque, analysis was performed to determine how to disable the integral torque and whether or not to reset the integrator once the integral torque was reenabled. Three ways to disable the integral torque were investigated: zero the input into the integrator, which causes the integral part of the PID control torque to be held constant; zero the integral torque directly but allow the integrator to continue integrating; or zero the integral torque directly and reset the integrator on integral torque reactivation. The analysis looked at complexity of the control logic, slew time plus settling time between each calibration maneuver step, and ability to reject steady-state error. Based on the results of the analysis, the decision was made to zero the input into the integrator without resetting it. Throughout the analysis, a high fidelity simulation was used to test the various implementation methods.
All spacecraft orbiting in a low earth orbit (LEO) experience external torques due to environmental effects. Examples of these torques include those induced by aerodynamic, gravity-gradient, and solar forces. It is the gravity-gradient and aerodynamic torques that produce the greatest disturbances to the attitude of a spacecraft in LEO, and large asymmetric spacecraft, such as the space station, are affected to a greater degree because the magnitude of the torques will, in general, be larger in proportion to the moments of inertia. If left unchecked, these torques would cause the attitude of the space station to oscillate in a complex manner and the resulting motion would destroy the micro-gravity environment as well as prohibit the orbiter from docking. The application of control torques will maintain the proper attitude, but the controllers have limited momentum capacity. When any controller reaches its limit, propellant must then be used while the device is reset to a zero or negatively-biased momentum state. Consequently, the rate at which momentum is accumulated is a significant factor in the amount of propellant used and the frequency of resupply necessary to operate the station. A torque profile in which the area curve for a positive torque is not equal to the area under the curve for a negative torque is 'biased,' and the consequent momentum build-up about that axis is defined as secular momentum because it continues to grow with time. Conversely, when the areas are equal, the momentum is cyclic and bounded. A Torque Equilibrium Attitude (TEA) is thus defined as an attitude at which the external torques 'balance' each other as much as possible, and which will result in lower momentum growth in the controllers. Ideally, the positive and negative external moments experienced by a spacecraft at the TEA would exactly cancel each other out and small cyclic control torques would be required only for precise attitude control. Over time, the only momentum build-up in the controllers would be due to electro-mechanical losses within the device. However, the atmospheric torques are proportional to the density of the atmosphere and the density varies with the orbital position, time of day, time of year, and the solar cycle. In addition, there are unmodeled disturbances and uncertainties in the mass and inertias. Therefore, there is no constant attitude that will completely balance the environmental torques and the dynamic TEA cannot be solved in closed form. The objective of this research was to determine a method to calculate a dynamic TEA such that the rate of momentum build-up in the controllers would be minimized and to implement this method in the MATRIX(x) simulation software by Integrated Systems, Inc.
Near Earth Asteroid Scout (NEA Scout) was a mission to test solar sail propulsion for orbital transfer from cislunar space to flyby and image an asteroid. Had it succeeded, one of the mission goals was to characterize the solar torque on the sail to ensure successful attitude control for the orbit transfer and imaging the asteroid. The simulation used to develop the flight attitude control software uses the generalized model for solar sails, a tensor equation of the forces and torques on sails of arbitrary shape. Rios-Reyes and Scheeres developed a general process to update the torque tensor coefficients using estimates of sail torque over a range of directions to the sun. Their process was adapted and implemented for the specific case of NEA Scout using spacecraft telemetry collected during sail characterization maneuvers in combination with simulation models and parameters. The NEA Scout maneuvers were limited to the operating range of the mission and constraints of the control hardware and allowed safe testing of each attitude before proceeding to the next. The NEA Scout reaction wheel speeds are used to measure accumulated momentum, while the Active Mass Translator (AMT) position is used to subtract out the torque from the center of mass crossed with the sail force and isolate the torque from only the sail shape. The process was tested by running attitude control simulations of the characterization maneuvers, generating simulated telemetry, estimating the solar torques, then using a least squares estimating the solar torque coefficients using least-squares and then performing a least-squares fit to the solar torque tensor coefficients. These estimated coefficients were tested by evaluating the solar torques under the same conditions as the simulated telemetry and comparing to the true simulated torques. Solar force model updates can be performed separately by observing the effect of the sail on the trajectory, and the torque model can be refined using those solar force updates. This process met the needs of the NEA Scout mission and can be adapted to characterize the solar torque for other missions with different sails.
Near Earth Asteroid Scout (NEA Scout) was a mission to test solar sail propulsion for orbital transfer from cislunar space to flyby and image an asteroid. One of the goals of the mission was to characterize the solar torque on the sail to ensure successful attitude control for the orbit transfer and imaging the asteroid. The simulation used to develop the flight attitude control software uses the generalized model for solar sails, a tensor equation of the forces and torques on sails of arbitrary shape. Rios-Reyes and Scheeres developed a general process to update the torque tensor coefficients using estimates of sail torque over a range of directions to the sun. Their process was adapted and implemented for the specific case of NEA Scout using spacecraft telemetry collected during sail characterization maneuvers in combination with simulation models and parameters. The NEA Scout maneuvers were limited to the operating range of the mission and constraints of the control hardware and allowed safe testing of each attitude before proceeding to the next. The NEA Scout reaction wheel speeds are used to measure accumulated momentum, while the Active Mass Translator (AMT) position is used to subtract out the torque from the center of mass crossed with the sail force and isolate the torque from only the sail shape. The process was tested by running attitude control simulations of the characterization maneuvers, generating simulated telemetry, estimating the solar torques, then using a least squares estimating the solar torque coefficients using least-squares and then performing a least-squares fit to the solar torque tensor coefficients. These estimated coefficients were tested by evaluating the solar torques under the same conditions as the simulated telemetry and comparing to the true simulated torques. Solar force model updates can be performed separately by observing the effect of the sail on the trajectory, and the torque model can be refined using those solar force updates. This process met the needs of the NEA Scout mission and can be adapted to characterize the solar torque for other missions with different sails.
This invention comprises a torque drive mechanism utilizing axially translatable, mutually engageable transmission members having mating crown gears, driven and driving members with a three-element drive train being biased together by resilient means or by a fluid actuator system, the apparatus being operable to transmit a precisely controlled degree of torque to a driven member. The apparatus is applicable for use in hand tools and as a replacement for impact torque drivers, torque wrenches, motorized screw drivers, or the like, wherein the applied torque must be precisely controlled or limited. The bevel torque drive includes a drive gear which is axially displaceable and rotatable within cylindrical driver housing, a rotatable intermediate gear, and an output gear. Key rotationally secures displaceable gear with respect to input shaft but permits axial movement therebetween. A thrust bearing is preferably connected to the lower end of shaft for support to reduce play and friction between shaft and a transmission joint disc during rotation of the gear train. Coaxially mounted coiled spring is footed against displaceable gear for biasing the displaceable gear toward and into engagement with the intermediate gear for driving intermediate gear and output gear. Torque control is achieved by the use of straight or spiral beveled gears which are of configurations adapted to withdraw from mutual engagement upon the torque exceeding a predetermined limit. The novel, advantageous features of the invention include the configuration of the mating, crown gear sets and the axially translatable, slidable drive gear. The mechanism is capable of transmitting a high degree of torque within a narrow, compact transmission housing. The compact size and narrow, elongated configuration of the housing is particularly applicable for use in hand tools and in multiple torque driver mechanisms in which it is necessary to drive multiple fasteners which are located in close proximity. Prior torque drivers such as 'click-type' torque wrenches do not actually limit torque application but only provide an audible warning that the limit has been reached.
A tool makes it possible to couple a torque wrench to an externally knurled, internally threaded, round cable connector. The purpose served by the tool is to facilitate the tightening of multiple such connectors (or the repeated tightening of the same connector) to repeatable torques. The design of a prior cable-connector/ torque-wrench coupling tool provided for application of the torque-wrench jaws to a location laterally offset from the axis of rotation of the cable connector, making it necessary to correct the torque reading for the offset. Unlike the design of the prior tool, the design of the present tool provides for application of the torque-wrench jaws to a location on the axis of rotation, obviating correction of the torque reading for offset. The present tool (see figure) consists of a split collet containing a slot that provides clearance for inserting and bending the cable, a collet-locking sleeve, a collet-locking nut, and a torque-wrench adaptor that is press-fit onto the collet. Once the collet is positioned on the cable connector, the collet-locking nut is turned to force the collet-locking sleeve over the collet, compressing the collet through engagement of tapered surfaces on the outside of the collet and the inside of the locking sleeve. Because the collet is split and therefore somewhat flexible, this compression forces the collet inward to grip the connector securely. The torque wrench is then applied to the torque-wrench adaptor in the usual manner for torquing a nut or a bolt.
Direct current (dc) motors are used in terrestrial photovoltaic (PV) systems such as in water-pumping systems for irrigation and water supply. Direct current motors may also be used for space applications. Simple and low weight systems including dc motors may be of special interest in space where the motors are directly coupled to the solar cell array (with no storage). The system will operate only during times when sufficient insolation is available. An important performance characteristic of electric motors is the starting to rated torque ratio. Different types of dc motors have different starting torque ratios. These ratios are dictated by the size of solar cell array, and the developed motor torque may not be sufficient to overcome the load starting torque. By including a maximum power point tracker (MPPT) in the PV system, the starting to rated torque ratio will increase, the amount of which depends on the motor type. The starting torque ratio is calculated for the permanent magnet, series and shunt excited dc motors when powered by solar cell arrays for two cases: with and without MPPT's. Defining a motor torque magnification by the ratio of the motor torque with an MPPT to the motor torque without an MPPT, a magnification of 3 was obtained for the permanent magnet motor and a magnification of 7 for both the series and shunt motors. The effect of the variation of solar insolation on the motor starting torque was covered. All motor types are less sensitive to insolation variation in systems including MPPT's as compared to systems with MPPT's. The analysis of this paper will assist the PV system designed to determine whether or not to include an MPPT in the system for a specific motor type.
Methods and apparatus are provided for a torque driver including a displaceable gear to limit torque transfer to a fastener at a precisely controlled torque limit. A biasing assembly biases a first gear into engagement with a second gear for torque transfer between the first and second gear. The biasing assembly includes a pressurized cylinder controlled at a constant pressure that corresponds to a torque limit. A calibrated gage and valve is used to set the desired torque limit. One or more coiled output linkages connect the first gear with the fastener adaptor which may be a socket for a nut. A gear tooth profile provides a separation force that overcomes the bias to limit torque at the desired torque limit. Multiple fasteners may be rotated simultaneously to a desired torque limit if additional output spur gears are provided. The torque limit is adjustable and may be different for fasteners within the same fastener configuration.
Methods and apparatus are provided for a torque driver including a displaceable gear to limit torque transfer to a fastener at a precisely controlled torque limit. A biasing assembly biases a first gear into engagement with a second gear for torque transfer between the first and second gear. The biasing assembly includes a pressurized cylinder controlled at a constant pressure that corresponds to a torque limit. A calibrated gage and valve is used to set the desired torque limit. One or more coiled output linkages connect the first gear with the fastener adaptor which may be a socket for a nut. A gear tooth profile provides a separation force that overcomes the bias to limit torque at the desired torque limit. Multiple fasteners may be rotated simultaneously to a desired torque limit if additional output spur gears are provided. The torque limit is adjustable and may be different for fasteners within the same fastener configuration.
Tests of a 167 Kilowatt (224 Horsepower) split torque face gearbox were performed by the Boeing Company in Mesa, Arizona, while working under a Defense Advanced Research Projects Agency (DARPA) Technology Reinvestment Program (TRP). This paper provides a summary of these cooperative tests, which were jointly funded by Boeing and DARPA. Design, manufacture and testing of the scaled-power TRP proof-of-concept (POC) split torque gearbox followed preliminary evaluations of the concept performed early in the program. The split torque tests were run using 200 N-m (1767 in-lbs) torque input to each side of the transmission. During tests, two input pinions were slow rolled while in mesh with the two face gears. Two idler gears were also used in the configuration to recombine torque near the output. Resistance was applied at the output face gear to create the required loading conditions in the gear teeth. A system of weights, pulleys and cables were used in the test rig to provide both the input and output loading. Strain gages applied in the tooth root fillets provided strain indication used to determine torque splitting conditions at the input pinions. The final two pinion-two idler tests indicated 52% to 48% average torque split capabilities for the two pinions. During the same tests, a 57% to 43% average distribution of the torque being recombined to the upper face gear from the lower face gear was measured between the two idlers. The POC split torque tests demonstrated that face gears can be applied effectively in split torque rotorcraft transmissions, yielding good potential for significant weight, cost and reliability improvements over existing equipment using spiral bevel gearing.
In aerospace design, where minimizing weight is always a priority, achieving the full capacity from fasteners is essential. To do so, the initial bolt preload must be maximized. The benefits of high preload are well documented and include improved fatigue resistance, a stiffer joint, and resistance to loosening. But many factors like elastic interactions and embedment tend to lower the initial preload placed on the bolt. These factors provide additional motivation to maximize the initial preload. But, to maximize bolt preload, you must determine what torque to apply. Determining this torque is greatly complicated by the large preload scatter generally seen with torque control. This paper presents a detailed methodology for generating limit torques for threaded fasteners. This methodology accounts for the large scatter in preload found with torque control, and therefore, addresses the statistical nature of the problem. It also addresses prevailing torque, a feature common in aerospace fasteners. Although prevailing torque provides a desired locking feature, it can also increase preload scatter. In addition, it can limit the amount of preload that can be generated due to the torsion it creates in the bolt. This paper discusses the complications of prevailing torque and how best to handle it. A wide range of torque-tension bolt testing was conducted in support of this research. The results from this research will benefit the design engineer as well as analyst involved in the design of bolted joints, leading to better, more optimized structural designs.
Abstract Accurate knowledge of the mechanical loads of wind turbine gearboxes has become essential in modern, highly loaded gearbox designs, as maintaining or even improving gearbox reliability with increasing torque density demands is proving to be challenging. Unfortunately, the traditional method of measuring dynamic mechanical torque using strain gauges placed on the outer surface of a rotating shaft and transmitting the resulting signal is unsuitable for serial deployment due to technical and economic constraints. An alternative method based on fiber-optic strain sensors placed on the stationary outer surface of the gearbox ring gear has been proposed. Like shaft torsion, the radial deformation of the ring gear is proportionate to the rotor torque. Placing the sensors on a stationary component is a cost-effective alternative for serial implementation because the need for complex and expensive data transfer via wireless transmission or a slip ring is eliminated. In this paper, we present the results of an extensive field experiment conducted to evaluate the torque measurement accuracy of this novel sensing solution installed on the gearbox of a Gamesa G97 2-MW wind turbine at the National Renewable Energy Laboratory’s Flatirons Campus. Torque measurements derived from fiber-optic strain sensors placed on the ring gear of the planetary stage are compared to conventional torque measurements from strain gauges placed on the main shaft. Two different torque estimation data processing methods were evaluated, with the method based on operational deflection shapes providing the most accurate results with an average normalized root mean square error below 0.7% for a load revolution distribution analysis. The effect of operating conditions on the torque estimate was also investigated, and the third planet-passing operational deflection shape was found to be the least sensitive to nontorque load-related effects. The fiber-optic strain sensors’ successful operation during the complete test campaign has demonstrated a robust and accurate solution for fleet-wide enhanced gearbox remaining useful life estimation.
The topological semimetal CrPt 3 has potential for generating unconventional spin torques due to its ferrimagnetic ordering, topological band structure, and high anomalous Hall effect. CrPt 3 exhibits ferrimagnetic behavior only in its chemically ordered phase and is paramagnetic in its chemically disordered phase. By controlling the growth and annealing temperatures, we prepare epitaxial films of both chemically ordered and chemically disordered phases of CrPt 3 , allowing us to investigate the effect of magnetic ordering on unconventional-torque generation. We use angle-dependent spin-torque-ferromagnetic-resonance and second-harmonic Hall measurements to probe the spin torques generated from epitaxial CrPt 3 in CrPt 3 /Cu/Ni 81 Fe 19 heterostructures. With current applied along specific directions with respect to the crystal order, we reveal unconventional spin torques in both ordered and disordered films. When current flows parallel to the [$1\bar{1}1$] and [ $\bar{1}11$] directions, we observe an unconventional fieldlike torque that is opposite in sign for the two directions. Finally, our calculations reveal that this unconventional torque originates from an indirect nonlocal spin-orbit torque due to spin scattering at the CrPt 3 /Cu interface, in addition to symmetry breaking at this interface.
Accurate knowledge of the mechanical loads of wind turbine gearboxes has become essential in modern, highly loaded gearbox designs, as maintaining or even improving gearbox reliability with increasing torque density demands is proving to be challenging. Unfortunately, the traditional method of measuring dynamic mechanical torque using strain gauges placed on the outer surface of a rotating shaft and transmitting the resulting signal is unsuitable for serial deployment due to technical and economic constraints. An alternative method based on fiber-optic strain sensors placed on the stationary outer surface of the gearbox ring gear has been proposed. Like shaft torsion, the radial deformation of the ring gear is proportionate to the rotor torque. Placing the sensors on a stationary component is a cost-effective alternative for serial implementation because the need for complex and expensive data transfer via wireless transmission or a slip ring is eliminated. In this paper, we present the results of an extensive field experiment conducted to evaluate the torque measurement accuracy of this novel sensing solution installed on the gearbox of a Gamesa G97 2-MW wind turbine at the National Renewable Energy Laboratory's Flatirons Campus. Torque measurements derived from fiber-optic strain sensors placed on the ring gear of the planetary stage are compared to conventional torque measurements from strain gauges placed on the main shaft. Two different torque estimation data processing methods were evaluated, with the method based on operational deflection shapes providing the most accurate results with an average normalized root mean square error below 0.7% for a load revolution distribution analysis. The effect of operating conditions on the torque estimate was also investigated, and the third planet-passing operational deflection shape was found to be the least sensitive to nontorque load-related effects. The fiber-optic strain sensors' successful operation during the complete test campaign has demonstrated a robust and accurate solution for fleet-wide enhanced gearbox remaining useful life estimation.