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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 19 records
All sourcesNASA NTRSDOE OSTI
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 NTRS2008

Improved Descent-Rate Limiting Mechanism

An improved braking cable-payout mechanism has been developed. Whereas other such mechanisms operate at payout speeds that vary with the length of payout, this mechanism operates at approximately constant payout speed, regardless of the length of cord that has already been paid out. The present mechanism includes a spool, a capstan assembly, and centrifugal brakes. The spool is used to store the cord and, unlike in the prior mechanism, is not involved in the primary braking function. That is, the spool operates in such a way that the cord is unwound from the spool at low tension. The spool is connected to the rest of the mechanism through a constant- torque slip clutch. The clutch must slip in order to pay out the cord. As the cord leaves the spool, it passes into the capstan assembly, wherein its direction is changed by use of the first of three idler sheaves and it is then routed into the first of three grooves on a capstan. After completing less than a full circle in the first groove, the cord passes over the second idler sheave, which is positioned to enable the cord to make the transition to the second groove on the capstan. Similarly, a third idler sheave enables the cord to make the transition to the third groove on the capstan. After traveling less than a full circle in the third groove, the cord leaves the capstan along the payout path. The total wrap angle afforded by this capstan-and-idler arrangement is large enough to prevent slippage between the cord and the capstan. The capstan is connected to a shaft that, in turn, is connected to a centrifugal brake. Hence, the effective payout radius, for purposes of braking, is not the varying radius of the remaining cord on the spool but, rather, the constant radius of the grooves in the capstan. The payout speed is determined primarily by this radius and by the characteristics of the centrifugal brake. Therefore, the payout speed is more nearly constant in this mechanism than in the prior mechanism.

Rivellini, Tommaso P.↗
NASA NTRS2013

Comprehensive Modeling and Analysis of Rotorcraft Variable Speed Propulsion System With Coupled Engine/Transmission/Rotor Dynamics

This project develops comprehensive modeling and simulation tools for analysis of variable rotor speed helicopter propulsion system dynamics. The Comprehensive Variable-Speed Rotorcraft Propulsion Modeling (CVSRPM) tool developed in this research is used to investigate coupled rotor/engine/fuel control/gearbox/shaft/clutch/flight control system dynamic interactions for several variable rotor speed mission scenarios. In this investigation, a prototypical two-speed Dual-Clutch Transmission (DCT) is proposed and designed to achieve 50 percent rotor speed variation. The comprehensive modeling tool developed in this study is utilized to analyze the two-speed shift response of both a conventional single rotor helicopter and a tiltrotor drive system. In the tiltrotor system, both a Parallel Shift Control (PSC) strategy and a Sequential Shift Control (SSC) strategy for constant and variable forward speed mission profiles are analyzed. Under the PSC strategy, selecting clutch shift-rate results in a design tradeoff between transient engine surge margins and clutch frictional power dissipation. In the case of SSC, clutch power dissipation is drastically reduced in exchange for the necessity to disengage one engine at a time which requires a multi-DCT drive system topology. In addition to comprehensive simulations, several sections are dedicated to detailed analysis of driveline subsystem components under variable speed operation. In particular an aeroelastic simulation of a stiff in-plane rotor using nonlinear quasi-steady blade element theory was conducted to investigate variable speed rotor dynamics. It was found that 2/rev and 4/rev flap and lag vibrations were significant during resonance crossings with 4/rev lagwise loads being directly transferred into drive-system torque disturbances. To capture the clutch engagement dynamics, a nonlinear stick-slip clutch torque model is developed. Also, a transient gas-turbine engine model based on first principles mean-line compressor and turbine approximations is developed. Finally an analysis of high frequency gear dynamics including the effect of tooth mesh stiffness variation under variable speed operation is conducted including experimental validation. Through exploring the interactions between the various subsystems, this investigation provides important insights into the continuing development of variable-speed rotorcraft propulsion systems.

DeSmidt, Hans A.↗
DOE OSTI2021

Stage 2 Sub-Scale Magnetic Gear

The goal of this project is to design, fabricate, and test a hermetically sealed 50 kilowatt (kW) multistage magnetically geared generator (MGG). In order to reduce risk, a sub-scale 5kW multistage MGG was first built. This project will benefit MHK device developers by providing an MHK PTO that overcomes the reliability concerns of the mechanical gears and the sizing constraints of the direct-drive generators. 7.67:1 gear ratio magnetic gear with a measured peak torque of 1796 N-m

16 TIDAL AND WAVE POWER↗
NASA NTRS1979

Advanced teleoperators

Advanced teleoperators are discussed, with emphasis on the remote manipulation system designed to perform such actions as grasping, orienting, moving, placing, and inserting objects. Geometrical performance dimensions are considered, indicating that a manipulator is limited to three-orders-of-magnitude ratio of workspace extension to positioning accuracy. The control system is examined, showing that a manipulative task requires coordination of several joints, with the relationship between the task definers and the joint variables given by complex trigonometrical transformations. Control modes developed in the last 30 years are noted, including program controlled industrial 'robots' which can endlessly repeat a fixed sequence of motions without operator intervention, and the sensor-referenced/computer-controlled mode manipulators. Advanced proximity sensor systems are taken into account, with emphasis on the applications of the force-torque and slip models. The proximity sensor system for the shuttle-size manipulator is described.

Bejczy, A. K.↗
NASA NTRS1980

High-performance, multiroller traction drive

Fixed-speed-ratio traction drive (NASVYTRAC) has been developed that can transmit high power across large speed ratio using compact cluster of rollers. Traction drive transmits power without gear teeth, through shear forces on thin lubricant film that separates drive rollers. Automatic loading mechanism regulates normal load between rollers so sufficient normal load is present to transmit required torque without slip or overloading.

Lowenthal, S.↗
DOE OSTI2021

Tool-workpiece stick-slip conditions and their effects on torque and heat generation rate in the friction stir welding

Friction stir welding (FSW) has found increased applications in automotive and aerospace industries due to its advantages of solid-state bonding, no fusion and melting, and versatility in various working conditions and material combinations. However, the relationship among processing parameters, material properties, and bonding extent and fidelity remains largely empirical, primarily because of the lack of the mechanistic understanding of the tool-workpiece frictional behavior that affects our subsequent understanding of microstructural evolution and interface bonding formation. While the tool-workpiece stick-slip condition is believed to dictate the resulting torque and heat generation rate during the welding process, it remains rare and elusive to conduct a quantitative experimental measurement of such interfacial field. On the other hand, numerical simulations based on Computational Fluid Dynamics (CFD) rely on ad hoc assumptions of interfacial pressure and shear-stress conditions, but predictions can only be validated via the medium- and far-range temperature field which is known to be insensitive to the interfacial frictional behavior. This work first presents a comparison among two CFD-based simulation methodologies and the Coupled Eulerian Lagrangian (CEL) model in finite element method, the last of which uses the Coulomb friction so that the stick-slip is naturally developed. Based on the Hill-Bower similarity relationship in the contact analysis, an analytical model is developed here to prove why a constant stick-slip fraction will be developed in the steady state, to correlate the stick-slip fraction to processing parameters such as the tool spin rate, and further to derive dimensionless functions for torque and heat-generation-rate predictions. Pros and cons of various numerical approaches in predicting stick-slip are discussed, and our analytical model has been found to agree well with our numerical simulation and literature experimental results. These analyses provide the critical strain-rate and temperature fields that are needed for the bonding analysis in our future work.

36 MATERIALS SCIENCE↗
NASA NTRS1933

Measurement of the Differential and Total Thrust and Torque of Six Full-Scale Adjustable-Pitch Propellers

Force measurements giving total thrust and torque, and propeller slip stream surveys giving differential thrust and torque were simultaneously made on each of six full-scale propellers in the 20-foot propeller-research tunnel of the National Advisory Committee for Aeronautics. They were adjustable-pitch metal propellers 9.5 feet in diameter; three had modified Clark Y blade sections and three had modified RAF-6 blade sections. This report gives the differential thrust and torque and the variation caused by changing the propeller tip speed and the pitch setting. The total thrust and torque obtained from integration of the thrust and torque distribution curves are compared with those obtained by direct force measurements.

Stickle, George W↗
NASA NTRS1982

Vertical axis wind turbine drive train transient dynamics

Start up of a vertical axis wind turbine causes transient torque oscillations in the drive train with peak torques which may be over two and one half times the rated torque of the turbine. A computer code, based on a lumped parameter model of the drive train, was developed and tested for the low cost 17 meter turbine; the results show excellent agreement with field data. The code was used to predict the effect of a slip clutch on transient torque oscillations. It was demonstrated that a slip clutch located between the motor and brake can reduce peak torques by thirty eight percent.

Clauss, D. B.↗
NASA NTRS1989

Signal and power roll ring testing update

The development of the roll ring as a long-life, low-torque alternative to the slip ring is discussed. A roll ring consists of one or more circular flexures captured by their own spring force in the annular space between two concentric conductors or contact rings. The advantages of roll rings over other types of electrical transfer devices are: extremely low drag torque, high transfer efficiencies in high-power configurations, extremely low wear debris generation, long life, and low weight for high-power applications.

Smith, Dennis W.↗
NASA NTRS1977

Displays for supervisory control of manipulators

The problem of displaying information generated by sensors attached to the terminal device of a remotely controlled manipulator is considered. The sensors under consideration are proximity, force-torque, tactile and slip-page sensors. The paper describes and evaluates several examples that have been implemented in the JPL teleoperator project using audio and graphic displays of information generated by four proximity sensors attached to a manipulator end effector. Design schemes are also discussed related to the display of information generated by a six-dimensional force-torque sensor, a multipoint proportional tactile sensor, and a directional slippage sensor. The paper concludes with a discussion of future integrated displays of visual (TV) and handbased sensor information.

Bejczy, A. K.↗
NASA NTRS1981

Tests of an overrunning clutch in a wind turbine

An overrunning clutch that slipped freely under reverse torque was tested in the drive train of the Mod-0 wind turbine. In low variable wind conditions, the clutch engaged and disengaged smoothly without perturbation or oscillations. The clutch permitted the generator to be connected to the line using a relay instead of an automatic synchronizer. The alternator was connected to the line when the rpm reached 95% of synchronous speed and it motored to synchronous speed in about 0.15 seconds with a momentary power spike of 50 kW. The performance of the clutch was the same with and without the fluid coupling. The ideal power with the clutch was 5 to 7 kW compared to up to 50 kW without the clutch. The overrunning clutch merits consideration in future wind turbine designs as a means of simplifying the control system, increasing energy capture, and increasing the life of blades and electrical switch gear.

Seidel, R. C.↗
NASA NTRS1974

Phase-locked servo system

A phase lock servo system is described for synchronizing the rotation of a slip ring assembly with the rotation of an air bearing table so that a minimum of torque will be imparted through cables extending from the slip ring assembly to the air bearing table as such is rotated. The system includes two servo loops. The first servo loop includes a rate gyroscope carried on the air bearing table which generates a signal through a summing junction to be compared with a signal coming from a tachometer coupled to the slip ring assembly. The corrective signal is applied to a torque motor for rotating the slip ring assembly. The second servo loop includes a pair of photo detector cells which generate pulses responsive to the rotation of the air bearing table and slip ring assembly which are fed through a phase detector, and a variable gain amplifier to the summing junction circuit to provide a fine adjustment for rotating the slip ring assembly.

Burdin, C.↗
NASA NTRS1974

Variable-frequency inverter controls torque, speed, and braking in ac induction motors

Dc to ac inverter provides optimum frequency and voltage to ac induction motor, in response to different motor-load and speed requirements. Inverter varies slip frequency of motor in proportion to required torque. Inverter protects motor from high current surges, controls negative slip to apply braking, and returns energy stored in momentum of load to dc power source.

Nola, F. J.↗
NASA NTRS1992

A 23.2:1 ratio, 300-watt, 26 N-m output torque, planetary roller-gear robotic transmission: Design and evaluation

The design philosophy and measurements performed on a new roller-gear transmission prototype for a robotic manipulator are described. The design incorporates smooth rollers in a planetary configuration integrated with conventional toothed gears. The rollers were designed to handle low torque with low backlash and friction while the complementary gears support higher torques and prevent accumulated creep or slip of the rollers. The introduction of gears with finite numbers of teeth to function in parallel with the rollers imposes severe limits on available designs. Solutions for two-planet row designs are discussed. A two-planet row, four-planet design was conceived, fabricated, and tested. Detailed calculations of cluster geometry, gear stresses, and gear geometry are given. Measurement data reported here include transmission linearity, static and dynamic friction, inertia, backlash, stiffness, and forward and reverse efficiency. Initial test results are reported describing performance of the transmission in a servomechanism with torque feedback.

Newman, Wyatt S.↗
NASA NTRS2006

Platform for Testing Robotic Vehicles on Simulated Terrain

The variable terrain tilt platform (VTTP) is a means of providing simulated terrain for mobility testing of engineering models of the Mars Exploration Rovers. The VTTP could also be used for testing the ability of other robotic land vehicles (and small vehicles in general) to move across terrain under diverse conditions of slope and surface texture, and in the presence of obstacles of various sizes and shapes. The VTTP consists mostly of a 16-ft-(4.88-m)-square tilt table. The tilt can be adjusted to any angle between 0 (horizontal) and 25 . The test surface of the table can be left bare; can be covered with hard, high-friction material; or can be covered with sand, gravel, and/or other ground-simulating material or combination of materials to a thickness of as much as 6 in. (approx. 15 cm). Models of rocks, trenches, and other obstacles can be placed on the simulated terrain. For example, for one of the Mars- Rover tests, a high-friction mat was attached to the platform, then a 6-in.- ( 15 cm) deep layer of dry, loose beach sand was deposited on the mat. The choice of these two driving surface materials was meant to bound the range of variability of terrain that the rover was expected to encounter on the Martian surface. At each of the different angles at which tests were performed, for some of the tests, rocklike concrete obstacles ranging in height from 10 to 25 cm were placed in the path of the rover (see figure). The development of the VTTP was accompanied by development of a methodology of testing to characterize the performance and modes of failure of a vehicle under test. In addition to variations in slope, ground material, and obstacles, testing typically includes driving up-slope, down-slope, cross-slope, and at intermediate angles relative to slope. Testing includes recording of drive-motor currents, wheel speeds, articulation of suspension mechanisms, and the actual path of the vehicle over the simulated terrain. The collected data can be used to compute curves that summarize torque, speed, power-demand, and slip characteristics of wheels during the traverse.

Lindemann, Randel↗
NASA NTRS1996

The design, development and qualification of a lightweight antenna pointing mechanism

This paper describes the design, development, and qualification of a new lightweight and compact Antenna Pointing Mechanism (APM). The APM was specially designed to meet the stringent mass, envelope, and environmental requirements of OFFEQ experimental satellite. During the development phase, some problems were encountered with the brushless DC motors, slip ring contact resistance, and bearing drag torque. All of these problems were resolved, and two APM units have been operating successfully in orbit since April, 1995.

Shmulevitz, M.↗