ALBERT

Description: An improved method of calibrating a wind-tunnel force balance involves the use of a unique load application system integrated with formal experimental design methodology. The Single-Vector Force Balance Calibration System (SVS) overcomes the productivity and accuracy limitations of prior calibration methods. A force balance is a complex structural spring element instrumented with strain gauges for measuring three orthogonal components of aerodynamic force (normal, axial, and side force) and three orthogonal components of aerodynamic torque (rolling, pitching, and yawing moments). Force balances remain as the state-of-the-art instrument that provide these measurements on a scale model of an aircraft during wind tunnel testing. Ideally, each electrical channel of the balance would respond only to its respective component of load, and it would have no response to other components of load. This is not entirely possible even though balance designs are optimized to minimize these undesirable interaction effects. Ultimately, a calibration experiment is performed to obtain the necessary data to generate a mathematical model and determine the force measurement accuracy. In order to set the independent variables of applied load for the calibration 24 NASA Tech Briefs, October 2003 experiment, a high-precision mechanical system is required. Manual deadweight systems have been in use at Langley Research Center (LaRC) since the 1940s. These simple methodologies produce high confidence results, but the process is mechanically complex and labor-intensive, requiring three to four weeks to complete. Over the past decade, automated balance calibration systems have been developed. In general, these systems were designed to automate the tedious manual calibration process resulting in an even more complex system which deteriorates load application quality. The current calibration approach relies on a one-factor-at-a-time (OFAT) methodology, where each independent variable is incremented individually throughout its full-scale range, while all other variables are held at a constant magnitude. This OFAT approach has been widely accepted because of its inherent simplicity and intuitive appeal to the balance engineer. LaRC has been conducting research in a "modern design of experiments" (MDOE) approach to force balance calibration. Formal experimental design techniques provide an integrated view to the entire calibration process covering all three major aspects of an experiment; the design of the experiment, the execution of the experiment, and the statistical analyses of the data. In order to overcome the weaknesses in the available mechanical systems and to apply formal experimental techniques, a new mechanical system was required. The SVS enables the complete calibration of a six-component force balance with a series of single force vectors.

Description: Response surface methods (or methodology), RSM, have been applied to improve data quality for two vastly different spatial ly-re solved optical measurement techniques. In the first application, modern design of experiments (MDOE) methods, including RSM, are employed to map the temperature field in a direct-connect supersonic combustion test facility at NASA Langley Research Center. The laser-based measurement technique known as coherent anti-Stokes Raman spectroscopy (CARS) is used to measure temperature at various locations in the combustor. RSM is then used to develop temperature maps of the flow. Even though the temperature fluctuations at a single point in the flowfield have a standard deviation on the order of 300 K, RSM provides analytic fits to the data having 95% confidence interval half width uncertainties in the fit as low as +/-30 K. Methods of optimizing future CARS experiments are explored. The second application of RSM is to quantify the shape of a 5-meter diameter, ultra-light, inflatable space antenna at NASA Langley Research Center.

Description: A new wind tunnel testing process under development at NASA Langley Research Center, called Modern Design of Experiments (MDOE), differs from conventional wind tunnel testing techniques on a number of levels. Chief among these is that MDOE focuses on the generation of adequate prediction models rather than high-volume data collection. Some cultural issues attached to this and other distinctions between MDOE and conventional wind tunnel testing are addressed in this paper.

Description: This report is an introductory tutorial on the application of formal experiment design methods to wind tunnel testing, for the benefit of aeronautical engineers with little formal experiment design training. It also describes the results of a Study to determine whether increases in the sample rate and dwell time of the National Transonic Facility data system Would result in significant changes in force and moment data. Increases in sample rate from 10 samples per second to 50 samples per second were examined, as were changes in dwell time from one second per data point to two seconds. These changes were examined for a representative aircraft model in a range of tunnel operating conditions defined by angles of attack from 0 deg to 3.8 degrees, total pressure from 15.0 psi to 24.1 psi, and Mach numbers from 0.52 to 0.82. No statistically significant effect was associated with the change in sample rate. The change in dwell time from one second to two seconds affected axial force measurements, and to a lesser degree normal force measurements. This dwell effect comprises a "rectification error" caused by incomplete cancellation of the positive and negative elements of certain low frequency dynamic components that are not rejected by the one-Hz low-pass filters of the data system. These low frequency effects may be due to tunnel circuit phenomena and other sources. The magnitude of the dwell effect depends on dynamic pressure, with angle of attack and Mach number influencing the strength of this dependence. An analysis is presented which suggests that the magnitude of the rectification error depends on the ratio of measurement dwell time to the period of the low-frequency dynamics, as well as the amplitude of the dynamics The essential conclusion of this analysis is that extending the dwell time (or, equivalently, replicating short-dwell data points) reduces the rectification error.

Description: Response surface methods (or methodology), RSM, have been applied to improve data quality for two vastly different spatially-resolved optical measurement techniques. In the first application, modern design of experiments (MDOE) methods, including RSM, are employed to map the temperature field in a direct-connect supersonic combustion test facility at NASA Langley Research Center. The laser-based measurement technique known as coherent anti-Stokes Raman spectroscopy (CARS) is used to measure temperature at various locations in the combustor. RSM is then used to develop temperature maps of the flow. Even though the temperature fluctuations at a single point in the flowfield have a standard deviation on the order of 300 K, RSM provides analytic fits to the data having 95% confidence interval half width uncertainties in the fit as low as +/- 30 K. Methods of optimizing future CARS experiments are explored. The second application of RSM is to quantify the shape of a 5-meter diameter, ultra-lightweight, inflatable space antenna at NASA Langley Research Center. Photogrammetry is used to simultaneously measure the shape of the antenna at approximately 500 discrete spatial locations. RSM allows an analytic model to be developed that describes the shape of the majority of the antenna with an uncertainty of 0.4 mm, with 95% confidence. This model would allow a quantitative comparison between the actual shape of the antenna and the original design shape. Accurately determining this shape also allows confident interpolation between the measured points. Such a model could, for example, be used for ray tracing of radio-frequency waves up to 95 GHz. to predict the performance of the antenna.

Description: The uncertainty of videogrammetric techniques used for the measurement of static aeroelastic wind tunnel model deformation and wind tunnel model pitch angle is discussed. Sensitivity analyses and geometrical considerations of uncertainty are augmented by analyses of experimental data in which videogrammetric angle measurements were taken simultaneously with precision servo accelerometers corrected for dynamics. An analysis of variance (ANOVA) to examine error dependence on angle of attack, sensor used (inertial or optical). and on tunnel state variables such as Mach number is presented. Experimental comparisons with a high-accuracy indexing table are presented. Small roll angles are found to introduce a zero-shift in the measured angles. It is shown experimentally that. provided the proper constraints necessary for a solution are met, a single- camera solution can he comparable to a 2-camera intersection result. The relative immunity of optical techniques to dynamics is illustrated.

Description: This paper serves as a tutorial to introduce the wind tunnel research community to configuration experiment designs that can satisfy resource constraints in a configuration study involving several variables, without arbitrarily eliminating any of them from the experiment initially. The special case of a configuration study featuring variables at two levels is examined in detail. This is the type of study in which each configuration variable has two natural states - 'on or off', 'deployed or not deployed', 'low or high', and so forth. The basic principles are illustrated by results obtained in configuration studies conducted in the Langley National Transonic Facility and in the ViGYAN Low Speed Tunnel in Hampton, Virginia. The crucial role of interactions among configuration variables is highlighted with an illustration of difficulties that can be encountered when they are not properly taken into account.

Description: This paper examines the role of unexplained systematic variation on the reproducibility of wind tunnel test results. Sample means and variances estimated in the presence of systematic variations are shown to be susceptible to bias errors that are generally non-reproducible functions of those variations. Unless certain precautions are taken to defend against the effects of systematic variation, it is shown that experimental results can be difficult to duplicate and of dubious value for predicting system response with the highest precision or accuracy that could otherwise be achieved. Results are reported from an experiment designed to estimate how frequently systematic variations are in play in a representative wind tunnel experiment. These results suggest that significant systematic variation occurs frequently enough to cast doubts on the common assumption that sample observations can be reliably assumed to be independent. The consequences of ignoring correlation among observations induced by systematic variation are considered in some detail. Experimental tactics are described that defend against systematic variation. The effectiveness of these tactics is illustrated through computational experiments and real wind tunnel experimental results. Some tutorial information describes how to analyze experimental results that have been obtained using such quality assurance tactics.