ALBERT

Description: Remote handling in nuclear waste management requires a robotic system with precise motion as well as a large workspace. The concept of a small arm mounted on the end of a large arm may satisfy such needs. However, the performance of such a serial configuration lacks payload capacity which is a crucial factor for handling a massive object. Also, this configuration induces more flexibility on the structure. To overcome these problems, the topology of bracing the tip of the small arm (not the large arm) and having an end effector in the middle of the chain is proposed in this paper. Also, control of these cooperating disparate manipulators is accomplished in computer simulations. Thus, this robotic system can have the accuracy of the small arm, and at the same time, it can have the payload capacity and large workspace of the large arm.

Description: This paper concerns the suppression of the vibration of a large flexible robot by inertial forces of a small robot which is located at the tip of the large robot. A controller for generating damping forces to a large robot is designed based on the two time scale model. The controller does not need to calculate the quasi-steady variables and is efficient in computation. Simulation results show the effectiveness of the inertial forces and the controller designed.

Description: The inverse dynamic equation of a flexible manipulator was solved in the time domain. By dividing the inverse system equation into the causal part and the anticausal part, we calculated the torque and the trajectories of all state variables for a given end point trajectory. The interpretation of this method in the frequency domain was explained in detail using the two-sided Laplace transform and the convolution integral. The open loop control of the inverse dynamic method shows an excellent result in simulation. For real applications, a practical control strategy is proposed by adding a feedback tracking control loop to the inverse dynamic feedforward control, and its good experimental performance is presented.

Description: This research seeks to provide an advanced force control strategy for a flexible manipulator. Two main issues with force control of flexible arms are discussed: non-collocation and robustness.

Description: Many applications of robotic and teleoperated manipulator arms require operation in contact and non-contact regimes. This paper deals with both regimes and the transition between them with special attention given to problems of flexibility in the links and drives. This is referred to as contact control. Inverse dynamics is used to plan the tip motion of the flexible link so that the free motion can stop very near the contact surface without collision due to overshoot. Contact must occur at a very low speed since the high frequency impact forces are too sudden to be affected by any feedback generated torques applied to a joint at the other end of the link. The effect of approach velocity and surface properties are discussed. Force tracking is implemented by commands to the deflection states of the link and the contact force. This enables a natural transition between tip position and tip force control that is not possible when the arm is treated as rigid. The effect of feedback gain, force trajectory, and desired final force are of particular interest and are studied. Experimental results are presented on a one link arm and the system performance in the overall contact task is analyzed. Extension to multi-link cases with potential applications are discussed.

Description: Many applications of robotic manipulator arms require operation in contact and noncontact regimes. Control of impact between the arm's tip and the environment has been largely ignored in prior research. The impact phenomena was investigated through simulation and experiment for the realization of the bracing strategy, and the key factors of the behavior were understood well. The approaching velocity is dominant parameter for the magnitude of the impact force. The impact is also affected by the compliance of the environmental surface.

Description: The short term objective of this research is the completion of experimental configuration of the Small Articulated Robot (SAM) and the derivations of the actuator dynamics of the Robotic Arm, Large and Flexible (RALF). In order to control vibrations SAM should have larger bandwidth than that of the vibrations. The bandwidth of SAM consist of 3 parts; structural rigidity, processing speed of controller, and motor speed. The structural rigidity was increased to a reasonably high value by attaching aluminum angles at weak points and replacing thin side plates by thicker ones. The high processing speed of the controller was achieved by using parallel processors (three 68000 process, three interface board, and one main processor (IBM-XT)). Maximum joint speed and acceleration of SAM is known as about 4 rad/s and 15 rad/sq s. Hence SAM can move only .04 rad at 3 Hz which is the natural frequency of RALF. This will be checked by experiment.

Description: The approach employed by NASA Lewis for the long-term durability assessment of the Stirling engine hot-section components is summarized. The approach consists of: preliminary structural assessment; development of a viscoplastic constitutive model to accurately determine material behavior under high-temperature thermomechanical loads; an experimental program to characterize material constants for the viscoplastic constitutive model; finite-element thermal analysis and structural analysis using a viscoplastic constitutive model to obtain stress/strain/temperature at the critical location of the hot-section components for life assessment; and development of a life prediction model applicable for long-term durability assessment at high temperatures. The approach should aid in the provision of long-term structural durability and reliability of Stirling engines.

Description: OPMILL is a computer operating system for a Kearney and Trecker milling machine that provides a fast and easy way to program machine part manufacture with an IBM compatible PC. The program gives the machinist an "equation plotter" feature which plots any set of equations that define axis moves (up to three axes simultaneously) and converts those equations to a machine milling program that will move a cutter along a defined path. Other supported functions include: drill with peck, bolt circle, tap, mill arc, quarter circle, circle, circle 2 pass, frame, frame 2 pass, rotary frame, pocket, loop and repeat, and copy blocks. The system includes a tool manager that can handle up to 25 tools and automatically adjusts tool length for each tool. It will display all tool information and stop the milling machine at the appropriate time. Information for the program is entered via a series of menus and compiled to the Kearney and Trecker format. The program can then be loaded into the milling machine, the tool path graphically displayed, and tool change information or the program in Kearney and Trecker format viewed. The program has a complete file handling utility that allows the user to load the program into memory from the hard disk, save the program to the disk with comments, view directories, merge a program on the disk with one in memory, save a portion of a program in memory, and change directories. OPMILL was developed on an IBM PS/2 running DOS 3.3 with 1 MB of RAM. OPMILL was written for an IBM PC or compatible 8088 or 80286 machine connected via an RS-232 port to a Kearney and Trecker Data Mill 700/C Control milling machine. It requires a "D:" drive (fixed-disk or virtual), a browse or text display utility, and an EGA or better display. Users wishing to modify and recompile the source code will also need Turbo BASIC, Turbo C, and Crescent Software's QuickPak for Turbo BASIC. IBM PC and IBM PS/2 are registered trademarks of International Business Machines. Turbo BASIC and Turbo C are trademarks of Borland International.

Description: AutoCAD to Mass Properties was developed to facilitate quick mass properties calculations of structures having many simple elements in a complex configuration such as trusses or metal sheet containers. Calculating the mass properties of structures of this type can be a tedious and repetitive process, but ACTOMP helps automate the calculations. The structure can be modelled in AutoCAD or a compatible CAD system in a matter of minutes using the 3-Dimensional elements. This model provides all the geometric data necessary to make a mass properties calculation of the structure. ACTOMP reads the geometric data of a drawing from the Drawing Interchange File (DXF) used in AutoCAD. The geometric entities recognized by ACTOMP include POINTs, 3DLINEs, and 3DFACEs. ACTOMP requests mass, linear density, or area density of the elements for each layer, sums all the elements and calculates the total mass, center of mass (CM) and the mass moments of inertia (MOI). AutoCAD utilizes layers to define separate drawing planes. ACTOMP uses layers to differentiate between multiple types of similar elements. For example if a structure is made of various types of beams, modeled as 3DLINEs, each with a different linear density, the beams can be grouped by linear density and each group placed on a separate layer. The program will request the linear density of 3DLINEs for each new layer it finds as it processes the drawing information. The same is true with POINTs and 3DFACEs. By using layers this way a very complex model can be created. POINTs are used for point masses such as bolts, small machine parts, or small electronic boxes. 3DLINEs are used for beams, bars, rods, cables, and other similarly slender elements. 3DFACEs are used for planar elements. 3DFACEs may be created as 3 or 4 Point faces. Some examples of elements that might be modelled using 3DFACEs are plates, sheet metal, fabric, boxes, large diameter hollow cylinders and evenly distributed masses. ACTOMP was written in Microsoft QuickBasic (Version 2.0). It was developed for the IBM PC microcomputer and has been implemented on an IBM PC compatible under DOS 3.21. ACTOMP was developed in 1988 and requires approximately 5K bytes to operate.

Description: The APT code is one of the most widely used software tools for complex numerically controlled (N/C) machining. APT is an acronym for Automatically Programmed Tools and is used to denote both a language and the computer software that processes that language. Development of the APT language and software system was begun over twenty years ago as a U. S. government sponsored industry and university research effort. APT is a "problem oriented" language that was developed for the explicit purpose of aiding the N/C machine tools. Machine-tool instructions and geometry definitions are written in the APT language to constitute a "part program." The APT part program is processed by the APT software to produce a cutter location (CL) file. This CL file may then be processed by user supplied post processors to convert the CL data into a form suitable for a particular N/C machine tool. This June, 1989 offering of the APT system represents an adaptation, with enhancements, of the public domain version of APT IV/SSX8 to the DEC VAX-11/780 for use by the Engineering Services Division of the NASA Goddard Space Flight Center. Enhancements include the super pocket feature which allows concave and convex polygon shapes of up to 40 points including shapes that overlap, that leave islands of material within the pocket, and that have one or more arcs as part of the pocket boundary. Recent modifications to APT include a rework of the POCKET subroutine and correction of an error that prevented the use within a macro of a macro variable cutter move statement combined with macro variable double check surfaces. Former modifications included the expansion of array and buffer sizes to accommodate larger part programs, and the insertion of a few user friendly error messages. The APT system software on the DEC VAX-11/780 is organized into two separate programs: the load complex and the APT processor. The load complex handles the table initiation phase and is usually only run when changes to the APT processor capabilities are made. This phase initializes character recognition and syntax tables for the APT processor by creating FORTRAN block data programs. The APT processor consists of four components: the translator, the execution complex, the subroutine library, and the CL editor. The translator examines each APT statement in the part program for recognizable structure and generates a new statement, or series of statements, in an intermediate language. The execution complex processes all of the definition, motion, and related statements to generate cutter location coordinates. The subroutine library contains routines defining the algorithms required to process the sequenced list of intermediate language commands generated by the translator. The CL editor re-processes the cutter location coordinates according to user supplied commands to generate a final CL file. A sample post processor is also included which translates a CL file into a form for use with a Wales Strippit Fabramatic Model 30/30 sheet metal punch. The user should be able to readily develop post processors for other N/C machine tools. The APT language is a statement oriented, sequence dependent language. With the exception of such programming techniques as looping and macros, statements in an APT program are executed in a strict first-to-last sequence. In order to provide programming capability for the broadest possible range of parts and of machine tools, APT input (and output) is generalized, as represented by 3-dimensional geometry and tools, and arbitrarily uniform, as represented by the moving tool concept and output data in absolute coordinates. A command procedure allows the user to select the desired part program, ask for a graphics file of cutter motions in IGES format, and submit the procedure as a batch job, if desired. The APT system software is written in FORTRAN 77 for batch and interactive execution and has been implemented on a DEC VAX series computer under VMS 4.4. The enhancements for this version of APT were last updated in June, 1989. The NASA adaptation, with enhancements, of the public domain version of the APT IV/SSX8 software to the DEC VAX-11/780 is available by license for a period of ten (10) years to approved licensees. The licensed program product delivered includes the APT IV/SSX8 system source code, object code, executable images, and command procedures and one set of supporting documentation. Additional copies of the supporting documentation may be purchased at any time at the price indicated below.

Description: The SHABERTH computer program was developed to predict operating characteristics of bearings in a multibearing load support system. Lubricated and non-lubricated bearings can be modeled. SHABERTH calculates the loads, torques, temperatures, and fatigue life for ball and/or roller bearings on a single shaft. The program also allows for an analysis of the system reaction to the termination of lubricant supply to the bearings and other lubricated mechanical elements. SHABERTH has proven to be a valuable tool in the design and analysis of shaft bearing systems. The SHABERTH program is structured with four nested calculation schemes. The thermal scheme performs steady state and transient temperature calculations which predict system temperatures for a given operating state. The bearing dimensional equilibrium scheme uses the bearing temperatures, predicted by the temperature mapping subprograms, and the rolling element raceway load distribution, predicted by the bearing subprogram, to calculate bearing diametral clearance for a given operating state. The shaft-bearing system load equilibrium scheme calculates bearing inner ring positions relative to the respective outer rings such that the external loading applied to the shaft is brought into equilibrium by the rolling element loads which develop at each bearing inner ring for a given operating state. The bearing rolling element and cage load equilibrium scheme calculates the rolling element and cage equilibrium positions and rotational speeds based on the relative inner-outer ring positions, inertia effects, and friction conditions. The ball bearing subprograms in the current SHABERTH program have several model enhancements over similar programs. These enhancements include an elastohydrodynamic (EHD) film thickness model that accounts for thermal heating in the contact area and lubricant film starvation; a new model for traction combined with an asperity load sharing model; a model for the hydrodynamic rolling and shear forces in the inlet zone of lubricated contacts, which accounts for the degree of lubricant film starvation; modeling normal and friction forces between a ball and a cage pocket, which account for the transition between the hydrodynamic and elastohydrodynamic regimes of lubrication; and a model of the effect on fatigue life of the ratio of the EHD plateau film thickness to the composite surface roughness. SHABERTH is intended to be as general as possible. The models in SHABERTH allow for the complete mathematical simulation of real physical systems. Systems are limited to a maximum of five bearings supporting the shaft, a maximum of thirty rolling elements per bearing, and a maximum of one hundred temperature nodes. The SHABERTH program structure is modular and has been designed to permit refinement and replacement of various component models as the need and opportunities develop. A preprocessor is included in the IBM PC version of SHABERTH to provide a user friendly means of developing SHABERTH models and executing the resulting code. The preprocessor allows the user to create and modify data files with minimal effort and a reduced chance for errors. Data is utilized as it is entered; the preprocessor then decides what additional data is required to complete the model. Only this required information is requested. The preprocessor can accommodate data input for any SHABERTH compatible shaft bearing system model. The system may include ball bearings, roller bearings, and/or tapered roller bearings. SHABERTH is written in FORTRAN 77, and two machine versions are available from COSMIC. The CRAY version (LEW-14860) has a RAM requirement of 176K of 64 bit words. The IBM PC version (MFS-28818) is written for IBM PC series and compatible computers running MS-DOS, and includes a sample MS-DOS executable. For execution, the PC version requires at least 1Mb of RAM and an 80386 or 486 processor machine with an 80x87 math co-processor. The standard distribution medium for the IBM PC version is a set of two 5.25 inch 360K MS-DOS format diskettes. The contents of the diskettes are compressed using the PKWARE archiving tools. The utility to unarchive the files, PKUNZIP.EXE, is included. The standard distribution medium for the CRAY version is also a 5.25 inch 360K MS-DOS format diskette, but alternate distribution media and formats are available upon request. The original version of SHABERTH was developed in FORTRAN IV at Lewis Research Center for use on a UNIVAC 1100 series computer. The Cray version was released in 1988, and was updated in 1990 to incorporate fluid rheological data for Rocket Propellant 1 (RP-1), thereby allowing the analysis of bearings lubricated with RP-1. The PC version is a port of the 1990 CRAY version and was developed in 1992 by SRS Technologies under contract to NASA Marshall Space Flight Center.

Description: The analysis of the dynamic characteristics of a complex system, such as a spacecraft or a robot, is usually best accomplished through the study of a simulation model. The simulation model must have the same dynamic characteristics as the complex system, while lending itself to mathematical quantification. The NBOD2 computer program was developed to aid in the analysis of spacecraft attitude dynamics. NBOD2 is a very general program that may be applied to a large class of problems involving coupled N-body systems. NBOD2 provides the dynamics analyst with the capability to automatically derive and numerically solve the equations of motion for any system that can be modeled as a topological tree of coupled rigid bodies, flexible bodies, point masses, and symmetrical momentum wheels. NBOD2 uses a topological tree model of the dynamic system to derive the vector-dyadic equations of motion for the system. The user builds this topological tree model by using rigid and flexible bodies, point masses, and symmetrical momentum wheels with appropriate connections. To insure that the relative motion between contiguous bodies is kinematically constrained, NBOD2 assumes that contiguous rigid and flexible bodies are connected by physically reliable 0, 1, 2, and 3-degrees-of-freedom gimbals. These gimbals prohibit relative translational motion, while permitting up to 3 degrees of relative rotational freedom at hinge points. Point masses may have 0, 1, 2, or 3-degrees of relative translational freedom, and symmetric momentum wheels may have a single degree of rotational freedom relative to the body in which they are imbedded. Flexible bodies may possess several degrees of vibrational freedom in addition to the degrees of freedom associated with the connection gimbals. Data concerning the natural modes and vibrations of the flexible bodies must be supplied by the user. NBOD2 combines the best features of the discrete-body approach and the nested body approach to reduce the topological tree to a complete set of nonlinear equations of motion in vector-dyadic form for the system being analyzed. NBOD2 can then numerically solve the equations of motion. Input to NBOD2 consists of a user-supplied description of the system to be modeled. The NBOD2 system includes an interactive, tutorial, input support program to aid the NBOD2 user in preparing input data. Output from NBOD2 consists of a listing of the complete set of nonlinear equations of motion in vector-dyadic form and any userspecified set of system state variables. The NBOD2 program is written in FORTRAN 77 for batch execution and has been implemented on a DEC VAX-11/780 computer. The NBOD2 program was developed in 1978 and last updated in 1982.

Description: Part fabrication from composite materials usually costs less when larger fiber tow bundles are used. On the other hand, mechanical properties generally are lower for composites made using larger size tows. This situation gives rise to a choice between costs and properties in determining the best fiber tow bundle size to employ in preparing prepreg materials for part fabrication. To address this issue, unidirectional and eight harness satin fabric composite specimens were fabricated from 3k, 6k, and 12k carbon fiber reinforced LARC-TPI powder coated towpreg. Short beam shear strengths and longitudinal and transverse flexure properties were obtained for the unidirectional specimens. Tension properties were obtained for the eight harness satin woven towpreg specimens. Knowledge of the variation of properties with tow size may serve as a guide in material selection for part fabrication.

Description: An intelligent sensor model system has been built and used for automated control of the PMR-15 cure process in the autoclave. The system uses frequency-dependent FM sensing (FDEMS), the Loos processing model, and the Air Force QPAL intelligent software shell. The Loos model is used to predict and optimize the cure process including the time-temperature dependence of the extent of reaction, flow, and part consolidation. The FDEMS sensing system in turn monitors, in situ, the removal of solvent, changes in the viscosity, reaction advancement and cure completion in the mold continuously throughout the processing cycle. The sensor information is compared with the optimum processing conditions from the model. The QPAL composite cure control system allows comparison of the sensor monitoring with the model predictions to be broken down into a series of discrete steps and provides a language for making decisions on what to do next regarding time-temperature and pressure.

Description: The ZMOTTO program was developed to model mathematically a spark-ignited internal combustion engine. ZMOTTO is a large, general purpose program whose calculations can be established at five levels of sophistication. These five models range from an ideal cycle requiring only thermodynamic properties, to a very complex representation demanding full combustion kinetics, transport properties, and poppet valve flow characteristics. ZMOTTO is a flexible and computationally economical program based on a system of ordinary differential equations for cylinder-averaged properties. The calculations assume that heat transfer is expressed in terms of a heat transfer coefficient and that the cylinder average of kinetic plus potential energies remains constant. During combustion, the pressures of burned and unburned gases are assumed equal and their heat transfer areas are assumed proportional to their respective mass fractions. Even the simplest ZMOTTO model provides for residual gas effects, spark advance, exhaust gas recirculation, supercharging, and throttling. In the more complex models, 1) finite rate chemistry replaces equilibrium chemistry in descriptions of both the flame and the burned gases, 2) poppet valve formulas represent fluid flow instead of a zero pressure drop flow, and 3) flame propagation is modeled by mass burning equations instead of as an instantaneous process. Input to ZMOTTO is determined by the model chosen. Thermodynamic data is required for all models. Transport properties and chemical kinetics data are required only as the model complexity grows. Other input includes engine geometry, working fluid composition, operating characteristics, and intake/exhaust data. ZMOTTO accommodates a broad spectrum of reactants. The program will calculate many Otto cycle performance parameters for a number of consecutive cycles (a cycle being an interval of 720 crankangle degrees). A typical case will have a number of initial ideal cycles and progress through levels of nonideal cycles. ZMOTTO has restart capabilities and permits multicycle calculations with parameters varying from cycle to cycle. ZMOTTO is written in FORTRAN IV (IBM Level H) but has also been compiled with IBM VSFORTRAN (1977 standard). It was developed on an IBM 3033 under the TSS operating system and has also been implemented under MVS. Approximately 412K of 8 bit bytes of central memory are required in a nonpaging environment. ZMOTTO was developed in 1985.

Description: The APT code is one of the most widely used software tools for complex numerically controlled (N/C) machining. APT is an acronym for Automatically Programmed Tool and is used to denote the programming language. Development of the APT language and software system was begun in the late 1950's as a U. S. government sponsored industry and university research effort. APT is a "problem oriented" language that was developed for the explicit purpose of aiding the N/C machine tools. The original APT program contained undocumented nonstandard FORTRAN, thus making porting of the processor to different operating systems difficult. P-APT (Portable APT) is a revised version of APT that was written to conform to the FORTRAN 77 standard. All machine-dependent code has either been replaced or isolated and documented. Machine-tool instructions and geometry definitions are written in the APT language to constitute a "part program". The APT part program is processed by the P-APT software to produce a cutter location (CL) file. This CL file may then be processed by user supplied post processors to convert the CL data into a form suitable for a particular N/C machine tool. This current offering of the P-APT system represents an adaptation, with enhancements, of the public domain version of APT IV/SSX8. Enhancements include the super pocket feature that allows concave pockets with curved sides and islands. The P-APT system software is organized into two separate programs: the load complex and the APT processor. The load complex handles the table initiation phase and is usually only run when changes to the P-APT processor capabilities are made. This phase initializes character recognition and syntax tables for the P-APT processor by creating FORTRAN block data programs. The P-APT processor consists of four components: the translator, the execution complex, the subroutine library, and the CL editor. The translator examines each APT statement in the part program for recognizable structure and generates a new statement, or series of statements, in an intermediate language. The execution complex processes all of the definition, motion, and related statements to generate cutter location coordinates. The subroutine library contains routines defining the algorithms required to process the sequenced list of intermediate language commands generated by the translator. The CL editor re-processes the cutter location coordinates according to user supplied commands to generate a final CL file. The APT language is a statement oriented, sequence dependent language. With the exception of such programming techniques as looping and macros, statements in an APT program are executed in a strict first-to-last sequence. In order to provide programming capability for the broadest possible range of parts and machine tools, APT input (and output) is generalized, as represented by 3-dimensional geometry and tools, and is arbitrarily uniform, as represented by the moving tool concept and output data in absolute coordinates. P-APT is written in FORTRAN 77 for execution on Sun4 series computers running SunOS. Although P-APT is written in standard FORTRAN 77 and was designed to be readily portable code, it has only been fully tested on a Sun4 series computer running SunOs. By making documented modifications to the source code, it may also be ported to a DEC VAX series computer running VMS. P-APT required 3.1Mb of RAM for execution. A minimum of 16Mb of RAM and 32Mb of disk space used for swap space is recommended. The standard distribution medium for this program is a .25 inch streaming magnetic tape cartridge in UNIX tar format. P-APT is available by license for a period of ten (10) years to approved licensees. The licensed program product includes the P-APT source code, makefiles, examples, and one set of supporting documentation. Additional copies of the documentation may be purchased at the price indicated below. P-APT was developed in 1992.

Description: Cavitation of the oil film in a dynamically loaded journal bearing was studied using high-speed photography and pressure measurement simultaneously. Comparison of the visual and pressure data provided considerable insight into the occurence and non-occurrence of cavitation. It was found that (1), cavitation typically occurred in the form of one bubble with the pressure in the cavitation bubble close to the absolute zero; and (2), for cavitation-producing operating conditions, cavitation did not always occur; with the oil film then supporting a tensile stress.

Description: The primary objective of this paper is to evaluate the optical pointing performance of the PSR Moderate Focus-Mission Structure when subjected to both mechanical and thermal disturbances. The mechanical disturbances are based on secondary mirror chopping. Results indicate that dynamic responses of the primary reflector and the secondary reflector subjected to chopping disturbances of the secondary reflector about its center of mass are within the figure maintenance control capabilities. The effects of modal damping, truss-type secondary support, interface boundary constraints, and alternate configurations, are also evaluated in the analysis. Thermal distortions of the structure were also evaluated based on the on-orbit temperature profiles derived from the submillimeter telescope missions. Results from thermal deformation analysis indicate that figure initialization control is needed for the PSR Moderate Focus-Mission. However, a figure maintenance system may not be required if adequate thermal isolation is incorporated into the support truss design for the PSR Moderate Focus-Mission Structure.

Description: This paper describes experimental research being performed at the Jet Propulsion Laboratory to develop and validate control concepts arising out of NASA's Control Structure Interaction program. The facility is meant to be a ground testbed with relevance to a broad class of future precision optical space systems. The objective of the experimental program is to investigate a multi-layer control approach to the maintenance of nanometer level optical pathlength control in the presence of external disturbances and multiple structural resonances. A brief overview of the experimental facility is presented. The control design methodology is discussed, and several experimental results are presented.

Description: Segmented reflectors have been proposed for space-based applications such as optical communication and large-diameter telescopes. An actuation system for mirrors in a space-based segmented mirror array has been developed as part of the National Aeronautics and Space Administration-sponsored Precision Segmented Reflector program. The actuation system, called the Articulated Panel Module (APM), articulates a mirror panel in 3 degrees of freedom in the submicron regime, isolates the panel from structural motion, and simplifies space assembly of the mirrors to the reflector backup truss. A breadboard of the APM has been built and is described. Three-axis modeling, analysis, and testing of the breadboard is discussed.

Description: ESDAPT is a graphical programming environment for developing APT (Automatically Programmed Tool) programs for controlling numerically controlled machine tools. ESDAPT has a graphical user interface that provides the user with an APT syntax sensitive text editor and windows for displaying geometry and tool paths. APT geometry statement can also be created using menus and screen picks. ESDAPT interprets APT geometry statements and displays the results in its view windows. Tool paths are generated by batching the APT source to an APT processor (COSMIC P-APT recommended). The tool paths are then displayed in the view windows. Hardcopy output of the view windows is in color PostScript format. ESDAPT is written in C-language, yacc, lex, and XView for use on Sun4 series computers running SunOS. ESDAPT requires 4Mb of disk space, 7Mb of RAM, and MIT's X Window System, Version 11 Release 4, or OpenWindows version 3 for execution. Program documentation in PostScript format and an executable for OpenWindows version 3 are provided on the distribution media. The standard distribution medium for ESDAPT is a .25 inch streaming magnetic tape cartridge (Sun QIC-24) in UNIX tar format. This program was developed in 1992.

Description: The authors present an analysis of why control systems are ineffective in compensating for acceleration disturbances due to Coulomb friction. Linear arguments indicate that the effects of Coulomb friction on a body are most difficult to reject when the control actuator is separated from the body of compliance. The linear arguments were illustrated in a nonlinear simulation of optimal linear tracking control in the presence of nonlinear friction. The results of endpoint acceleration measurements for four robot designs are presented and are compared with simulation and to equivalent measurements on a human. It is concluded that Coulomb friction in common bearings and transmission induces unacceptable levels of endpoint acceleration, that these accelerations cannot be adequately attenuated by control, and that robots for microgravity work will require special design considerations for inherently low friction.

Description: The authors describe the progress that has been made towards the development of a mobile robot that can be used by hazardous materials emergency response teams to perform a variety of tasks including incident localization and characterization, hazardous material identification/classification, site surveillance and monitoring, and ultimately incident mitigation. In September of 1991, the HAZBOT II vehicle performed its first end-to-end demonstration involving a scenario in which the vehicle: navigated to the incident location from a distant (150-200 ft.) deployment site; entered a building through a door with thumb latch style handle and door closer; located and navigated to the suspected incident location (a chemical storeroom); unlocked and opened the storeroom's door; climbed over the storeroom's 12 in. high threshold to enter the storeroom; and located and identified a broken container of benzene.

Description: A general framework is presented for the matrix-form, linear optical model analysis of controlled optomechanical systems; the models are conjoined with linear models of structures and controls to compute system performance as a function of optics, structures, and control parameters. Covariance analysis, optimization, and estimation/simulation are used. Attention is given to a tolerancing example for the Hubble Space Telescope's Wide Field and Planetary Camera, which involves the creation of a linear model of residual pupil shear.

Description: The vibrations of a flexible rotor are controlled using piezoelectric actuators. The controller includes active analog components and a hybrid interface with a digital computer. The computer utilizes a grid search algorithm to select feedback gains that minimize a vibration norm at a specific operating speed. These gains are then downloaded as active stillnesses and dampings with a linear fit throughout the operating speed range to obtain a very effective vibration control.

Description: An analytical and experimental investigation of a vibratory system with a clearance was conducted. A finite element model and an equivalent single-degree-of-freedom closed-form solution were used to determine the dynamic parameters and response of an experimental structure interacting with a gap. The closed-form solution is obtained by taking advantage of the piecewise linearity of the system. Results from these solution methods are in agreement with experimental data. The results also suggest that the closed-form solution approximates the response of the experimental structure with accuracy greater than that of the finite element model. The closed-form solution was also used to determine the gap size of the structure. The parameter identification procedure utilized in this study appears to be simple to use and can be readily extended to other types of piecewise-linear multi-degree-of-freedom systems.

Description: Extensive experimental investigation has been carried out on used flight bearings of the high pressure oxidizer turbopumps (HPOTP) of the space shuttle main engine (SSME) in order to determine the dominant wear modes, their extent, and causes. The paper presents the methodology, various surface analysis techniques used, results, and discussion. The mode largely responsible for premature bearing wear has been identified as adhesive/shear peeling of the upper layers of bearing balls and rings. This mode relies upon the mechanisms of scale formation, breakdown, and removal, all of which are greatly enhanced by the heavy oxidation environment of the HPOTP. Major causes of the high wear rates appear to be lubrication and cooling, both inadequate for the imposed conditions of operation. Numerous illustrations and evidence are provided.

Description: Udimet 720 has been selected for use on Stirling power converters for space applications. Because Udimet 720 is generally considered susceptible to strain age cracking if traditional fusion welding is used, other joining methods are being considered. A process for transient liquid phase diffusion bonding of Udimet 720 has been theoretically developed in an effort to eliminate the strain age crack concern. This development has taken into account such variables as final grain size, joint homogenization, joint efficiency related to bonding aid material, bonding aid material application method, and thermal cycle.

Description: The computer program MASPROP was developed to rapidly calculate the mass properties of complex rigid structural systems. This program's basic premise is that complex systems can be adequately described by a combination of basic elementary structural shapes. Thirteen widely used basic structural shapes are available in this program. They are as follows: Discrete Mass, Cylinder, Truncated Cone, Torus, Beam (arbitrary cross section), Circular Rod (arbitrary cross section), Spherical Segment, Sphere, Hemisphere, Parallelepiped, Swept Trapezoidal Panel, Symmetric Trapezoidal Panels, and a Curved Rectangular Panel. MASPROP provides a designer with a simple technique that requires minimal input to calculate the mass properties of a complex rigid structure and should be useful in any situation where one needs to calculate the center of gravity and moments of inertia of a complex structure. Rigid body analysis is used to calculate mass properties. Mass properties are calculated about component axes that have been rotated to be parallel to the system coordinate axes. Then the system center of gravity is calculated and the mass properties are transferred to axes through the system center of gravity by using the parallel axis theorem. System weight, moments of inertia about the system origin, and the products of inertia about the system center of mass are calculated and printed. From the information about the system center of mass the principal axes of the system and the moments of inertia about them are calculated and printed. The only input required is simple geometric data describing the size and location of each element and the respective material density or weight of each element. This program is written in FORTRAN for execution on a CDC 6000 series computer with a central memory requirement of approximately 62K (octal) of 60 bit words. The development of this program was completed in 1978.

Description: A method to visualize and characterize the complex flow fields in brush seals is presented. A configuration characteristic of the brush seal confined in a two-dimensional tunnel with water as the working fluid was studied. Visualization of the flow field revealed regions that are characteristically jetting, vortical, and crossflow and exist upstream, downstream or within the seal. Such flows are engendered by variations in fiber void that are spatial and temporal and affect changes in seal leakage and stability. While the effects of interface motion and cylindrical configuration have not been considered herein, it is believed that the observed flow fields characterize flow phenomenology in brush seals.

Description: Automated tow placement (ATP) utilizes robotic technology to lay down adjacent polymer-matrix-impregnated carbon fiber tows on a tool surface. Consolidation and cure during ATP requires that void elimination and polymer matrix adhesion be accomplished in the short period of heating and pressure rolling that follows towpreg ribbon placement from the robot head to the tool. This study examined the key towpreg ribbon properties and dimensions which play a significant role in ATP. Analysis of the heat transfer process window indicates that adequate heating can be achieved at lay down rates as high as 1 m/sec. While heat transfer did not appear to be the limiting factor, resin flow and fiber movement into tow lap gaps could be. Accordingly, consideration was given to towpreg ribbon having uniform yet non-rectangular cross sections. Dimensional integrity of the towpreg ribbon combined with customized ribbon architecture offer great promise for processing advances in ATP of high performance composites.

Description: Such large LEO spacecraft as the Space Station Freedom will encounter high atomic oxygen fluences which entail the use of protective coatings for their polymeric structural materials. Such coatings have demonstrated polymer mass losses due to oxidation that are much smaller than those of unprotected materials. Attention is here given to protective and/or electrically conductive coatings of SiO(x), Ge, and indium-tin oxide which have been exposed to atomic oxygen in order to ascertain mass loss, electrical conductivity, and optical property dependence on atomic oxygen exposure.

Description: An analysis was undertaken to determine the effect of fluid film compressibility on the performance of fluid film bearings. A new version of the Reynolds equation was developed, using a polytropic expansion, for both steady-state and dynamic conditions. Polytropic exponents from 1 (isothermal) to 1000 (approaching an incompressible liquid) were evaluated for two bearing numbers, selected from a range of practical interest for cryogenic application, and without cavitation. Bearing loads were insensitive to fluid compressibility for low bearing numbers, as was expected. The effect of compressibility on attitude angle was significant, even when the bearing number was low. A small amount of fluid compressibility was enough to obtain stable running conditions. Incompressible liquid lacked stability at all conditions. Fluid compressibility can be used to control the bearing dynamic coefficients, thereby influencing the dynamic behavior of the rotor-bearing system.

Description: Analytical models for piezoelectric actuators, adapted from flat plate concepts, are developed for noise and vibration control applications associated with vibrating circular cylinders. The loadings applied to the cylinder by the piezoelectric actuators for the bending and in-plane force models are approximated by line moment and line force distributions, respectively, acting on the perimeter of the actuator patch area. Coupling between the cylinder and interior acoustic cavity is examined by studying the modal spectra, particularly for the low-order cylinder modes that couple efficiently with the cavity at low frequencies. Within the scope of this study, the in-plane force model produced a more favorable distribution of low-order modes, necessary for efficient interior noise control, than did the bending model.

Description: The traditional approach used in modeling of composites reinforced by three-dimensional (3-D) braids is to assume a simple unit cell geometry of a 3-D braided structure with known fiber volume fraction and orientation. In this article, we first examine 3-D braiding methods in the light of braid structures, followed by the development of geometric models for 3-D braids using a unit cell approach. The unit cell geometry of 3-D braids is identified and the relationship of structural parameters such as yarn orientation angle and fiber volume fraction with the key processing parameters established. The limiting geometry has been computed by establishing the point at which yarns jam against each other. Using this factor makes it possible to identify the complete range of allowable geometric arrangements for 3-D braided preforms. This identified unit cell geometry can be translated to mechanical models which relate the geometrical properties of fabric preforms to the mechanical responses of composite systems.

Description: The classical EHL (elastohydrodynamic lubrication) point contact problem is solved using a new system-approach, similar to that introduced by Houpert and Hamrock for the line-contact problem. Introducing a body-fitted coordinate system, the troublesome free-boundary is transformed to a fixed domain. The Newton-Raphson method can then be used to determine the pressure distribution and the cavitation boundary subject to the Reynolds boundary condition. This method provides an efficient and rigorous way of solving the EHL point contact problem with the aid of a supercomputer and a promising method to deal with the transient EHL point contact problem. A typical pressure distribution and film thickness profile are presented and the minimum film thicknesses are compared with the solution of Hamrock and Dowson. The details of the cavitation boundaries for various operating parameters are discussed.

Description: This paper advances two linear operator factorizations of the manipulator mass matrix. Embedded in the factorizations are many of the techniques that are regarded as very efficient computational solutions to inverse and forward dynamics problems. The operator factorizations provide a high-level architectural understanding of the mass matrix and its inverse, which is not visible in the detailed algorithms. They also lead to a new approach to the development of computer programs or organize complexity in robot dynamics.

Description: Two formulas, one for the characteristic time of filling a void with the vapor of the surrounding liquid, and one of filling the void by diffusion of the dissolved gas in the liquid, are derived. By comparing these time scales with that of the dynamic operation of oil film bearings, it is concluded that the evaporation process is usually fast enough to fill the cavitation bubble with oil vapor; whereas the diffusion process is much too slow for the dissolved air to liberate itself and enter the cavitation bubble. These results imply that the formation of a two phase fluid in dynamically loaded bearings, as often reported in the literature, is caused by air entrainment. They further indicate a way to simplify the treatment of the dynamic problem of bubble evolution.

Description: An advanced, finite volume code has been extensively used in a parametric design study of simple stepped seals, in order to ascertain a leakage-minimizing optimal design and test it, in conjunction with the baseline case of the wear-ring seal of a high pressure pump. It is found that a significant leakage effect arises from this shifting of the rotor and stator sealing surfaces; at extremely low rpm, a significant shaft speed effect occurs for the optimized design in some shaft locations.

Description: Major issues and recent advances in the structural dynamics of rotating systems are summarized. The objectives and benefits of such systems are briefly discussed. Directions for future research are suggested.

Description: A nonlinear constrained optimization of a hydrodynamic bearing was performed yielding three main variables: radial clearance, bearing length to diameter ratio, and lubricating oil viscosity. As an objective function a combined model of temperature rise and oil supply has been adopted. The optimized model of the bearing has been simulated for population of 1000 cases using Monte Carlo statistical method. It appeared that the so called 'optimal solution' generated more than 50 percent of failed bearings, because their minimum oil film thickness violated stipulated minimum constraint value. As a remedy change of oil viscosity is suggested after several sensitivities of variables have been investigated.

Description: The design of an articulated space crane under NASA's 'Pathfinder' program continues to push forward. However, the large size and extreme flexibility of the crane entail major difficulties in precision positioning. To illustrate this and to gain more insight into its structural dynamic behavior, we have built three-dimensional rigid, flexible, homogenized and non-homogenized finite element models (FEM) of the articulated space crane and simulated its three-dimensional maneuvering. We have also begun to develop control strategies for the flexible system using first a simplified finite element model. The model captures much of the system's low frequency characteristics. From the FEM, a reduced-order model (ROM) based controller is designed based on a specific configuration of the crane. The ROM controller rotates the fixed shape crane about the alpha joint and uses three torque wheels at the tip to actuate its control law. Our analysis of the closed-loop system shows the destabilizing effect of control interaction with unmodeled system dynamics (Controller-Structure-Interaction). Making use of a parallel bank of residual-mode filters (RMF), we are able to compensate for CSI and restore system stability and performance. The implementation of the discrete-time control law on the simplified multi-body model is completed using the SAMCEF code.

Description: The design of an articulated space crane under NASA's 'Pathfinder' program continues to push forward. However, the large size and extreme flexibility of the crane entail major difficulties in precision positioning. We have begun to develop control strategies for the flexible system using a simplified finite element model. The model captures much of the system's low frequency characteristics. From the FEM, a reduced-roder model (ROM) based controller is designed based on a specific configuration of the crane. The ROM controller rotates the fixed shape crane about the alpha joint and uses three torque wheels at the tip to actuate its control law. Our analysis of the closed-loop system shows the de-stabilizing effect of control interaction its unmodeled system dynamics (Controller-Structure Interaction). Making use of a parallel bank of residual-mode filters (RMF), we are able to compensate for CSI and restore system stability and performance. Finally, the implementation of the discrete-time control law on the simplified multi-body model is completed using SAMCEF.

Description: Fluid transmission lines and fittings have been found to significantly affect the dynamic and steady state operation of the engineering system in which they are incorporated. Therefore, a better understanding of the operation of a system can be obtained by including the performance of the transmission lines and fittings within the system model. The most accurate model of a transmission line or fitting is obtained by using a distributed parameter model. However, a distributed parameter model tends to be very complex. This complexity can be avoided without significant loss of model accuracy by using a lumped parameter model when the length of the fluid path through the transmission line or fitting is short. This article develops a lumped parameter model for short fluid transmission lines and fittings, describes the conditions under which the model is valid, and presents the model parameters associated with the servo hydraulic system of the Deep Space Network (DSN) 70-meter antennas.

Description: Welding programs which show that parallel gas welding is a reliable process are discussed. When monitoring controls and nondestructive tests are incorporated into the process, parallel gap welding becomes more reliable and cost effective. The panel fabrication techniques and the HAC thermal cycling test indicate reliable product integrity. The design and building of automated tooling and fixturing for welding are discussed.

Description: The adhesion, friction, and wear properties of materials are reviewed and some of the factors influencing these properties are discussed. The forms of lubrication and types of lubricants will also be discussed.

Description: Because of the immense noise background during the operation of a large engine such as the SSME, the relatively low level unique ball bearing signatures were often buried by the overall machine signal. As a result, the most commonly used bearing failure detection technique, pattern recognition using power spectral density (PSD) constructed from the extracted bearing signals, is rendered useless. Data enhancement techniques were carried out by using a HP5451C Fourier Analyzer. The signal was preprocessed by a Digital Audio Crop. DAC-1024I noise cancelling filter in order to estimate the desired signal corrupted by the backgound noise. Reference levels of good bearings were established. Any deviation of bearing signals from these reference levels indicate the incipient bearing failures.

Description: The requirements, capabilities, and unique design features of the instrument payload subsystem payload clamp assembly (PCA) are presented. The PCA is designed to have the flexibility to accommodate a wide payload range varying from 0.5 m to 3 m in diameter and from 500 kg to 3000 kg mass. This is achieved by modular clamp design in connection with replaceable struts. The design features include clamping of payload in a statically determined way and actuation of clamp latches by means of single linear actuator via ropes. The vibration and TV environmental conditions for the mechanism are extremely severe. A structural and prototype model was built. Test results of the operating characteristic are presented. In addition, problems of tribology are highlighted.

Description: An antenna pointing mechanism for large reflector antennas on direct broadcasting communication satellites was built and tested. After listing the requirements and constraints for this equipment the model is described, and performance figures are given. Futhermore, results of the qualification level tests, including functional, vibrational, thermovacuum, and accelerated life tests are reported. These tests were completed successfully.

Description: The requirements, capabilities, and unique design features of the instrument pointing system drive units (DU) are presented. The DU's are identical for all three gimbal axes (elevation, cross elevation, and azimuth) and provide alternating rotation of shaft versus the housing of + or - 180 deg. The design features include: two ball bearing cartridges using cemented carbide balls coated with TiC a layer; redundant brushless torque motors and resolvers; a load by-pass mechanism driven by a dc torque motor to off-load the bearings during ascent/descent, ground transportation, and to provide an emergency breaking capability; and cabling over each gimbal axis by means of cable follow-up consisting of 13 signal and 15 power flat band cable loops. Test results of disturbance torque characteristics are presented.

Description: SOFA, a device designed for the highly accurate 2 axis pointing of antenna or any feature installed on a spacecraft is described. The major characteristic of this system is complete freedom from friction and wear out, resulting in numerous advantages, such as outstanding precision, virtually endless service life, high simplicity, and reliability. The sizing method is described and performances are analyzed. The results from analogue simulations are presented. A functional model of the electrical and mechanical parts was built and subjected to on ground tests using a 2 axis platform simulating the spacecraft's motions. The results obtained are thoroughly in keeping with the predictions and simulations. Various possible applications of the SOFA system are mentioned.

Description: Test results on the mechanical drive have indicated that the system is capable of deploying a typical telescopic mast under ambient conditions. The design can be considered for a wide range of space applications since, in theory, there is no limit to the number of tubes that can be deployed. The mechanical system offers a number of advantages over a gas driven system, such as the ability to retract and also provide a significant mass saving.

Description: A two-dimensional concept for Spacelab rack 7 was developed to study the interaction of liquid lubricants and surfaces under static and dynamic conditions in a low-gravity environment fluid wetting and spreading experiments of a journal bearing experiments, and means to accurately measure and record the low-gravity environment during experimentation are planned. The wetting and spreading process of selected commercial lubricants on representative surface are to the observes in a near-zero gravity environment.

Description: A test program to determine the relative sliding durability of an alumina-silica candidate ceramic fiber for high temperature sliding seal applications is described. Pin-on-disk tests were used to evaluate the potential seal material by sliding a tow or bundle of the candidate ceramic fiber against a superalloy test disk. Friction was measured during the tests and fiber wear, indicated by the extent of fibers broken in the tow or bundle, was measured at the end of each test. Test variables studied included ambient temperatures from 25 to 900 C, loads from 1.3 to 21.2 N, and sliding velocities from 0.025 to 0.25 m/sec. In addition, the effects of fiber diameter and elastic modulus on friction and wear were measured. Thin gold films deposited on the superalloy disk surface were evaluated in an effort to reduce friction and wear of the fibers. In most cases, wear increased with test temperature. Friction ranged from 0.36 at 500 C and low velocity (0.025 m/sec) to over 1.1 at 900 C and high velocity (0.25 m/sec). The gold films resulted in satisfactory lubrication of the fibers at 25 C. At elevated temperatures diffusion of substrate elements degraded the films. These results indicate that the alumina-silica (Al2O3-SiO2) fiber is a good candidate material system for high temperature sliding seal applications. More work is needed to reduce friction.

Description: A safehold mode has been implemented for Hubble Space Telescope that ensures a power-positive and thermally safe state without the use of rate gyros. This paper presents an overview of this zero-gyro sunpoint safemode, followed by details of the algorithm, the control system design, and results of simulations and of an on-orbit test of the algorithm.

Description: The lubrication problem of infinitely long slider bearings with a mixture of fluid and particulate solid at small volume fraction level is studied. Closed-form analytical solutions for pressure and shear stress are obtained for a class of solid aggregates. The results reduce to those of pure fluid in the limiting case. A parametric study of the bearing performance with particulate solid is presented.

Description: The stability of a journal bearing is numerically predicted when an unidirectional periodic external load is applied. The analysis is performed using a cavitation algorithm, which mimics the JFO theory by accounting for the mass balance through the complete bearing. Hence, the history of the film is taken into consideration. The loading pattern is taken to be sinusoidal and the frequency of the load cycle is varied. The results are compared with the predictions using Reynolds boundary conditions for both film rupture and reformation. With such comparisons, the need for accurately predicting the cavitation regions for complex loading patterns is clearly demonstrated. For a particular frequency of loading, the effects of mass, amplitude of load vibration and frequency of journal speed are also investigated.

Description: A new approach for plasma spray deposition of ceramic thermal barrier coatings directly to smooth substrates is described. Ceramic thermal barrier coatings were directly applied to substrates that had been coated with low-pressure plasma sprayed NiCrAlY bond coats and then centerless ground to simulate a smooth oxidation-resistant substrate. As the high-temperature oxidation behavior of NiAl+Zr is superior to that of MCrALY alloy, the bond coat is not required for oxidation resistance.

Description: Pressure-assisted infiltration of porous compacts of Cu coated and uncoated single crystals of platelet shaped alpha (hexagonal) SiC was used to study infiltration dynamics and particulate wettability with a 2014 Al alloy. The infiltration lengths were measured for a range of experimental variables which included infiltration pressure, infiltration time, and SiC size. A threshold pressure (P(th)) for flow initiation through compacts was identified from an analysis of infiltration data; P(th) decreased while penetration lengths increased with increasing SiC size (more fundamentally, due to changes in interparticle pore size) and with increasing infiltration times. Cu coated SiC led to lower P(th) and 60-80 percent larger penetration lengths compared to uncoated SiC under identical processing conditions.

Description: A kinematic analysis of anthropomorphic seven-degree-of-freedom serial link spatial manipulators with revolute joints is presented. To uniquely determine joint angles for a given end-effector position and orientation, the redundancy is parameterized by a scalar variable which corresponds to the angle between the arm plane and a reference plane. The forward kinematic mappings from joint-space to end-effector coordinates and arm angle and the augmented Jacobian matrix which gives end-effector and arm angle rates as functions of joint rates are given. Conditions under which the augmented Jacobian becomes singular are given and are shown to correspond to the arm being either at a kinematically singular configuration or at a nonsingular configuration for which the arm angle ceases to parameterize the redundancy.

Description: Presented is an analysis and evaluation of a prototype traction-drive joint for robotic manipulators, developed under NASA sponsorship. A dynamic model is developed using the Lagrange formulation. Controllability, observability, dynamic stabiliby, and response characteristics of the joint to test inputs are studied. A linear quadratic regulator (LQR) is implemented on the joint model to determine a basis for evaluating the performance of the traction-drive joint under servo control. An evaluation of the results and directions for future investigations are presented.

Description: The nonlinear frequency response characteristics of a geared rotor-bearing system are examined. A three-DOF dynamic model is developed which includes nonlinearities associated with radial clearances in the radial rolling element bearings and backlash between a spur gear pair; linear time-invariant gear meshing stiffness is assumed. The corresponding linear system problem is also solved, and predicted natural frequencies and modes match with finite element method results. The applicability of both analytical and numerical solution techniques to the multi-DOF nonlinear problem is investigated. Satisfactory agreement is found between the theory presented here and the available experimental data. Nonlinear modal interactions and differences between internal static transmission error excitation and external torque excitation are discussed. In addition, parametric studies are performed to understand the effect of system parameters such as bearing stiffness to gear mesh stiffness ratio, alternating to mean force ratio and radial bearing preload to mean force ratio on the nonlinear dynamic behavior.

Description: This investigative program examines leakage testing of elastomeric O-ring seals for a solid rocket casing and provides direction towards an improved nondestructive postassembly test. It also details test equipment for the Space Shuttle systems solid rocket boosters (SRB). The results are useful to designers of hardware for pressure containment vessels which use O-ring seals. Using several subscale seal and groove configuration test fixtures equipped with either two or three O-ring seals in series, seal integrity is investigated with both a pressure decay and flowmeter methods. Both types of test equipment adequately detect the practical range of expected seal leak rates of 1 to 0.0001 sccs. The flowmeter leak test equipment appears to reduce testing time substantially. Limited seal leakage testing is performed on full-sized rocket motor segment seals, a pre-Challenger short stack, providing comparison of bore seals to test specimen bore and face seals. The conclusions are that seal reliability, verified via a performance pressure test, can be affected by temperature, quantity of grease, test pressure, and seal pressure load direction. Potential seal failure scenarios including contamination, seal damage, and sealing surface damage are discussed. Recommendations are made for an improved test procedure.

Description: Thermographic nondestructive evaluation techniques were investigated for possible application on Space Shuttle solid rocket booster field joint hardware. This investigation included evaluation of the clevis and tang mating surfaces for scratches and measurement of grease film thickness. The field joint insulation system was inspected for voids and disbonds.

Description: A variety of solid state powder processing methods have been examined for their potential to produce high temperature materials. These techniques included solid state diffusion, mechanical alloying, reaction milling, and exothermic reactions. While both mechanical alloying and exothermic reactions are capable of producing high temperature composites in addition to yielding solid solution and precipitation hardened alloys, reaction milling can only be used to make composite materials. Although at present this method has only been applied to make carbide strengthened Al, recent work indicates that reaction milling is capable of yielding high strength NiAl-AlN composites.

Description: The paper proposes a reduced-order analytical model of a spur gear pair which consists of two identical spur gears, two identical flexible shafts, and four identical rolling element bearings of a given radial stiffness. The error associated with the undamped eigensolution is estimated by a comparison with a benchmark finite element model.

Description: The lubrication characteristic of a fluid with solid particles is studied using the continuum theory of mixtures. The governing equations are formulated and appropriate boundary conditions are introduced for an arbitrary-shaped lubricant film thickness. As a special case, closed-form analytical perturbation solutions for pressure and shear stress are obtained for a mixture of a conventional oil and solid particles with small values of solid-volume fraction sheared in the clearance space of an infinitely long slider bearing. It is found that when compared with a pure fluid, the mixture of the fluid and solid generates a higher pressure and therefore a higher load-carrying capacity with the added advantage of a reduction in the coefficient of friction.

Description: The dynamic behavior of multistage gear transmission system, with the effects of gear-box-induced vibrations and rotor mass-imbalances is analyzed. The model method, using undamped frequencies and planar mode shapes, is used to reduce the degree-of-freedom of the system. The various rotor-bearing stages as well as lateral and torsional vibrations of each individual stage are coupled through localized gear-mesh-tooth interactions. Gear-box vibrations are coupled to the gear stage dynamics through bearing support forces. Transient and steady state dynamics of lateral and torsional vibrations of the geared system are examined in both time and frequency domain. A typical three-staged geared system is used as an example. Effects of mass-imbalance and gear box vibrations on the system dynamic behavior are presented in terms of modal excitation functions for both lateral and torsional vibrations. Operational characteristics and conclusions are drawn from the results presented.

Description: This paper conceptualizes a powder lubrication mechanisms which closely resembles that of a hydrodynamic fluid film. Based on the observations of past investigations and on the author's experiments, it is postulated that a layered shearing of the compacted powder generates velocity, density, and temperature profiles akin to fluid film bearings. Thus, a lubricant consisting of a fine powder unserted either deliberately or one generated by the water of the mating surfaces, constitutes a viable lubricant that generates the required flows and pressures to prevent contact between the surfaces.

Description: Procedures for the preliminary design for composite adhesive joints are described. Typical joints, their respective free body diagrams, and approximate equations for estimating the stresses in each of these typical joints are summarized. Equations are also presented to check the critical conditions of the joint such as minimum length, maximum adhesive shear stress, and peel-off stress. To illustrate the procedure, sample designs are described in step-by-step fashion for a butt joint with single doubler subjected to static loads, cyclic loads, and environmental effects. The results show that unsymmetric adhesive joints are inefficient and should be avoided, and hygrothermal environments and cyclic loads dramatically reduce the structural integrity of the joint and require several joint lengths compared with those for static load with no environmental effects.

Description: By using the Lee-Springer filament winding model temperatures, degrees of cure, viscosities, stresses, strains, fiber tensions, fiber motions, and void diameters were calculated in graphite-epoxy composite cylinders during the winding and subsequent curing. The results demonstrate the type of information which can be generated by the model. It is shown, in reference to these results, how the model, and the corresponding WINDTHICK code, can be used to select the appropriate process variables.

Description: A model was developed which describes the filament winding process of composite cylinders. The model relates the significant process variables such as winding speed, fiber tension, and applied temperature to the thermal, chemical and mechanical behavior of the composite cylinder and the mandrel. Based on the model, a user friendly code was written which can be used to calculate (1) the temperature in the cylinder and the mandrel, (2) the degree of cure and viscosity in the cylinder, (3) the fiber tensions and fiber positions, (4) the stresses and strains in the cylinder and in the mandrel, and (5) the void diameters in the cylinder.

Description: Analytical and experimental studies were performed to validate the model developed by Lee and Springer for simulating the manufacturing process of filament wound composite cylinders. First, results calculated by the Lee-Springer model were compared to results of the Calius-Springer thin cylinder model. Second, temperatures and strains calculated by the Lee-Springer model were compared to data. The data used in these comparisons were generated during the course of this investigation with cylinders made of Hercules IM-6G/HBRF-55 and Fiberite T-300/976 graphite-epoxy tows. Good agreement was found between the calculated and measured stresses and strains, indicating that the model is a useful representation of the winding and curing processes.

Description: The backlash nonlinearity excited primarily by transmission error between spur gear pairs is studied for both external and internal excitations. The digital simulation technique and the method of harmonic balance are used to develop steady state solutions for the internal sinuosidal excitations. The analytic predictions agreed well with available experimental data. Digital simulation is used to observe that at the chaotic and subharmonic resonances may exist in a gear pair depending on the mean or design load, mean to alternating force ratio, damping, and backlash.

Description: This paper describes a new high-temperature friction and wear test apparatus (tribometer). The tribometer can be used as a pin-on-disk or pin-on-ring configuration and is specially designed to measure the tribological properties of ceramics and high temperature metallic alloys from room temperature to 1200 C. Sliding mode can be selected to be either unidirectional at velocities up to 22 m/sec or oscillating at frequencies up to 4.6 Hz and amplitudes up to + or - 60 deg. The test atmosphere is established by a controlled flow rate of a purge gas. All components within the test chamber are compatible with oxidizing, inert or reducing gases.

Description: A numerical transient solution of the hydrodynamically lubricated point contact problem is obtained using the ball-on-plane model. Results, which include the variation of the minimum film thickness and phase-lag with time as functions of excitation frequency, are compared with the analytic solution of the transient step bearing problem with the same dynamic loading function.

Description: The development of a continuous ceramic fiber which could be used in rocket engine and rocket boosters applications was investigated at the Marshall Space Flight Center. Methods of ceramic fiber production such as melt spinning, chemical vapor deposition, and precursor polymeric fiber decomposition are discussed and compared with sol-gel processing. The production of ceramics via the sol-gel method consists of two steps, hydrolysis and polycondensation, to form the preceramic, followed by consolidation into the glass or ceramic structure. The advantages of the sol-gel method include better homogeneity and purity, lower preparation temperature, and the ability to form unique compositions. The disadvantages are the high cost of raw materials, large shrinkage during drying and firing which can lead to cracks, and long processing times. Preparation procedures for aluminosilicate sol-gel and for continuous mullite fibers are described.

Description: Future space power systems may include Nb-1Zr/Inconel 718 dissimilar metal joints for operation at 1000 K for 60,000 h. The serviceability of pressure-brazed and diffusion-welded joints was investigated. Ni-based metallic glass foil filler metals were used for brazing. Ni and Fe foils were used as diffusion welding inter-layers. Joint soundness was determined by metallographic examination in the as-brazed and as-welded condition, after aging at 1000 K, and after thermal cycling. Brazed joints thermally cycled in the as-brazed condition and diffusion-welded joints were unsatisfactory because of cracking problems. Brazed joints may meet the service requirements if the joints are aged at 1000 K prior to thermal cycling.

Description: Two all-metal demountable cryogenic seals with an outside diameter of 36.6 mm, inside diameter of 27.2 mm and thickness of 0.51 mm were leak-tested at room temperature (300 K), liquid nitrogen temperature (21 cycles at 77 K), liquid helium temperature (nine cycles at 4.2K) and superfluid helium temperature (four cycles at 1.6 K). Each seal was mounted and demounted for 13 cycles. Thickness measurements at 90 deg intervals along the circumference showed a maximum seal compression of 0.038 mm. Leak rate measurements at all temperatures showed no detectable leak above the helium background level, typically 0.1 x 10 exp -9 std cu cm/s, during testing.

Description: A numerical study is performed of oil groove type (circumferential and axial), groove number (single and double) and groove location on journal bearing performance. The analysis involves the use of a cavitation algorithm. The interaction between cavitation phenomena and grooving is determined. Quantitative information is provided which will aid designers to better locate oil feed grooves.

Description: Variable polarity plasma arc (VPPA) techniques used at NASA's Marshall Space Flight Center for the fabrication of the Space Shuttle External Tank are presentedd. The high plasma arc jet velocities of 300-2000 m/s are produced by heating the plasma gas as it passes through a constraining orifice, with the plasma arc torch becoming a miniature jet engine. As compared to the GTA jet, the VPPA has the following advantages: (1) less sensitive to contamination, (2) a more symmetrical fusion zone, and (3) greater joint penetration. The VPPA welding system is computerized, operating with a microprocessor, to set welding variables in accordance with set points inputs, including the manipulator and wire feeder, as well as torch control and power supply. Some other VPPA welding technique advantages are: reduction in weld repair costs by elimination of porosity; reduction of joint preparation costs through elimination of the need to scrape or file faying surfaces; reduction in depeaking costs; eventual reduction of the 100 percent-X-ray inspection requirements. The paper includes a series of schematic and block diagrams.

Description: Two-phase turbines would be useful in Rankine cycles using low-quality or saturated-liquid working fluids. The chief problem is low efficiency due to slip losses in nozzles and due to liquid impact and friction losses in rotors. To raise efficiency, a staging method was tested in which the first stage operated at high speed with low relative liquid velocity, and the second stage recovered the first-stage exit energy. The theoretical efficiency for an experimental turbine operating with Refrigerant-22 was raised from 55 percent to 66 percent, and the measured efficiency was raised from 52 percent to 57 percent.

Description: An overview of the DOE/NASA Automotive Stirling Engine Project is presented. The background and objectives of the project are reviewed. Project activities are described and technical progress and status are presented and assessed. Prospects for achieving the objective 30 percent fuel economy improvement are considered good. The key remaining technology issues are primarily related to life, reliability and cost, such as piston rod seals, and low cost heat exchanges. Previously announced in STAR as N83-27924

Description: The analysis presented herein deals with the evaluation of the pressure, velocity, and temperature profiles in a finite-length plane journal bearing. The geometry of the case under study consists of a spatially tilted shaft. The two-dimensional Reynolds equation accounts for the variation of the clearance gap h with x and z and is used to model the pressure field. The latter is solved for a variety of shaft tilt angles and then used to calculate the two-dimensional flow field. Finally, the flow field is used in the energy equation to solve for the film temperature profile, when the effect of viscous dissipation is taken into account.

Description: In this paper, some of the effects of unbalance on the nonlinear response and stability of flexible rotor-bearing systems is presented from both a theoretical and experimental standpoint. In a linear system, operating above its stability threshold, the amplitude of motion grows exponentially with time and the orbits become unbounded. In an actual system, this is not necessarily the case. The actual amplitudes of motion may be bounded due to various nonlinear effects in the system. These nonlinear effects cause limit cycles of motion. Nonlinear effects are inherent in fluid film bearings and seals. Other contributors to nonlinear effects are shafts, couplings and foundations. In addition to affecting the threshold of stability, the nonlinear effects can cause jump phenomena to occur at not only the critical speeds, but also at stability onset or restabilization speeds.

Description: The paper addresses the potential that ceramic materials can play an important role in future automotive powerplants - both advanced heat engines and advanced battery systems. A number of related experimental programs are reviewed including ceramics for gasoline and diesel piston engines, gas turbine and Stirling Engines and sodium-sulfur batteries. A strong integrated program to develop ceramics technology is recommended.

Description: An analysis was conducted for into mesh oil jet lubrication with an arbitrary offset and inclination angle from the pitch point for the case where the oil jet velocity is equal to or less than pitch line velocity. The analysis includes the case for the oil jet offset from the pitch point in the direction of the pinion and where the oil jet is inclined to intersect the common pitch point. Equations were developed for the minimum oil jet velocity required to impinge on the pinion or gear and the optimum oil jet velocity to obtain the maximum impingement depth.

Description: Two techniques for reducing friction forces are presented. The techniques are applied to the generalized problem of reducing the friction between kinematic pairs which connect a moveable link to a frame. The basic principles are: (1) Let the moveable link be supported by two bearings where the relative velocities of the link with respect to each bearing are of opposite directions. Thus the resultant force (torque) of friction acting on the link due to the bearings is approximately zero. Then, additional perturbation of motion parallel to the main motion of the moveable link will require only a very small force; (2) Let the perturbation in motion be perpendicular to the main motion. Equations are developed which explain these two methods. The results are discussed in relation to friction in geared couplings, gyroscope gimbal bearings and a rotary conveyor system. Design examples are presented.

Description: Oil is still a problem for the U.S. and its allies. Transportation uses 61 percent of U.S. oil and its share is increasing, so more efficient technology should be concentrated there. Trucks' share of oil use is increasing because they are already much more efficient than autos. The primary truck opportunities are streamlining, more efficient engines, and shifting freight to railroads. More efficient engines are possible using ceramics to allow elimination of cooling systems and better use of waste exhaust heat. A 60 percent improvement seems possible if ceramics can be made tough enough and durable enough.

Description: In order to validate theoretical predictions of a wave journal bearing concept, a bench test rig was assembled at NASA Lewis Research Center to measure the steady-state performance of a journal air bearing. The tester can run up to 30,000 RPM and the spindle has a run out of less than 1 micron. A three wave journal bearing (50 mm diameter and 58 mm length) has been machined at NASA Lewis. The pressures at 16 ports along the bearing circumference at the middle of the bearing length were measured and compared to the theoretical prediction. The bearing ran at speeds up to 15,000 RPM and certain loads. Good agreement was found between the measured and calculated pressures.

Description: This viewgraph presentation presents the following results for the example comparison: EG&G code with face deformations suppressed and SPIRALG agree well with each other as well as with the experimental data; 0 rpm stiffness data calculated by EG&G code are about 70-100 percent lower than that by SPIRALG; there is no appreciable difference between 0 rpm and 16,000 rpm stiffness and damping coefficients calculated by SPIRALG; and the film damping above 500 psig calculated by SPIRALG is much higher than the O-Ring secondary seal damping (e.g. 50 lbf.s/in).

Description: Seals examined were the eight-pad Rayleigh step, the tapered spiral groove, and two hydrostatic seals. The spiral groove configuration is the preferred choice because of superior stiffness. Second choice is Rayleigh step because of combined higher operating film thickness and good stiffness at low clearance. Recess hydrostatic has reasonable performance, but stiffness falls off at low clearance. Also, pneumatic hammer characteristics must be investigated. Experience at high pressure ratios is limited. An advantage is that it would have good low speed performance.

Description: The purposes of the computer tools for face seal analysis are new product optimization, existing seals on new applications, existing seals on off-duty conditions, and trouble-shooting. Discussed in this viewgraph presentation are interface forces, friction/heat generation, heat transfer/temperature distribution, axisymmetric pressure/thermal distortion, leakage, and an example case.