ALBERT

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: 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: 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 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 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: 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.

Description: The development of the brush seal is considered to be most promising among the advanced type seals that are presently in use in the high speed turbomachinery. The brush is usually mounted on the stationary portions of the engine and has direct contact with the rotating element, in the process of limiting the 'unwanted' leakage flows between stages, or various engine cavities. This type of sealing technology is providing high (in comparison with conventional seals) pressure drops due mainly to the high packing density (around 100 bristles/sq mm), and brush compliance with the rotor motions. In the design of modern aerospace turbomachinery leakage flows between the stages must be minimal, thus contributing to the higher efficiency of the engine. Use of the brush seal instead of the labyrinth seal reduces the leakage flow by one order of magnitude. Brush seals also have been found to enhance dynamic performance, cost less, and are lighter than labyrinth seals. Even though industrial brush seals have been successfully developed through extensive experimentation, there is no comprehensive numerical methodology for the design or prediction of their performance. The existing analytical/numerical approaches are based on bulk flow models and do not allow the investigation of the effects of brush morphology (bristle arrangement), or brushes arrangement (number of brushes, spacing between them), on the pressure drops and flow leakage. An increase in the brush seal efficiency is clearly a complex problem that is closely related to the brush geometry and arrangement, and can be solved most likely only by means of a numerically distributed model.

Description: This viewgraph presentation presents test results of brush seals for cryogenic applications. Leakage for a single brush seal was two to three times less than for a 12-tooth labyrinth seal. The maximum temperature rise for a single brush seal was less than 50 R and occurred at 25 psid across the seal and 35,000 rpm. A static blowout test demonstrated sealing capability up to 550 psid. The seal limit was not obtained. The power loss for a single brush at 35,000 rpm and 175 psid was 2.45 hp. Two brushes far apart leak less than two brushes tight packed. Rotor wear was approximately 0.00075 mils and bristle wear was 1-3 mils after 4-1/2 hours.

Description: This viewgraph presentation describes the development of user interfaces for OS/2 versions of computer codes for the analysis of seals. Current status, new features, work in progress, and future plans are discussed.

Description: Japan has been one of the most successful countries in the world in the realm of terrestrial robot applications. The panel found that Japan has in place a broad base of robotics research and development, ranging from components to working systems for manufacturing, construction, and human service industries. From this base, Japan looks to the use of robotics in space applications and has funded work in space robotics since the mid-1980's. The Japanese are focusing on a clear image of what they hope to achieve through three objectives for the 1990's: developing long-reach manipulation for tending experiments on Space Station Freedom, capturing satellites using a free-flying manipulator, and surveying part of the moon with a mobile robot. This focus and a sound robotics infrastructure is enabling the young Japanese space program to develop relevant systems for extraterrestrial robotics applications.

Description: Future long-link, ultra-speed, surface transport systems will require electromagnetically (EM) driven and restrained vehicles operating under reduced-atmosphere in very straight tubes. Such tube-flight trains will be safe, energy conservative, pollution-free, and in a protected environment. Hypersonic (and even hyperballistic) speeds are theoretically achievable. Ultimate system choices will represent tradeoffs between amoritized capital costs (ACC) and operating costs. For example, long coasting links might employ aerodynamic lift coupled with EM restraint and drag make-up. Optimized, combined EM lift, and thrust vectors could reduce energy costs but at increased ACC. (Repulsive levitation can produce lift-over-drag l/d ratios a decade greater than aerodynamic), Alternatively, vehicle-emanated, induced-mirror fields in a conducting (aluminum sheet) road bed could reduce ACC but at substantial energy costs. Ultra-speed tube flight will demand fast-acting, high-precision sensors and computerized magnetic shimming. This same control system can maintain a magnetic 'guide way' invariant in inertial space with inertial detectors imbedded in tube structures to sense and correct for earth tremors. Ultra-speed tube flight can complete with aircraft for transit time and can provide even greater passenger convenience by single-model connections with local subways and feeder lines. Although cargo transport generally will not need to be performed at ultra speeds, such speeds may well be desirable for high throughput to optimize channel costs. Thus, a large and expensive pipeline might be replaced with small EM-driven pallets at high speeds.

Description: This study is an application of H-infinity and micro-synthesis for designing robust tracking controllers for the Large Angle Magnetic Suspension Test Facility. The modeling, design, analysis, simulation, and testing of a control law that guarantees tracking performance under external disturbances and model uncertainties is investigated. The type of uncertainties considered and the tracking performance metric used is discussed. This study demonstrates the tradeoff between tracking performance at low frequencies and robustness at high frequencies. Two sets of controllers were designed and tested. The first set emphasized performance over robustness, while the second set traded off performance for robustness. Comparisons of simulation and test results are also included. Current simulation and experimental results indicate that reasonably good robust tracking performance can be attained for this system using multivariable robust control approach.

Description: The combination of a high-speed motor, dry gas seals, and magnetic bearings realized in this unit facilitates the elimination of oil. The motor is coupled with a quill shaft to the compressor. This yields higher natural frequencies of the rotor than with the use of a diaphragm coupling and helps to maintain a sufficient margin of the maximum speed to the frequency of the second compressor bending mode. However, the controller of each bearing then has to take the combined modes of both machines into account. The requirements for the controller to ensure stability and sufficient damping of all critical speeds are designed and compared with the implemented controller. The calculated closed loop behavior was confirmed experimentally, except the stability of some higher modes due to slight frequency deviations of the rotor model to the actual rotor. The influence of a mechanical damper as a device to provide additional damping to high models is demonstrated theoretically. After all, it was not necessary to install the damper, since all modes cold be stabilized by the controller.

Description: Magnetic bearings have demonstrated the capability for achieving positioning accuracies at the nanometer level in precision motion control stages. This makes possible the positioning of a wafer in six degrees of freedom with the precision necessary for photolithography. To control the position of an object at the nanometer level, a model of the magnetic bearing actuator force-current-airgap relationship must be accurately obtained. Additionally, to reduce thermal effects the design of the actuator should be optimized to achieve maximum power efficiency and flux density. Optimization of the actuator is accomplished by proper pole face sizing and utilizing a magnetic core material which can be magnetized to the highest flux density with low magnetic loss properties. This paper describes the construction of a magnetic bearing calibration fixture designed for experimental measurement of the actuator force characteristics. The results of a material study that review the force properties of nickel-steel, silicon-steel, and cobalt-vanadium-iron, as they apply to magnetic bearing applications are also presented.

Description: Through a series of component and system-level tests, the torque margin for the MSAT booms is being determined. The verification process has yielded a number of results and lessons that can be applied to many other types of deployable spacecraft mechanisms. The MSAT load absorber has proven to be an effective way to provide high energy dissipation using crushable honeycomb. Using two stages of crushable honeycomb and a fusible link, a complex crush load profile has been designed and implemented. The design features of the load absorber lend themselves to use in other spacecraft applications.

Description: The Ranger program at the Space Systems Laboratory (SSL) at the University of Maryland is a demonstration of an extremely low cost, space flight experiment. The Ranger vehicle is designed to perform teleoperated spacecraft maintenance. Completing the various tasks included in spacecraft maintenance requires several specific tools. This paper describes the Ranger interchangeable end effector mechanism (IEEM). Its design allows Ranger to change end effectors to utilize the appropriate tool for the various tasks. The Ranger vehicle is designed with four manipulators. A seven degree-of-freedom (DOF) grappling manipulator securely attaches the vehicle to the work site. A 6 DOF camera positioning manipulator allows the operator to position a stereo pair of video cameras for visual feedback. The two remaining manipulators are the 7 DOF dexterous arms. They are the primary means by which Ranger accomplishes its required tasks. At the end of each of these dexterous manipulators is an IEEM. This paper begins with a brief overview of the Space Systems Laboratory and the Ranger program. The constraints leading to the requirements for an IEEM are described. The following section then describes the design strategies and the down selection process resulting in two candidate designs, taper and pneumatic connector type. Next, the leading candidate design is described in detail, followed by a preliminary discussion of failure modes and planned testing. The paper concludes with a brief review and a section discussing future work.

Description: A tension mechanism is used to apply a tension force to the Space Station Freedom Solar Array Blanket. This tension is necessary to meet the deployed frequency requirement of the array as well as maintain the flatness of the flexible substrate solar cell blanket. The mechanism underwent a series of design iterations before arriving at the final design. This paper discusses the design and testing of the mechanism.

Description: The original FTS concept for Space Station Freedom (SSF) was to provide telerobotic assistance to enhance crew activity and safety and to reduce crew EVA (Extra Vehicular Activity) activity. The first flight of the FTS manipulator systems would demonstrate several candidate tasks and would verify manipulator performance parameters. These first flight tasks included unlocking a SSF Truss Joint, mating/demating a fluid coupling, contact following of a contour board, demonstrating peg-in-hole assembly, and grasping and moving a mass. Future tasks foreseen for the FTS system included ORU (Orbit Replaceable Unit) change-out, Hubble Space Telescope Servicing, Gamma Ray Observatory refueling, and several in-situ SSF servicing and maintenance tasks. Operation of the FTS was planned to evolve from teleoperation to fully autonomous execution of many tasks. This wide range of mission tasks combined with the desire to evolve toward fully autonomy forced several requirements which may seen extremely demanding to the telerobotics community. The FTS requirements appear to have been created to accommodate the open-ended evolution plan such that operational evolution would not be impeded by function limitations. A recommendation arising from the FTS program to remedy the possible impacts from such ambitious requirements is to analyze candidate robotic tasks. Based on these task analyses, operational impacts against development impacts were weighed prior to requirements definition. Many of the FTS requirements discussed in the following sections greatly influenced the development cost and schedule of the FTS manipulator. The FTS manipulator has been assembled at Martin Marietta and is currently in testing. Successful component tests indicate a manipulator which achieves unprecedented performance specifications.

Description: The Dexterous End Effector Flight Experiment is a flight demonstration of newly developed equipment and methods which make for more dexterous manipulation of robotic arms. The following concepts are to be demonstrated: The Force Torque Sensor is a six axis load cell located at the end of the RMS which displays load data to the operator on the orbiter CCTV monitor. TRAC is a target system which provides six axis positional information to the operator. It has the characteristic of having high sensitivity to attitude misalignment while being flat. AUTO-TRAC is a variation of TRAC in which a computer analyzes a target, displays translational and attitude misalignment information, and provides cues to the operator for corrective inputs. The Magnetic End Effector is a fault tolerant end effector which grapples payloads using magnetic attraction. The Carrier Latch Assembly is a fault tolerant payload carrier, which uses mechanical latches and/or magnetic attraction to hold small payloads during launch/landing and to release payloads as desired. The flight experiment goals and objectives are explained. The experiment equipment is described, and the tasks to be performed during the demonstration are discussed.

Description: The Robotic All Terrain Lunar Exploration Rover (RATLER) design concept began at Sandia National Laboratories in late 1991 with a series of small, proof-of-principle, working scale models. The models proved the viability of the concept for high mobility through mechanical simplicity, and eventually received internal funding at Sandia National Laboratories for full scale, proof-of-concept prototype development. Whereas the proof-of-principle models demonstrated the mechanical design's capabilities for mobility, the full scale proof-of-concept design currently under development is intended to support field operations for experiments in telerobotics, autonomous robotic operations, telerobotic field geology, and advanced man-machine interface concepts. The development program's current status is described, including an outline of the program's work over the past year, recent accomplishments, and plans for follow-on development work.

Description: The use of robotics in situations involving hazardous materials can significantly reduce the risk of human injuries. The Emergency Response Robotics Project, which began in October 1990 at the Jet Propulsion Laboratory, is developing a teleoperated mobile robot allowing HAZMAT (hazardous materials) teams to remotely respond to incidents involving hazardous materials. The current robot, called HAZBOT III, can assist in locating characterizing, identifying, and mitigating hazardous material incidents without risking entry team personnel. The active involvement of the JPL Fire Department HAZMAT team has been vital in developing a robotic system which enables them to perform remote reconnaissance of a HAZMAT incident site. This paper provides a brief review of the history of the project, discusses the current system in detail, and presents other areas in which robotics can be applied removing people from hazardous environments/operations.

Description: The Omni-Directional Vehicle (ODV) development program sponsored by the Office of Naval Research at the Coastal Systems Station has investigated the application of ODV technology for use in the Navy shipboard environment. ODV technology as originally received by the Navy in the form of the Cadillac-Gage Side Mover Vehicle was applicable to the shipboard environment with the potential to overcome conditions of reduced traction, ship motion, decks heeled at high angles, obstacles, and confined spaces. Under the Navy program, ODV technology was investigated and a series of experimental vehicles were built and successfully tested under extremely demanding conditions. The ODV drive system has been found to be applicable to autonomous, remotely, or manually operated vehicles. Potential commercial applications include multi-directional forklift trucks, automatic guided vehicles employed in manufacturing environments, and remotely controlled platforms used in nuclear facilities or for hazardous waste clean up tasks.

Description: The purpose of this design project was to design an active planar stiffening device for the existing ACES (Acoustic Containerless Experiment System) structure. the ACES structure was modeled using simple beam theory. Various concepts were generated about how the stiffening device should be configured in order to perform at an optimum level. The optimum configuration was selected to be a single set of spreaders located approximately 63% of the distance down the beam. Actuation was to be provided by a DC electric motor. From the test results, the design group was able to draw conclusions and make recommendations about the utility of further research into this area.

Description: Complex missions require routine and unscheduled inspection for safe operation. The purpose of research in this task is to facilitate structural inspection of the planned Space Station while mitigating the need for extravehicular activity (EVA), and giving the operator supervisory control over detailed and somewhat mundane, but important tasks. The telerobotic system enables inspection relative to a given reference (e.g., the status of the facility at the time of the last inspection) and alerts the operator to potential anomalies for verification and action. There are two primary objectives of this project: (1) To develop technologies that enable well-integrated NASA ground-to-orbit telerobotics operations, and (2) to develop a prototype common architecture workstation which implements these capabilities for other NASA technology projects and planned NASA flight applications. This task develops and supports three telerobot control modes which are applicable to time delay operation: Preview teleoperation, teleprogramming, and supervised autonomy.

Description: The strategic decisions taken by ASI in the last few years in building up the overall A&R program, represent the technological drivers for other applications (i.e., internal automation of the Columbus Orbital Facility in the ESA Manned Space program, applications to mobile robots both in space and non-space environments, etc...). In this context, the main area of application now emerging is the scientific missions domain. Due to the broad range of applications of the developed technologies, both in the in-orbit servicing and maintenance of space structures and scientific missions, ASI foresaw the need to have a common technological development path, mainly focusing on: (1) control; (2) manipulation; (3) on-board computing; (4) sensors; and (5) teleoperation. Before entering into new applications in the scientific missions field, a brief overview of the status of the SPIDER related projects is given, underlining also the possible new applications for the LEO/GEO space structures.

Description: This report summarizes the research and development status and perspective on space robotics in Japan. The R & D status emphasizes the current on-going projects at NASDA including the JEM Remote Manipulator System (JEMRMS) to be used on Space Station Freedom and the robotics experiments on Engineering Satellite 7 (ETS-7). As a future perspective, not only NASDA, but also ISAS and other government institutes have been promoting their own research in space robotics in order to support wide spread space activities in the future. Included in this future research is an autonomous satellite retrieval experiment, a dexterous robot experiment, an on-orbit servicing platform, an IVA robot, and several moon/planetary rovers proposed by NASDA or ISAS and other organizations.

Description: A containerless image furnace with an electrostatic positioning device has been developed as one of the material experiment facilities on the Japanese experimental module (JEM). It is characterized by heating/melting/cooling the sample whose position is kept without any contacts by actively controlled electrostatic force exerted between the sample and a set of electrodes. The experiment using the image furnace requires various servicing operations. We have been developing a robotic servicing system with an internal robot accommodated in the rack as an alternative to the crew. It aims to reduce the load on the crew by automating regular tasks and to increase the flexibility applicable to simple irregular tasks by introducing a remote teleoperation scheme. The present robot has poor capability to replace the crew. In order to compensate it, introducing of the concept of the robot friendliness and improving the controllability of the teleoperation by the ground operator aids are essential. In this paper, we identify the tasks to be performed by the robotic servicing system and discuss the way to compensate the capability of the robot. In addition we describe the evaluation tests using an experimental model.

Description: NASA has identified telerobotics and telescience as essential technologies to reduce the crew extra-vehicular activity (EVA) and intra-vehicular activity (IVA) workloads. Under this project, we are developing and flight testing a novel IVA robot to relieve the crew of tedious and routine tasks. Through ground telerobotic control of this robot, we will enable ground researchers to routinely interact with experiments in space. Our approach is to develop an IVA robot system incrementally by employing a series of flight tests with increasing complexity. This approach has the advantages of providing an early IVA capability that can assist the crew, demonstrate capabilities that ground researchers can be confident of in planning for future experiments, and allow incremental refinement of system capabilities and insertion of new technology. In parallel with this approach to flight testing, we seek to establish ground test beds, in which the requirements of payload experimenters can be further investigated. In 1993 we reviewed manifested SpaceHab experiments and defined IVA robot requirements to assist in their operation. We also examined previous IVA robot designs and assessed them against flight requirements. We rejected previous design concepts on the basis of threat to crew safety, operability, and maintainability. Based on this insight, we developed an entirely new concept for IVA robotics, the CHARLOTTE robot system. Ground based testing of a prototype version of the system has already proven its ability to perform most common tasks demanded of the crew, including operation of switches, buttons, knobs, dials, and performing video surveys of experiments and switch panels.

Description: Carnegie Mellon University has undertaken a research, development, and demonstration program to enable a robotic lunar mission. The two-year mission scenario is to traverse 1,000 kilometers, revisiting the historic sites of Apollo 11, Surveyor 5, Ranger 8, Apollo 17, and Lunokhod 2, and to return continuous live video amounting to more than 11 terabytes of data. Our vision blends autonomously safeguarded user driving with autonomous operation augmented with rich visual feedback, in order to enable facile interaction and exploration. The resulting experience is intended to attract mass participation and evoke strong public interest in lunar exploration. The encompassing program that forwards this work is the Lunar Rover Initiative (LRI). Two concrete technology demonstration projects currently advancing the Lunar Rover Initiative are: (1) The Dante/Mt. Spurr project, which, at the time of this writing, is sending the walking robot Dante to explore the Mt. Spurr volcano, in rough terrain that is a realistic planetary analogue. This project will generate insights into robot system robustness in harsh environments, and into remote operation by novices; and (2) The Lunar Rover Demonstration project, which is developing and evaluating key technologies for navigation, teleoperation, and user interfaces in terrestrial demonstrations. The project timetable calls for a number of terrestrial traverses incorporating teleoperation and autonomy including natural terrain this year, 10 km in 1995. and 100 km in 1996. This paper will discuss the goals of the Lunar Rover Initiative and then focus on the present state of the Dante/Mt. Spurr and Lunar Rover Demonstration projects.

Description: This paper describes the design and development of a mobile robotic system to process orbiter thermal protection system (TPS) tiles. This work was justified by a TPS automation study which identified tile rewaterproofing and visual inspection as excellent applications for robotic automation.

Description: Japan is collaborating on the multinational space station program. The JEM, Japanese Experiment Module, has both a pressurized module and an Exposed Facility (EF). JEM Remote Manipulator System (JEMRMS) will play a dominant role in handling/servicing payloads and the maintenance of the EF, and consists of two robotic arms, a main arm and a small fine arm. JEM Flight Demonstration (JFD) is a space robotics experiment using the prototype small fine arm to demonstrate its capability, prior to the Space Station operation. The small fine arm will be installed in the Space Shuttle cargo bay and operated by a crew from a dedicated workstation in the Aft Flight Deck of the orbiter.

Description: Recently, a fluid turbine which has a brush attached to it has been designed and tested with water as fluid. The purpose of the turbine-brush is to clean up fouling in a tube. The Montreal Protocol prohibits the use of CFC products from refrigeration industry or from industry in general as a cleanser in 1996. Alternatives for the cleansers, devices or a combination of alternative devices with a cleanser should be found. One of the methods is to develop a device which cleans fouling with a cleaning medium. In this paper, we describe a turbine connected with a brush. However, the turbine with the brush should be simple and easy to install. This device is a combined small liquid turbine with a brush. The turbine is activated by the liquid flowing through the tube. Then the turbine turns the brush cleaning fouling along the tube. Based on the energy conservation and the Bernoulli equation along with an empirical relationship of drag force obtained from an experimental apparatus, a relationship of the rotational speed, the number of blades, and geometric variables of the turbine-brush was obtained. The predicted rotational speeds were compared with the experimental observations. Further work was recommended for improvements.

Description: Simplex is a turbopump that is being developed at NASA/Marshall Space Flight Center (MSFC) by an in-house team. The turbopump consists of a single-stage centrifugal impeller, vaned-diffuser pump powered by a single-stage, axial, supersonic, partial admission turbine. The turbine is driven by warm gaseous oxygen tapped off of the hybrid motor to which it will be coupled. Rolling element bearings are cooled by the pumping fluid. Details of the configuration and operating conditions are given by Marsh. CFD has been used extensively to verify one-dimensional (1D) predictions, assess aerodynamic and hydrodynamic designs, and to provide flow environments. The complete primary flow path of the pump-end and the hot gas path of the turbine, excluding the inlet torus, have been analyzed. All CFD analyses conducted for the Simplex turbopump employed the pressure based Finite Difference Navier-Stokes (FDNS) code using a standard kappa-epsilon turbulence model with wall functions. More detailed results are presented by Garcia et. al. To support the team, loading and temperature results for the turbine rotor were provided as inputs to structural and thermal analyses, and blade loadings from the inducer were provided for structural analyses.

Description: A meanline pump flow modeling method has been developed to provide a fast capability for modeling pumps of cryogenic rocket engines. Based on this method, a meanline pump flow code (PUMPA) has been written that can predict the performance of pumps at off-design operating conditions, given the loss of the diffusion system at the design point. The design point rotor efficiency is obtained from empirically derived correlations of loss to rotor specific speed. The rapid input setup and computer run time for the meanline pump flow code makes it an effective analysis and conceptual design tool. The map generation capabilities of the PUMPA code provide the information needed for interfacing with a rocket engine system modeling code.

Description: A viewgraph presentation is made of the objectives, capabilities, and test results of the computer code SCISEAL. Currently, the seal code has: a finite volume, pressure-based integration scheme; colocated variables with strong conservation approach; high-order spatial differencing, up to third-order; up to second-order temporal differencing; a comprehensive set of boundary conditions; a variety of turbulence models and surface roughness treatment; moving grid formulation for arbitrary rotor whirl; rotor dynamic coefficients calculated by the circular whirl and numerical shaker methods; and small perturbation capabilities to handle centered and eccentric seals.

Description: An evaluation of MTI seal codes is made by comparing cylindrical air and water seals. Results are presented in viewgraph format and show that: ICYL and GCYL geometry variations are desirable; load and direct stiffness calculations are good; damping and cross-coupled stiffness predictions are poor; added mass coefficients should be calculated; and variation in inlet tangential velocity is critical to design.

Description: A viewgraph presentation is given of the capabilities of the computer code GFACE. Capabilities include: varying geometries, including Rayleigh step, tapered land, and hydrostatic; variable grid; z, x-x, and y-y degrees of freedom; can determine position as a function of load; and English or SI units.

Description: This paper contains a summary of the experience of the authors in the field of electromechanical modeling for rotating machinery - active vibration control. Piezoelectric and magnetic bearing actuator based control are discussed.

Description: A high speed electric spindle based on active electromagnetic suspension technology has been designed, built, and tested. The main goal of the research work was the construction of a highly modular unit which can be used for teaching and research purposes. The design of the electromechanical components and of the control unit is described in detail, together with the characterization tests performed on the various subsystems. A description of the preliminary tests on the unit, conducted at speeds not in excess of the first deformation critical speed of the rotor, concludes the work.

Description: The loss mechanisms associated with magnetic bearings have yet to be adequately characterized or modeled analytically and thus pose a problem for the designer of magnetic bearings. This problem is particularly important for aerospace applications where low power consumption of components is critical. Also, losses are expected to be large for high speed operation. The iron losses in magnetic bearings can be divided into eddy current losses and hysteresis losses. While theoretical models for these losses exist for transformer and electric motor applications, they have not been verified for magnetic bearings. This paper presents the results from a low speed experimental test rig and compares them to calculated values from existing theory. Experimental data was taken over a range of 90 to 2,800 rpm for several bias currents and two different pole configurations. With certain assumptions agreement between measured and calculated power losses was within 16 percent for a number of test configurations.

Description: A modeling, analysis, and control design methodology is presented for maglev vehicle ride quality performance improvement as measured by the Pepler Index. Ride quality enhancement is considered through active control of secondary suspension elements and active aerodynamic surfaces mounted on the train. To analyze and quantify the benefits of active control, the authors have developed a five degree-of-freedom lumped parameter model suitable for describing a large class of maglev vehicles, including both channel and box-beam guideway configurations. Elements of this modeling capability have been recently employed in studies sponsored by the U.S. Department of Transportation (DOT). A perturbation analysis about an operating point, defined by vehicle and average crosswind velocities, yields a suitable linearized state space model for multivariable control system analysis and synthesis. Neglecting passenger compartment noise, the ride quality as quantified by the Pepler Index is readily computed from the system states. A statistical analysis is performed by modeling the crosswind disturbances and guideway variations as filtered white noise, whereby the Pepler Index is established in closed form through the solution to a matrix Lyapunov equation. Data is presented which indicates the anticipated ride quality achieved through various closed-loop control arrangements.

Description: Magnetic bearings have traditionally been considered for use in aerospace applications only where performance advantages have been the primary, if not only, consideration. Conventional wisdom has been that magnetic bearings have certain performance advantages which must be traded off against increased weight, volume, electric power consumption, and system complexity. These perceptions have hampered the use of magnetic bearings in many aerospace applications because weight, volume, and power are almost always primary considerations. This paper will review progress on several active aerospace magnetic bearings programs at SatCon Technology Corporation. The magnetic bearing programs at SatCon cover a broad spectrum of applications including: a magnetically-suspended spacecraft integrated power and attitude control system (IPACS), a magnetically-suspended momentum wheel, magnetic bearings for the gas generator rotor of a turboshaft engine, a vibration-attenuating magnetic bearing system for an airborne telescope, and magnetic bearings for the compressor of a space-rated heat pump system. The emphasis of these programs is to develop magnetic bearing technologies to the point where magnetic bearings can be truly useful, reliable, and well tested components for the aerospace community.

Description: Using measured values of two-dimensional forces in a magnetic actuator, equations of motion for an active magnetic bearing are presented. The presence of geometric coupling between coordinate directions causes the equations of motion to be nonlinear. Two methods are used to examine the unbalance response of the system: simulation by direct integration in time; and determination of approximate steady state solutions by harmonic balance. For relatively large values of the derivative control coefficient, the system behaves in an essentially linear manner, but for lower values of this parameter, or for higher values of the coupling coefficient, the response shows a split of amplitudes in the two principal directions. This bifurcation is sensitive to initial conditions. The harmonic balance solution shows that the separation of amplitudes actually corresponds to a change in stability of multiple coexisting solutions.

Description: In this paper we develop a dynamical model of a rotor and the active magnetic bearings used to support the rotor. We use this model to develop a stable state feedback control of the magnetic bearing system. We present the development of a rigid body model of the rotor, utilizing both Rotation Matrices (Euler Angles) and Euler Parameters (Quaternions). In the latter half of the paper we develop a stable state feedback control of the actively controlled magnetic bearing to control the rotor position under inbalances. The control law developed takes into account the variation of the model with rotational speed. We show stability over the whole operating range of speeds for the magnetic bearing system. Simulation results are presented to demonstrate the closed loop system performance. We develop the model of the magnetic bearing, and present two schemes for the excitation of the poles of the actively controlled magnetic bearing. We also present a scheme for averaging multiple sensor measurements and splitting the actuation forces amongst redundant actuators.

Description: A mathematical model of an active electromagnetic bearing which includes the actuator, the sensor and the control system is developed and implemented in a specialized finite element code for rotordynamic analysis. The element formulation and its incorporation in the model of the machine are described in detail. A solution procedure, based on a modal approach in which the number of retained modes is controlled by the user, is then shown together with other procedures for computing the steady-state response to both static and unbalance forces. An example of application shows the numerical results obtained on a model of an electric motor suspended on a five active-axis magnetic suspension. The comparison of some of these results with the experimental characteristics of the actual system shows the ability of the present model to predict its performance.

Description: Hydrostatic Journal Bearings (HJB's) are reliable and resilient fluid film rotor support elements ideal to replace roller bearings in cryogenic turbomachinery. HJB' will be used for primary space-power applications due to their long lifetime, low friction and wear, large load capacity, large direct stiffness, and damping force coefficients. An analysis for the performance characteristics of turbulent flow, orifice compensated, spherical hydrostatic journal bearings (HJB's) is presented. Spherical bearings allow tolerance for shaft misalignment without force performance degradation and have also the ability to support axial loads. The spherical HJB combines these advantages to provide a bearing design which could be used efficiently on high performance turbomachinery. The motion of a barotropic liquid on the thin film bearing lands is described by bulk-flow mass and momentum equations. These equations are solved numerically using an efficient CFD method. Numerical predictions of load capacity and force coefficients for a 6 recess, spherical HJB in a LO2 environment are presented. Fluid film axial forces and force coefficients of a magnitude about 20% of the radial load capacity are predicted for the case analyzed. Fluid inertia effects, advective and centrifugal, are found to affect greatly the static and dynamic force performance of the bearing studied.

Description: A rig for testing an externally pressurized (hydrostatic), water-lubricated bearing was developed. Applying a nonsynchronous sweep frequency, rotating perturbation force with a constant amplitude as an input, rotor vibration response data was acquired in Bode and Dynamic Stiffness formats. Using this data, the parameters of the rotor/bearing system were identified. The rotor/bearing model was represented by the generalized (modal) parameters of the first lateral mode, with the rotational character of the fluid force taken into account.

Description: A new fluid film bearing package has been tested in the Space Shuttle Main Engine (SSME) High Pressure Oxygen Turbopump (HPOTP). This fluid film element functions as both the pump end bearing and the preburner pump rear wear ring seal. Most importantly, it replaces a duplex ball bearing package which has been the primary life limiting component in the turbopump. The design and predicted performance of the turbopump are reviewed. Results are presented for measured pump and bearing performance during testing on the NASA Technology Test Bed (TTB) Engine located at MSFC. The most significant results were obtained from proximity probes located in the bearing bore which revealed large subsynchronous precession at ten percent of shaft speed during engine start which subsided prior to mainstage power levels and reappeared during engine shutdown at equivalent power levels below 65% of nominal. This phenomenon has been attributed to rotating stall in the diffuser. The proximity probes also revealed the location of the bearing in the bore for different operating speeds. Pump vibration characteristics were improved as compared to pumps tested with ball bearings. After seven starts and more than 700 seconds of testing, the pump showed no signs of performance degradation.

Description: This paper describes an experimental investigation into the dynamic characteristics of corrugated foil (bump foil) strips used in compliant surface foil bearings. This study provided and opportunity to quantify the structural damping of bump foil strips. The experimental data were compared to results obtained by a theoretical model developed earlier. The effects of bearing design parameters, such as static loads, dynamic displacement amplitudes, bump configurations, pivot locations, surface coatings, and lubricant were also evaluated. An understanding of the dynamic characteristics of bump foil strips resulting from this work offers designers a means for enhancing the design of high-performance compliant foil bearings.

Description: To improve the damping capability of squeeze film dampers, oil hole feed rather than circumferential groove feed is a practical proposition. However, circular orbit response can no longer be assumed, significantly complicating the design analysis. This paper details a feasible transient solution procedure for such dampers, with particular emphasis on the additional difficulties due to the introduction of oil holes. It is shown how a cosine power series solution may be utilized to evaluate the oil hole pressure contributions, enabling appropriate tabular data to be compiled. The solution procedure is shown to be applicable even in the presence of flow restrictors, albeit at the expense of introducing an iteration at each time step. Though not of primary interest, the procedure is also applicable to dynamically loaded journal bearings with oil hole feed.

Description: This paper investigates the stability and the stability degree of a flexible cracked rotor supported on different kinds of journal bearings. It is found that no matter what kind of bearings is used, the unstable zones caused by rotor crack locate always within the speed ratio (2/N) (1 - Delta K(sub xi)/4) is less than Omega is less than 2/N when gravity parameter W(sub R) is greater than 1.0, and locate always within the speed ratio (2 Omega(sub alpha)/N) (1 - Delta K(sub xi)/4) is less than Omega is less than 2 Omega(sub alpha)/N when W(sub R) is less than 0.1, where Delta K(sub xi) is the crack stiffness ratio, N = 1, 2, 3, 4, 5, ..., and Omega(sub alpha) = ((1 + 2 alpha)/2 alpha)(exp 1/2). When 0.1 is less than W(sub R) is less than 1.0, there is a region where no unstable zones caused by rotor crack exist. Outside the crack ridge zones, the rotor crack has almost no influence on system's stability and stability degree; while within the crack ridge zones, the stability and stability degree depend both on the crack and system's parameters. In some cases, the system may still be stable even when the crack is very large. For small gravity parameter (W(sub R) is less than 0.1), the mass ratio alpha has large influence on the position of unstable region, but its influence on the stability degree is small. The influence of fixed Sommerfeld number S(sub 0) on the crack stability degree is small although S(sub 0) has large influence on the stability degree of uncracked rotor.

Description: Boiler feed pump reliability and availability is recognized as important to the overall efficiency of power generation. Vibration monitoring is often used as a part of planned maintenance. This paper reviews a number of different types of boiler feed pump vibration problems describing some methods of solution in the process. It is hoped that this review may assist both designers and users faced with similar problems.

Description: This paper provided an opportunity to quantify the angular stiffness and equivalent viscous damping coefficients of an axial spline coupling used in high-speed turbomachinery. A unique test methodology and data reduction procedures were developed. The bending moments and angular deflections transmitted across an axial spline coupling were measured while a nonrotating shaft was excited by an external shaker. A rotor dynamics computer program was used to simulate the test conditions and to correlate the angular stiffness and damping coefficients. In addition, sensitivity analyses were performed to show that the accuracy of the dynamic coefficients do not rely on the accuracy of the data reduction procedures.

Description: It is because of the critical importance the prevention of vibration for high-load rotary machinery assumes in ensuring reliability of a plant as a whole that so many investigations and studies have been performed. A peculiar vibration encountered in a multistage turbine pump is presented and discussed. The pump was serving an active power plant in a part that was a veritable 'heart' of the entire plant, and the major vibration component was about 80 percent frequency of revolution. At first, the propagating stall was thought to be responsible, but the absence of higher harmonics made this presumption untenable. Or else, even though previous reports dealt with seemingly similar mechanical vibration troubles, they offer no clear diagnosis nor suggest simple remedial measures. It is for these reasons that the problem was investigated. Through fundamental tests and experiments, several insights into the nature of this anomalous vibration were gained, the fluid force that caused such a vibration was determined, and effective countermeasures were devised.

Description: The fluid force due to labyrinth seal sometimes makes the turbomachineries unstable under higher rotating speed, higher pressure and higher power. Therefore, it is important to predict the magnitude and the direction of the fluid force and to evaluate the stability of the rotor system in design process. This paper shows the experimental results of the fluid force induced by a straight labyrinth seal and the rotordynamic coefficients calculated from the fluid force. Influences of the number of fins under the rotating speed, whirling speed, inlet pressure, and inlet tangential velocity are mainly investigated on a stability of the rotor system. The results show that increase of the number of fins makes the fluid force small and the rotor system stable, an increase of inlet pressure makes the fluid forces large and an increase of inlet tangential velocity makes the rotor system unstable.

Description: First experimental investigations performed on a new test rig are presented. For a staggered labyrinth seal with fourteen cavities the stiffness coefficient and the leakage flow are measured. The experimental results are compared to calculated results which are obtained by a one-volume bulk-flow theory. A perturbation analysis is made for seven terms. It is found out that the friction factors have great impact on the dynamic coefficients. They are obtained by turbulent flow computation by a finite-volume model with the Reynolds equations used as basic equations.

Description: A theoretical and experimental investigation of the aerodynamic forces generated by a single gland labyrinth seal executing a simultaneous spinning/whirling motion has been conducted. A lumped parameter model for a single gland seal with coupling to an upstream cavity with leakage is developed along with an appropriate solution technique. From this theory, it is shown that the presence of the upstream cavity can, in some cases, augment the cross-stiffness and direct damping by a factor of four. The parameters that govern the coupling are presented along with predictions on their influence. A simple uncoupled model is used to identify the mechanisms responsible for cross force generation. This reduced system is nondimensionalized and the physical significance of the reduced parameters is discussed. Closed form algebraic formulas are given for some simple limiting cases. It is also shown that the total cross-force predicted by the uncoupled model can be represented as the sum of an ideal component due to an inviscid flow with entry swirl and a viscous part due to the change in swirl created by friction inside the gland. The frequency dependent ideal part is solely responsible for the rotordynamic direct damping. The facility designed and built to measure these frequency dependent forces is described. Experimental data confirm the validity and usefulness of this ideal/viscous decomposition. A method for calculating the damping coefficients based on the force decomposition using only the static measurements is presented. Experimental results supporting the predicted cross force augmentation due to the effect of upstream coupling are presented.

Description: This paper describes additional results from a continuing research program which aims to identify the dynamics of long annular seals in centrifugal pumps. A seal test rig designed at Heriot-Watt University and commissioned at Weir Pumps Research Laboratory in Alloa permits the identification of mass, stiffness, and damping coefficients using a least-squares technique based on the singular value decomposition method. The analysis is carried out in the time domain using a multi-fiequency forcing function. The experimental method relies on the forced excitation of a flexibly supported stator by two hydraulic shakers. Running through the stator embodying two symmetrical balance drum seals is a rigid rotor supported in rolling element bearings. The only physical connection between shaft and stator is the pair of annular gaps filled with pressurized water discharged axially. The experimental coefficients obtained from the tests are compared with theoretical values.

Description: An improved dynamic analysis for liquid annular seals with arbitrary profile based on a method, first proposed by Nelson and Nguyen, is presented. An improved first order solution that incorporates a continuous interpolation of perturbed quantities in the circumferential direction, is presented. The original method uses an approximation scheme for circumferential gradients, based on Fast Fourier Transforms (FFT). A simpler scheme based on cubic splines is found to be computationally more efficient with better convergence at higher eccentricities. A new approach of computing dynamic coefficients based on external specified load is introduced. This improved analysis is extended to account for arbitrarily varying seal profile in both axial and circumferential directions. An example case of an elliptical seal with varying degrees of axial curvature is analyzed. A case study based on actual operating clearances of an interstage seal of the Space Shuttle Main Engine High Pressure Oxygen Turbopump is presented.

Description: The flow field inside a whirling annular seal operating at a Reynolds number of 24,000 and a Taylor number of 6600 has been measured using a 3-D laser Doppler anemometer system. Two eccentricity ratios were considered, 0.10 and 0.50. The seal has a diameter of 164 mm, is 37.3 mm long, and has a clearance of 1.27 mm. The rotor was mounted eccentrically on the shaft such that the whirl ratio is 1.0 and the rotor follows a circular orbit. The mean axial velocity is not uniform around the circumference of the seal; near the inlet a region characterized by high velocity of the seal. By the exit, another region of high axial velocity is not uniform around the circumference of the seal; near the inlet a region characterized by high velocity of the seal. By the exit, another region of high axial velocity has developed, this time on the suction side of the seal. The magnitude and azimuthal distance of the migration increased with increasing whirl amplitude (eccentricity). Throughout the seal length, the azimuthal mean velocity varied inversely with the mean axial velocity. Increasing the whirl amplitude did not increase the magnitude of the azimuthal velocity at the seal exit.

Description: A new test apparatus is reconstructed and is applied to investigate static and dynamic characteristics of annular seals leaked by two phase flow (gas and liquid) for turbopumps. The fluid forces acting on the seals are measured for various parameters such as void ratio, the preswirl velocity, the pressure difference between the inlet and outlet of the seal, the whirling amplitude, and the ratio of whirling speed to spinning speed of the rotor. Influence of these parameters on the static and dynamic characteristics is investigated from the experimental results. As a result, with regard to the two phase flow, as the void ratio increases, the flow induced force decreases. Another dynamic characteristic of two phase flow is as almost similar as that of the monophase flow.

Description: Test results are presented for rotordynamic coefficients and leakage for three annular seals which use anti-swirl self-injection concept to yield significant improvement in whirl frequency ratios as compared to smooth and damper seals. A new anti-swirl self-inection mechanism is achieved by deliberately machining self-injection holes inside the seal stator mechanism which is used to achieve effective reduction of the tangential flow which is considered as a prime cause of rotor instability in high performance turbomachinery. Test results show that the self-injection mechanism significantly improves whirl frequency ratios; however, the leakage performance degrades due to the introduction of the self-injection mechanism. Through a series of the test program, an optimum anti-swirl self-injection seal which uses a labyrinth stator surface with anti-axial flow injections is selected to obtain a significant improvement in the whirl frequency ratio as compared to a damper seal, while showing moderate leakage performance. Best whirl frequency ratio is achieved by an anti-swirl self-injection seal of 12 holes anti-swirl and 6 degree anti-leakage injection with a labyrinth surface configuration. When compared to a damper seal, the optimum configuration outperforms the whirl frequency ratio by a factor of 2.

Description: A payload holddown and release mechanism, designated the Model 1172, was designed and built at G&H Technology during the winter of 1992/1993. The mechanism is able to restrain and release a 45-pound payload with minimal tipoff. The payload is held in place by a stainless steel band and released using electrically triggered non-explosive actuators. These actuators provide reliable operation with negligible shock and no special handling requirements. The performance of the mechanism was demonstrated in two flight tests. Data showed pitch and yaw tipoff rates of less than 0.07 radian (4 degree) per second. The Model 1172 design is an efficient replacement for conventional payload deployment devices, especially where low transmitted shock is required.

Description: The objective of the ARTS program was to develop lighter and less expensive spacecraft ordnance and release systems that answer to the requirements of a wide variety of spacecraft applications. These improvements were to be evaluated at the spacecraft system level, as it was determined that there were substantial system-level costs associated with the present ordnance and release subsystems. New, better devices were to be developed, then flight qualified, then integrated into a flight experiment in order to prove the reliability required for their subsequent use on high-reliability spacecraft. The secondary goal of the program was to quantify the system-level benefits of these new subsystems based upon the development program results. Three non-explosive release mechanisms and one laser-diode-based ordnance system were qualified under the program. The release devices being developed were required to release high preloads because it is easier to scale down a release mechanism than to scale it up. The laser initiator developed was required to be a direct replacement for NASA Standard Initiators, since these are the most common initiator in use presently. The program began in October, 1991, with completion of the flight experiment scheduled for February, 1994. This paper provides an overview of the ARTS program, discusses the benefits of using the ARTS components, introduces the new components, compares them with conventional systems and each other, and provides recommendations on how best to implement them.

Description: The work reported deals with the problem of operating a robot manipulator under a rate control mode while the end effector is not in contact with the external environment, and then switching to a force control mode when contact is made. The paper details how the modal changeover may be accomplished in a manner transparent to the operator, and will allow operator applied forces to be reflected at the robot end effector. A one degree of freedom demonstration system is used to illustrate the concept, which is then applied to a PUMA manipulator. Sample code for the implementation of the control is provided, experimental results show that the optimum setting for the gain is a function of the compliance of the end effector, and the compliance of the external constraint.

Description: NASA-KSC has developed a mechanism to handle and insert Racks into the Space Station Logistic Modules. This mechanism consists of a Base with 3 motorized degrees of freedom, a 3 section motorized Boom that goes from 15 to 44 feet in length, and a Rack Insertion End Effector (RIEE) with 5 hand wheels for precise alignment. During the 1993 NASA-ASEE Summer Faculty Fellowship Program at KSC, I designed an Active Vision (Camera) Arrangement and developed an algorithm to determine (1) the displacements required by the Room for its initial positioning and (2) the rotations required at the five hand-wheels of the RIEE, for the insertion of the Rack, using the centroids fo the Camera Images of the Location Targets in the Logistic Module. Presently, during the summer of '94, I completed the preliminary design of an easily portable measuring instrument using encoders to obtain the 3-Dimensional Coordinates of Location Targets in the Logistics Module relative to the RIEE mechanism frame. The algorithm developed in '93 can use the output of this instrument also. Simplification of the '93 work and suggestions for the future work are discussed.

Description: The Payload Changeout Room Inspection and Processing System (PIPS) is a highly redundant manipulator intended for performing tasks in the crowded and sensitive environment of the Space Shuttle Orbiter payload bay. Its dexterity will be exploited to maneuver the end effector in a workspace populated with obstacles. A method is described by which the end effector of a highly redundant manipulator is directed toward a target via a Lyapunov stability function. A cost function is constructed which represents the distance from the manipulator links to obstacles. Obstacles are avoided by causing the vector of joint parameters to move orthogonally to the gradient of the workspace cost function. A C language program implements the algorithm to generate a joint history. The resulting motion is graphically displayed using the Interactive Graphical Robot Instruction Program (IGRIP) produced by Deneb Robotics. The graphical simulation has the potential to be a useful tool in path planning for the PIPS in the Shuttle Payload Bay environment.

Description: A viewgraph presentation is made showing the capabilities of the computer code SPIRALI. Overall capabilities of SPIRALI include: computes rotor dynamic coefficients, flow, and power loss for cylindrical and face seals; treats turbulent, laminar, Couette, and Poiseuille dominated flows; fluid inertia effects are included; rotor dynamic coefficients in three (face) or four (cylindrical) degrees of freedom; includes effects of spiral grooves; user definable transverse film geometry including circular steps and grooves; independent user definable friction factor models for rotor and stator; and user definable loss coefficients for sudden expansions and contractions.

Description: This viewgraph presentation presents the following results: (1) The analytical results overpredict the experimental results for the direct stiffness values and incorrectly predict increasing stiffness with decreasing pressure ratios. (2) Theory correctly predicts increasing cross-coupled stiffness, K(sub YX), with increasing eccentricity and inlet preswirl. (3) Direct damping, C(sub XX), underpredicts the experimental results, but the analytical results do correctly show that damping increases with increasing eccentricity. (4) The whirl frequency values predicted by theory are insensitive to changes in the static eccentricity ratio. Although these values match perfectly with the experimental results at 16,000 rpm, the results at the lower speed do not correspond. (5) Theoretical and experimental mass flow rates match at 5000 rpm, but at 16,000 rpm the theoretical results overpredict the experimental mass flow rates. (6) Theory correctly shows the linear pressure profiles and the associated entrance losses with the specified rotor positions.

Description: Seal technology development is an important part of the Air Force's participation in the Integrated High Performance Turbine Engine Technology (IHPTET) initiative, the joint DOD, NASA, ARPA, and industry endeavor to double turbine engine capabilities by the turn of the century. Significant performance and efficiency improvements can be obtained through reducing internal flow system leakage, but seal environment requirements continue to become more extreme as the engine thermodynamic cycles advance towards these IHPTET goals. Brush seal technology continues to be pursued by the Air Force to reduce leakage at the required conditions. Likewise, challenges in engine mainshaft air/oil seals are also being addressed. Counter-rotating intershaft applications within the IHPTET initiative involve very high rubbing velocities. This viewgraph presentation briefly describes past and current seal research and development programs and gives a summary of seal applications in demonstrator and developmental engine testing.

Description: The objective of the brush seal development program is to develop a comprehensive design methodology for brush seals using application requirements from engine manufacturers and experimental characterization of seal design and tribological pairs. The goals are to substantially lower leakage compared to labyrinth seals, seal life consistent with man-rated mission requirements, to investigate single and multiple staged brush seals, temperature up to 1200 F and surface speed up to 900 fps, and pressure drop across the seal of 50 psid. Test results are presented in viewgraph format.

Description: In this paper we present a variety of nonlinear controllers for the magnetic bearing that ensure both stability and robustness. We utilize techniques of discontinuous control to design novel control laws for the magnetic bearing. We present in particular sliding mode controllers, time optimal controllers, winding algorithm based controllers, nested switching controllers, fractional controllers, and synchronous switching controllers for the magnetic bearing. We show existence of solutions to systems governed by discontinuous control laws, and prove stability and robustness of the chosen control laws in a rigorous setting. We design sliding mode observers for the magnetic bearing and prove the convergence of the state estimates to their true values. We present simulation results of the performance of the magnetic bearing subject to the aforementioned control laws, and conclude with comments on design.

Description: An implementation of a decoupled, single-input/single-output control approach for a large angle magnetic suspension test fixture is described. Numerical and experimental results are presented. The experimental system is a laboratory model large gap magnetic suspension system which provides five degree-of-freedom control of a cylindrical suspended element. The suspended element contains a core composed of permanent magnet material and is levitated above five electromagnets mounted in a planar array.

Description: Experiments were carried out to study the feasibility of active stabilization of vaneless diffuser rotating stalls. Pressure fluctuation at the diffuser inlet was monitored and used to control the rotating stall. AC control flow, which is produced by a load speaker, was introduced into the diffuser at the inlet. It is shown that the rotating stall can be suppressed when the phase of the control flow has a certain relation with the phase of the rotating stall. By considering the energy flux due to the AC control flow, it is shown that the rotating stall is suppressed when the control flow has the phase such that the energy is subtracted out from the diffuser flow. Discussions are made on the relations between the energy flux and the amplitude of the pressure fluctuation due to the rotating stalls.

Description: A new deployable and retractable telescoping boom capable of high deployed stiffness and strength is described. Deployment and retraction functions are controlled by simple, reliable, and fail-safe latches between the tubular segments. The latch and a BI-STEM (Storable Tubular Extendible Member) actuator work together to eliminate the need for the segments to overlap when deployed. This yields an unusually lightweight boom and compact launch configuration. An aluminum space-flight prototype with three joints displays zero structural deadband, low hysteresis, and high damping. The development approach and difficulties are discussed. Test results provide a joint model for sizing flight booms of any diameter and length.

Description: The MSAT Reflector Assembly is a state of the art subsystem for Mobile Satellite (MSAT), a geosynchronous-based commercial mobile telecommunication satellite program serving North America. The Reflector Assembly consisted of a deployable, three-hinge, folding-segment Boom, deployable 5.7 x 5.3-meter 16-rib Wrap-Rib Reflector, and a Reflector Pointing Mechanism (RPM). The MSAT spacecraft was based on a Hughes HS601 spacecraft bus carrying two Reflector Assemblies independently dedicated for L-band transmit and receive operations. Lockheed Missiles and Space Company (LMSC) designed and built the Reflector Assembly for MSAT under contract to SPAR Aerospace Ltd. Two MSAT satellites were built jointly by SPAR Aerospace Ltd. and Hughes Space and Communications Co. for this program, the first scheduled for launch in 1994. When scaled for wavelength, the assembly and alignment requirements for the Reflector Assembly were in many instances equivalent to or exceeded that of a diffraction-limited visible light optical system. Combined with logistical constraints inherent to large, compliant, lightweight structures; 'bolt-on' alignment; and remote, indirect spacecraft access; the technical challenges were formidable. This document describes the alignment methods, the special test equipment, and fixturing for Reflector Assembly assembly and alignment.

Description: The Kennedy Space Center Robotics Group recently completed development and testing on a novel approach to measure the mass properties of a rigid body. This unique design can measure the payload's weight, mass center location, and moments of inertia about three orthogonal axes. Furthermore, these measurements only require a single torque sensor and a single angular position sensor.

Description: Capabilities of the computer code IFACE are given in viewgraph format. These include: two dimensional, incompressible, isoviscous flow; rotation of both rotor and housing; roughness in both rotor and housing; arbitrary film thickness distribution, including steps, pockets, and tapers; three degrees of freedom; dynamic coefficients; prescribed force and moments; pocket pressures or orifice size; turbulence, Couette and Poiseuille flow; cavitation; and inertia pressure drops at inlets to film.

Description: In separate series of T-700 engine tests, direct comparisons were made between the forward-facing labyrinth and dual-brush compressor discharge seals. Compressor speeds to 43,000 rpm, surface speeds to 160 m/s (530 ft/s), pressures to 1 MPa (145 psi), and temperatures to 680 K (765 F) characterized these tests. The wear estimate for 40 hr of engine operations was less than 0.025 mm (0.001 in.) of the Haynes 25 alloy bristles running against a chromium-oxide-coated rub runner. The pressure drops were higher for the dual-brush than for the forward-facing labyrinth seal, implying better seal characteristics and engine performance for the brush seal. Modification of the secondary flow path requires that changes in cooling air and engine dynamics be accounted for.

Description: NASA Lewis Research Center is developing advanced seal concepts and sealing technology for advanced combined cycle ramjet/scramjet engines being designed for the National Aerospace Plane (NASP). Technologies are being developed for both the dynamic seals that seal the sliding interfaces between articulating engine panels and sidewalls, and for the static seals that seal the heat exchanger to back-up structure interfaces. This viewgraph presentation provides an overview of the candidate engine seal concepts, seal material assessments, and unique test facilities used to assess the leakage and thermal performance of the seal concepts.

Description: The following topics are discussed in this viewgraph presentation: ceramic brush seals, research and development, manufacturing, brazed assembly development, controlling braze flow, fiber selection, and braze results.

Description: The program objective is to demonstrate brush seals for replacing labyrinth seals in turboprop engines. The approach taken was to design and procure brush seals with assistance from Sealol, modify and instrument an existing T407 low pressure turbine test rig, replace inner balance piston and outer balance piston labyrinth seals with brush seals, conduct cyclic tests to evaluate seal leakage at operating pressures and temperatures, and evaluate effect of seal pack width and rotor eccentricity. Results are presented in viewgraph format and show that brush seals offer performance advantages over labyrinth seals.

Description: Three helically-grooved seals were tested and the results were compared to the MTI code SPIRALG. A smooth annular seal was tested at six eccentricity ratios from 0 to 0.5. The following are concluded in this viewgraph presentation: (1) Helical-grooved seals provide a substantial reduction in cross-coupled stiffness coefficients. Negative k(sub xy) values are obtained for no-swirl or low-swirl cases. (2) SPIRALG is completely unsuitable for the type of seal tested, namely, turbulent flow, wide grooves and lands, etc. (3) A good analysis code is needed to guide the design of helically-grooved annular seals including groove and smooth sections.

Description: Public awareness of environmental hazards, well-publicized effects of hazardous leakages (Three Mile Island, Challenger), and a general concern for planet earth have precipitated emission limits that drive the design requirements for seals applications. Types of seals, barrier fluids, and the necessity of thin lubricating films and stable turbomachine operation to minimize leakage and material losses generated by rubbing contact are discussed.

Description: Post-test investigation of a T-700 engine brush seal found regions void of bristles ('yanked out'), regions of bent-over bristles near the inlet, some 'snapped' bristles near the fence, and a more uniform smeared bristle interface between the first and last axial rows of bristles. Several bristles and four brush segments were cut from the brush seal, wax mounted, polished, and analyzed. Metallographic analysis of the bristle near the rub tip showed tungsten-rich phases uniformly distributed throughout the bristle, no apparent change within 1 mu m of the interface, and possibly a small amount of titanium, which would represent a transfer from the rotor. Analysis of the bristle wear face showed nonuniform tungsten, which is indicative of material resolidification. The cut end contained oxides and internal fractures; the worn end was covered with oxide scale. Material losses due to wear and elastoplastic deformation within the shear zone and third-body lubrication effects in the contact zone are discussed.

Description: The results of the analysis of the achievable disturbance attenuation to get an Angstrom motion control resolution and macroscopic travel in a precision magnetically-suspended motion control system are presented in this paper. Noise sources in the transducers, electronics, and mechanical vibrations are used to develop the control design.

Description: The tuning job of the compensator for levitating flexible rotors supported by active magnetic bearings (AMB) concerns providing a good damping effect to the critical speed modes while avoiding the spillover problem on the instability of higher bending modes. In this paper, an idea for design of the control law of the compensator based on utilizing a third order low pass filter (LPF) is proposed to essentially enable elimination of the spillover instability. According to the proposed design method, good damping effects for the critical speeds are obtained by the usual phase lead/lag function. Stabilization for all of higher bending modes is completed by the additional function of the 3rd order LPF due to its phase lag approaching about -270 degrees in the high frequency domain. This idea is made clear by experiments and simulations.

Description: The Transrapid maglev technology is at the threshold of commercial deployment and technologically all prerequisites for the successful operation of the system in public service are given. In post unification Germany the domestic maglev technology is envisioned to be applied in the Berlin-Hamburg project. At present, a public-private funding concept is being prepared and the lengthy planning process is about to be initiated. In the USA the AMG has presented a program to Americanize the technology and to make it available for commercial use in the U.S. in the very near future. The paramount features of this program are to generate economic development, provide a basis for transportation technology development, create opportunities for U.S. industry, improve the U.S. transportation infrastructure, and improve the environment and traveler safety. Maglev is ready for the U.S.; is the U.S. ready for maglev?

Description: Future active magnetic bearing systems (AMB) must feature easier on-site tuning, higher stiffness and damping, better robustness with respect to undesirable vibrations in housing and foundation, and enhanced monitoring and identification abilities. To get closer to these goals we developed a fast parallel link from the digitally controlled AMB to Matlab, which is used on a host computer for data processing, identification, and controller layout. This enables the magnetic bearing to take its frequency responses without using any additional measurement equipment. These measurements can be used for AMB identification.

Description: Grumman, under contract to the Army Corps of Engineers, completed a System Concept Definition (SCD) study to design a high-speed 134 m/s (300 m.p.h.) magnetically levitated (Maglev) transportation system. The primary development goals were to design a Maglev that is safe, reliable, environmentally acceptable, and low-cost. The cost issue was a predominant one, since previous studies have shown that an economically viable Maglev system (one that is attractive to investors for future models of passenger and/or freight transportation) requires a cost that is about $12.4 M/km ($20 Million per mile). The design is based on the electromagnetic suspension (EMS) system using superconducting iron-core magnets mounted along both sides of the vehicle. The EMS system has several advantages compared to the electrodynamic suspension (EDS) Maglev systems such as low stray magnetic fields in the passenger cabin and the surrounding areas, uniform load distribution along the full length of the vehicle, and small pole pitch for smoother propulsion and ride comfort. It is also levitated at all speeds and incorporates a wrap-around design of safer operation. The Grumman design has all the advantages of an EMS system identified above, while eliminating (or significantly improving) drawbacks associated with normal magnet powered EMS systems. Improvements include larger gap clearance, lighter weight, lower number of control servos, and higher off line switching speeds. The design also incorporates vehicle tilt (plus or minus 9 deg) for higher coordinated turn and turn out speed capability.

Description: A high-speed, reliable ball bearing has been designed for at least fifteen years of operation in space effectors, MWA's, and RWA's. Advanced bearing concepts have been used in this design, such as: no ball retainer, which eliminates all retainer-related problems; an external lubricazing system that will supply the lubricant at a specified flow rate; and a cartridge assembly that will allow the instrument user to purchase a ready to use bearing assembly, with lubricator. Currently, two assemblies are on life test at 12,000 RPM and have accumulated over 20,000 hours each, with consistent low-torque losses. This paper will describe each of the salient features.