Mechanical & Fluid Systems

Tool for Coupling a Torque Wrench to a Round Cable Connector

Torque is applied without offset.

A tool makes it possible to couple a torque wrench to an externally knurled, internally threaded, round cable connector. The purpose served by the tool is to facilitate the tightening of multiple such connectors (or the repeated tightening of the same connector) to repeatable torques.

Posted in: Briefs, Mechanical Components, Mechanics, Connectors and terminals, Tools and equipment, Fastening

Controlling Attitude of a Solar-Sail Spacecraft Using Vanes

A paper discusses a concept for controlling the attitude and thrust vector of a three-axis stabilized Solar Sail spacecraft using only four single degree of freedom articulated spar-tip vanes. The vanes, at the corners of the sail, would be turned to commanded angles about the diagonals of the square sail. Commands would be generated by an adaptive controller that would track a given trajectory while rejecting effects of such disturbance torques as those attributable to offsets between the center of pressure on the sail and the center of mass. The controller would include a standard proportional + derivative part, a feed forward part, and a dynamic component that would act like a generalized integrator. The controller would globally track reference signals, and in the presence of such control actuator constraints as saturation and delay, the controller would utilize strategies to cancel or reduce their effects. The control scheme would be embodied in a robust, nonlinear algorithm that would allocate torques among the vanes, always finding a stable solution arbitrarily close to the global optimum solution of the control effort allocation problem. The solution would include an acceptably small angle, slow limit-cycle oscillation of the vanes, while providing overall thrust vector pointing stability and performance.
Posted in: Briefs, TSP, Mechanical Components, Mechanics, Attitude control, Flight control actuators, Spacecraft

Fastener Options for Clinching Into Stainless

Differing stainless hardness levels and degrees of corrosion resistance can complicate fastener selection.

Designers often turn to self-clinching fasteners when they need a practical method to provide threads in thin metal sheets. The fasteners install permanently, reduce hardware, and promote thinner and lighter designs. In stainless applications, though, designers may run into some particularly hard choices. A prevalent misconception is that all stainless self-clinching fasteners will perform as intended in all stainless sheets. But, the relative hardness of the fastener and sheet looms as an overriding influence, because self-clinching requires that the fastener always be harder than its host sheet. In general, installation of self-clinching fasteners is accomplished by pressing the fastener into place in a properly sized drilled or punched hole. This process causes displaced sheet material (softer than the fastener) to cold-flow into a specially designed annular recess in the shank or pilot of the fastener, permanently locking the fastener in place.

Posted in: Briefs, Mechanical Components, Mechanics, Materials properties, Steel, Fasteners, Lightweighting

Integral Flexure Mounts for Metal Mirrors for Cryogenic Use

These mounts are compact and relatively inexpensive.

Semi-kinematic, six-degree-of-freedom flexure mounts have been incorporated as integral parts of metal mirrors designed to be used under cryogenic conditions as parts of an astronomical instrument. The design of the mirrors and their integral flexure mounts can also be adapted to other instruments and other operating temperatures. In comparison with prior kinematic cryogenic mirror mounts, the present mounts are more compact and can be fabricated easily using Ram-EDM (electrical discharge machining) process.

Posted in: Briefs, TSP, Mechanical Components, Mechanics, Mirrors, Mountings

Low-Cost Propellant Launch From a Tethered Balloon

A document presents a concept for relatively inexpensive delivery of propellant to a large fuel depot in low orbit around the Earth, for use in rockets destined for higher orbits, the Moon, and for remote planets. The propellant is expected to be at least 85 percent of the mass needed in low Earth orbit to support the NASA Exploration Vision. The concept calls for the use of many small (≈10 ton) spin-stabilized, multistage, solid-fuel rockets to each deliver ≈250 kg of propellant. Each rocket would be winched up to a balloon tethered above most of the atmospheric mass (optimal altitude 26 ±2 km). There, the rocket would be aimed slightly above the horizon, spun, dropped, and fired at a time chosen so that the rocket would arrive in orbit near the depot. Small thrusters on the payload (powered, for example, by boil-off gasses from cryogenic propellants that make up the payload) would precess the spinning rocket, using data from a low-cost inertial sensor to correct for small aerodynamic and solid rocket nozzle misalignment torques on the spinning rocket; would manage the angle of attack and the final orbit insertion burn; and would be fired on command from the depot in response to observations of the trajectory of the payload so as to make small corrections to bring the payload into a rendezvous orbit and despin it for capture by the depot. The system is low-cost because the small rockets can be mass-produced using the same techniques as those to produce automobiles and low-cost munitions, and one or more can be launched from a U.S. territory on the equator (Baker or Jarvis Islands in the mid-Pacific) to the fuel depot on each orbit (every 90 minutes, e.g., any multiple of 6,000 per year).

Posted in: Briefs, TSP, Mechanical Components, Mechanics, Propellants, Spacecraft fuel, Logistics, Refueling

Platform for Testing Robotic Vehicles on Simulated Terrain

Slope, ground material, and obstacles can be varied.

The variable terrain tilt platform (VTTP) is a means of providing simulated terrain for mobility testing of engineering models of the Mars Exploration Rovers. The VTTP could also be used for testing the ability of other robotic land vehicles (and small vehicles in general) to move across terrain under diverse conditions of slope and surface texture, and in the presence of obstacles of various sizes and shapes.

Posted in: Briefs, TSP, Mechanical Components, Mechanics, Computer simulation, Terrain, Robotics, Autonomous vehicles

On Release of Microbe-Laden Particles From Mars Landers

A paper presents a study in which rates of release of small particles from Mars lander spacecraft into the Martian atmosphere were estimated from first principles. Because such particles can consist of, or be laden with, terrestrial microbes, the study was undertaken to understand their potential for biological contamination of Mars. The study included taking account of forces and energies involved in adhesion of particles and of three mechanisms of dislodgement of particles from the surface of a Mars lander: wind shear, wind-driven impingement of suspended dust, and impingement of wind-driven local saltating sand particles. Wind shear was determined to be effective in dislodging only particles larger than about 10 microns and would probably be of limited interest because such large particles could be removed by preflight cleaning of the spacecraft and their number on the launched spacecraft would thus be relatively small. Dislodgement by wind-driven dust was found to be characterized by an adhesion half-life of the order of 10,000 years — judged to be too long to be of concern. Dislodgement by saltating sand particles, including skirts of dust devils, was found to be of potential importance, depending on the sizes of the spacecraft-attached particles and characteristics of both Mars sand-particle and spacecraft surfaces.

Posted in: Briefs, TSP, Mechanical Components, Mechanics, Particulate matter (PM), Hazardous materials, Aerodynamics, Spacecraft

Stable Satellite Orbits for Global Coverage of the Moon

A document proposes a constellation of spacecraft to be placed in orbit around the Moon to provide navigation and communication services with global coverage required for exploration of the Moon. There would be six spacecraft in inclined elliptical orbits: three in each of two orthogonal orbital planes, suggestive of a linked-chain configuration. The orbits have been chosen to (1) provide 99.999-percent global coverage for ten years and (2) to be stable under perturbation by Earth gravitation and solar-radiation pressure, so that no deterministic firing of thrusters would be needed to maintain the orbits. However, a minor amount of orbit control might be needed to correct for such unmodeled effects as outgassing of the spacecraft.

Posted in: Briefs, TSP, Mechanical Components, Mechanics, Architecture, Attitude control, Satellite communications

Oil Recycling System Controls Contamination

COMO oil recycling systems are designed to recycle virtually any type of industrial oil. (COMO) OilTrac™ fluid maintenance program/oil recycling systemCOMO Filtration SystemsJanesville,
Posted in: Application Briefs, Green Design & Manufacturing, Recycling Technologies, Fluid Handling, Recycling, Lubricating oils

Improved Gear Shapes for Face Worm Gear Drives

These shapes offer potential for increasing precision and reducing vibration and noise.

Shapes different from the traditional ones have been proposed for face worm gears and for conical and cylindrical worms that mesh with them. The proposed shapes are based on the concept of generating a face worm gear surface by use of a tilted head cutter instead of by the traditional use of a hob. (As used here, “head cutter” is also meant to signify, alternatively, a head grinding tool.)The gear-surface-generation equipment would be similar to that used for generation of spiral bevel and hypoid gears. In comparison with the corresponding traditional hob, a tilted head cutter according to the proposal would be larger, could be fabricated with greater precision, and would enable the generation of gear surfaces with greater precision and greater productivity.

Posted in: Briefs, TSP, Mechanical Components, Mechanics, Computer simulation, Fabrication, Gears

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