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TRANSCRIPT
Drive System Research NASA Glenn Research Center
Cleveland, Ohio, U.S.A.
by Dr. Robert F. Handschuh
Abstract
An overview of the NASA Glenn Research Center Drive Systems Research will be
presented. The primary purpose of this research is to improve performance, reliability,
and integrity of aerospace drive systems and space mechanisms. The research is
conducted through a combination of in-house, academia, and through contractors.
Research is conducted through computer code development and validated through
component and system testing. The drive system activity currently has four major thrust
areas including: thermal behavior of high speed gearing, health and usage monitoring,
advanced components, and space mechanisms.
https://ntrs.nasa.gov/search.jsp?R=20070017857 2020-04-19T14:15:36+00:00Z
Driv
e Sy
stem
Res
earc
hN
ASA
Gle
nn R
esea
rch
Cen
ter
Cle
vela
nd, O
hio,
U.S
.A.
by
Dr.
Rob
ert F
. Han
dsch
uhD
rive
Syst
ems
Team
Lea
d
Topi
cs•
Driv
es T
eam
bac
kgro
und,
obj
ectiv
es, a
nd a
ppro
ach
•Th
erm
al b
ehav
ior /
loss
-of-l
ube
oper
atio
n of
hig
h-sp
eed
helic
al g
ear t
rain
s•
Gea
r cra
ck p
ropa
gatio
n•
Hea
lth a
nd U
sage
Mon
itorin
g S
yste
ms
(HU
MS
)•
Adv
ance
com
pone
nt re
sear
ch: n
oise
, wav
e be
arin
gs,
supe
rfini
shin
g, &
gea
r geo
met
ry•
New
cap
abili
ty d
evel
opm
ent
•S
pace
mec
hani
sms
/ RS
B a
ctua
tor a
ctiv
ities
•S
umm
ary
Driv
e Sy
stem
Res
earc
h at
NA
SA G
RC
Driv
e Sy
stem
Tea
m O
bjec
tives
:P
erfo
rm re
sear
ch a
nd d
evel
opm
ent i
n m
echa
nica
l co
mpo
nent
and
sys
tem
s te
chno
logi
es to
impr
ove
the
perfo
rman
ce, r
elia
bilit
y, a
nd in
tegr
ity o
f aer
ospa
ce
driv
e sy
stem
s an
d sp
ace
mec
hani
sms.
A
ppro
ach:
•Exp
erim
enta
l fac
ilitie
s•A
naly
tical
mod
el d
evel
opm
ent
•Ind
ustry
coo
pera
tive
proj
ects
•Uni
vers
ity g
rant
s•O
ther
gov
ernm
ent a
genc
y pr
ojec
tsFu
ndin
g:•N
AS
A F
ocus
Pro
gram
s (R
C /
UE
ET)
•Cod
e T
wor
k•O
ther
gov
ernm
ent a
genc
ies
(Arm
y, N
RTC
,…)
NA
SA
GR
C D
rive
Sys
tem
Fac
ilitie
s
Spur
Gea
r Fati
gue T
est R
igsSp
iral B
evel
Fatig
ue T
est F
acilit
iesGe
ar N
oise /
Dyn
amics
Tes
t Fac
ility
Plan
etary
Test
Facil
ityOH
-58 T
rans
miss
ion T
est F
acilit
yHi
gh S
peed
Heli
cal G
ear T
rain
Test
Facil
ity
NA
SA G
RC
Spa
ce M
echa
nism
s Fa
cilit
ies
Pin-
on-D
isk T
ribom
eter
Vacu
um B
earin
g Rig
Bloc
k on R
ing R
igRo
ller D
rive R
igEn
viron
menta
l Rig
Varia
ble S
lide R
atio R
ig
NA
SA G
RC
Ana
lytic
al C
apab
ilitie
s 1
Initi
al c
rack
fron
t
Initi
al c
rack
sur
face
Cra
ck m
outh
Frac
ture
Mec
hani
cs -
BE
M
Gea
rN
oise
Toot
h Si
ze (M
odul
e)Fa
ce C
onta
ct R
atio
Phys
ics-
Bas
edM
odel
s
Fini
te E
lem
ent B
ased
S
truct
ural
-Th
erm
al
Hel
ical
Gea
r Dyn
amic
s
Pla
neta
ry G
ear D
ynam
ics
Driv
e Sy
stem
The
rmal
Man
agem
ent A
ctiv
ities
Obj
ectiv
e:D
evel
op a
n un
ders
tand
ing
of th
e th
erm
al b
ehav
ior o
f hig
h sp
eed
gear
sys
tem
s op
erat
ing
in n
orm
al a
nd e
mer
genc
y co
nditi
ons
that
incl
ude
loss
-of-l
ubric
atio
n.A
ppro
ach:
–C
oope
rativ
e pr
ojec
t with
Bel
l Hel
icop
ter
–N
AS
A G
RC
con
duct
ing
full
scal
e / c
ompo
nent
test
s–
NR
TC fu
nded
act
ivity
for “
Lubr
icat
ion
Mod
el fo
r Hig
h-S
peed
Tra
nsm
issi
on C
ompo
nent
s”St
atus
:–
Faci
lity
oper
atio
nal
–C
urre
ntly
test
ing
base
line
desi
gn
Hig
h Sp
eed
Hel
ical
Gea
r Tra
in
Bul
l Gea
r
Idle
r Gea
rs
Eng
ine
Inpu
t
Two
Sta
geP
lane
tary
Pro
pelle
r
Test
Rig
Test
Har
dwar
e
Hig
h Sp
eed
Hel
ical
Gea
r Tra
in
Rec
ent R
esul
ts
Loop
Pow
er (h
p)10
0020
0030
0040
0050
00Efficiency (%) 96
.0
96.5
97.0
97.5
98.0
98.5
99.0
1250
0 RP
M
1500
0 RP
M
Effic
ienc
y Pr
edic
tion
at H
igh
Spee
d an
d Lo
ad
Bull
Gea
r Sha
ft To
rque
(in*
lb)
2000
030
000
4000
050
000
6000
0
Drive Motor Power (hp) 140
160
180
200
220
1500
0 R
PM
1250
0 R
PM
Effe
ct o
f Sha
ft Sp
eed
at H
igh
Torq
ue
53
1dn
Windage~C
Loss
-of-L
ubric
atio
n C
ompo
nent
Act
ivity
Obj
ectiv
e / A
ppro
ach:
Util
ize
fatig
ue s
peci
men
to c
ondu
ct s
cree
ning
test
s fo
r los
s-of
-lu
bric
atio
n pe
rform
ance
enh
ance
men
t tes
ts.
Stat
us:
•Com
plet
ed b
asel
ine
test
ing
usin
g a
synt
hetic
liqu
id lu
bric
ant.
•Rec
ent t
estin
g w
ith n
ew o
il-m
ist l
ube
had
min
imal
wea
r, lo
w o
pera
ting
tem
pera
ture
, min
imal
am
ount
of l
ubric
ant r
equi
red
(mod
ified
po
lyph
enyl
eth
er)
Pre
viou
s S
OA
Lub
eN
ew O
il-M
ist L
ube
Ove
rhea
ted
Obj
ectiv
e:
Pro
vide
des
ign
guid
elin
es fo
r ultr
a-sa
fe g
ear d
esig
n.
Acc
ompl
ishm
ents
/ R
esul
ts:
•The
effe
ct o
f rim
thic
knes
s on
gea
r cra
ck p
ropa
gatio
n pa
th u
sing
FEA
, BE
M, &
frac
ture
mec
hani
cs w
as in
vest
igat
ed.
•Ana
lysi
s m
etho
dolo
gy v
alid
ated
by
gear
exp
erim
ents
.
•Des
ign
guid
elin
es h
ave
been
est
ablis
hed
to p
reve
nt c
atas
troph
ic ri
m
fract
ure
mod
es w
hen
cons
ider
ing
gear
toot
h be
ndin
g fa
tigue
.
•Effe
cts
of ri
m a
nd w
eb th
ickn
ess,
initi
al c
rack
loca
tions
, and
gea
r to
oth
geom
etry
fact
ors
such
as
diam
etra
l pitc
h, n
umbe
r of t
eeth
,pi
tch
radi
us, a
nd to
oth
pres
sure
ang
le w
ere
cons
ider
ed.
Gea
r Cra
ck P
ropa
gatio
n In
vest
igat
ions
Exp
erim
ents
Ana
lysi
s
Cra
ckfa
ce
Spur
Gea
r E
xper
imen
ts a
nd 3
-D A
naly
tical
Mod
el
3-D
Mod
el
Gea
r Cra
ck P
ropa
gatio
n D
esig
n M
apG
ear C
rack
Pro
paga
tion
Des
ign
Map
Toot
h fr
actu
res
Rim
frac
ture
s
No
crac
kpr
opag
atio
n
Initi
al c
rack
loca
tion,
θ0 (
deg)
5060
7080
9010
011
012
0
Bac
kup
ratio
,mB
0.5
0.6
0.7
0.8
0.9
1.0
1.1
1.2
1.3
Gea
r Des
ign
Para
met
ers:
•28
teet
h•
8 pi
tch
•1.
75" p
itch
radi
us•
0.03
0" in
itial
cra
ck•
5 ks
i√in
stre
ss
inte
nsity
thre
shol
d
θ 0
Pitc
hra
dius
App
lied
toot
h lo
ad
Initi
alcr
ack
bh
mB=b/h
Driv
e Sy
stem
Hea
lth a
nd U
sage
Mon
itorin
gO
bjec
tives
: Inc
reas
e re
liabi
lity
and
decr
ease
fals
e al
arm
s fo
r m
echa
nica
l com
pone
nt d
iagn
ostic
s. D
emon
stra
te in
tegr
atio
n of
oil
debr
is a
nd v
ibra
tion
base
d da
mag
e de
tect
ion
tech
niqu
es re
sults
in
impr
oved
cap
abili
ty.
App
roac
h:In
stru
men
t and
mon
itor a
ll G
RC
gea
r fat
igue
test
faci
litie
s an
dw
ork
with
oth
er g
ovt.
agen
cies
, uni
vers
ity, a
nd in
dust
ry
Acc
ompl
ishm
ents
/ R
esul
ts:
•P
relim
inar
y te
sts
show
oil
debr
is m
ass
com
para
ble
to v
ibra
tion
met
rics
in d
etec
ting
pitti
ng d
amag
e•
Dev
elop
ed a
tech
niqu
e fo
r min
imiz
ing
the
effe
ct o
f loa
d on
vi
brat
ion
tech
niqu
es
•A
pplie
d fu
zzy
logi
c an
alys
is te
chni
ques
to o
il de
bris
dat
a to
pre
dict
trans
mis
sion
hea
lth.
Vibr
atio
n Te
chni
ques
(F
M4,
NA
4) a
nd O
il D
ebris
Out
put o
f Fu
zzy
Logi
c M
odelDat
a Fu
sion
Res
ults
00.
10.
20.
30.
40.
50.
60.
70.
80.
91
050
010
0015
0020
0025
0030
0035
00
Rea
ding
Num
ber
Model Output
Nor
mal
Insp
ect
Dam
age
Gea
r Noi
se a
nd V
ibra
tion
Obj
ectiv
e: D
evel
op v
alid
ated
tool
s an
d te
chno
logi
es fo
r red
uced
so
urce
noi
se a
nd v
ibra
tion.
App
roac
h:In
-hou
se e
xper
imen
tal f
acilit
y fo
r ana
lytic
alm
odel
val
idat
ion
for n
oise
, vib
ratio
n an
d tra
nsm
issi
on
erro
r red
uctio
n.A
ccom
plis
hmen
ts /
Plan
s:–
Gea
r Noi
se a
nd T
rans
mis
sion
Err
or te
st g
earb
oxde
liver
ed fo
r GR
C te
st fa
cilit
y–
Col
labo
ratio
n w
ith O
hio
Sta
te U
nive
rsity
Gea
r Dyn
amic
s La
bora
tory
–O
ther
noi
se r
educ
tion
tech
nolo
gies
des
igne
d fo
r use
in
faci
lity
(i.e.
Flu
id F
ilm B
earin
gs)
Gea
r Tra
nsm
issi
on E
rror
Mea
sure
men
t Sys
tem
Gea
r Tra
nsm
issi
on E
rror
Mea
sure
men
t Sys
tem
Opt
ics
and
elec
tron
ics
Cap
abili
ties:
Mea
sure
sta
tic a
nd d
ynam
ic tr
ansm
issi
on e
rror
s,re
solu
tion
0.1
mic
rom
eter
(4 m
icro
-inch
)
Flui
d Fi
lm -
Wav
e B
earin
gO
bjec
tive:
Dev
elop
val
idat
ed m
odel
dat
a fo
r hig
h lo
ad a
nd h
igh
spee
d ap
plic
atio
ns s
uch
as th
at n
eede
d in
driv
e sy
stem
s in
gea
red
turb
ine
engi
ne a
nd a
dvan
ced
pow
er tr
ansm
issi
on a
pplic
atio
ns
App
roac
h:
•In-
hous
e te
st fa
cilit
y cu
rrent
ly s
cree
ning
coa
ting
tech
nolo
gy fo
r st
art –
stop
per
form
ance
and
sta
rved
lubr
icat
ion
oper
atio
n•F
acili
ty e
nhan
cem
ent c
urre
ntly
bei
ng d
esig
ned
to h
ave
capa
bilit
yto
test
UE
ET
plan
et b
earin
g at
full
scal
e (1
3000
RP
M, 3
0000
#,
68 m
m b
earin
g di
amet
er, 8
2 m
m w
idth
)
Stat
us /
Plan
s:
•Dem
onst
rate
coa
ting
effe
ctiv
enes
s (m
ultip
le o
f coa
ting
type
s)
•UE
ET
bear
ing
test
ope
ratio
nal S
epte
mbe
r 05
•Val
idat
ed c
onfig
urat
ion
read
y fo
r UE
ET
dem
onst
ratio
n te
sts
Wav
e B
earin
g Te
chno
logy
•Im
prov
ed s
tabi
lity
and
cool
ing
•Abi
lity
to ta
ilor s
tiffn
ess
and
dam
ping
•Use
of h
ard
slee
ves
Test
Fac
ility
Bea
ring
Con
cept
Surf
ace
Enha
ncem
ent A
ctiv
ities
Obj
ectiv
e:D
eter
min
e dr
ive
syst
em b
enef
its d
eriv
ed fr
om im
prov
ed
surfa
ce fi
nish
and
coa
ting
tech
nolo
gies
.A
ppro
ach:
–U
nive
rsity
of C
ardi
ff (W
ales
, UK
) con
duct
ed ro
ller
test
s / s
uper
finis
h ge
ar s
peci
men
–N
AS
A G
RC
con
duct
ed g
ear f
atig
ue te
sts
Stat
us:
–Te
stin
g co
mpl
eted
at G
RC
, rep
ort p
ublis
hed
Gea
r Per
form
ance
-Su
perf
inis
hing
spee
d (rp
m)
010
0020
0030
0040
0050
00
pow
erlo
ss (W)
0
100
200
300
400
grou
ndsu
perf
inis
hed
1 3
2 4Sc
orin
g Lo
ad In
crea
sed
slid
ing
spee
d (m
/s)
69
1215
1821
24
scor
ing
load (N)
0
1000
2000
3000
4000
grou
ndsu
perf
inis
hed
1 μm
100 μm
Surf
ace
Fini
sh Im
prov
ed
grou
nd
mill
ions
of s
tres
s cy
cles
26
2010
060
0
perc
ent
spec
imen
sfa
iled
1520509099gr
ound
supe
rfin
ishe
d su
spen
ded
(x3)
(x7)
supe
rfin
ishe
d
Surf
ace
Fatig
ue L
ife In
crea
sed
Pow
er L
oss
Redu
ced
Adv
ance
d G
ear G
eom
etry
Obj
ectiv
e:In
vest
igat
e ge
ar g
eom
etry
con
figur
atio
ns to
incr
ease
dr
ive
syst
em ra
tio w
ithou
t sac
rific
ing
gear
per
form
ance
.
App
roac
h:•
Mul
ti-ye
ar e
ffort
at th
e U
nive
rsity
of I
llino
is a
t Chi
cago
•D
r. Fa
ydor
Litv
in, P
rinci
pal I
nves
tigat
or, w
orld
reno
wne
d ge
ar
geom
etry
theo
retic
ian
Stat
us:
•C
urre
ntly
in th
e th
ird y
ear o
f gra
nt e
ffort
•M
any
NA
SA
Tec
hnic
al R
epor
ts /
Jour
nal A
rticl
es in
the
publ
icat
ion
proc
ess
Adv
ance
d G
ear G
eom
etry
Ana
lysi
s M
etho
dolo
gy:
• Diff
eren
tial g
eom
etry
use
d to
desc
ribe
the
surfa
ces
in 3
-D•T
ooth
con
tact
ana
lysi
s pe
rform
edus
ing
the
theo
retic
al s
urfa
ces
•3-D
fini
te e
lem
ent m
odel
s fo
r st
ress
ana
lysi
s pr
oduc
ed u
sing
thes
e su
rface
sC
onta
ct P
ath
Pre
dict
ion
Tran
smis
sion
Err
or C
urve
sA
dvan
ced
Hyb
rid G
ear A
rran
gem
ent
New
Tes
ting
Cap
abili
ties
Und
er D
evel
opm
ent
•B
earin
g D
iagn
ostic
s Te
st F
acili
ty–
Hig
h-sp
eed
and
load
cap
abili
ty to
be
used
for r
ollin
gel
emen
t bea
ring
HU
MS
test
ing
–Te
st fa
cilit
y de
sign
ed, f
abric
atio
n an
d in
stal
latio
non
goin
g–
Faci
lity
oper
atio
nal D
ecem
ber 0
5
•Si
ngle
Too
th B
endi
ng T
est F
acili
ty–
Hig
h-sp
eed
load
app
licat
ion
to 1
kH
z–
Test
fixt
ure
desi
gned
, MTS
mac
hine
pur
chas
ed,
July
05
inst
alla
tion
–Fa
cilit
y op
erat
iona
l Sep
tem
ber 0
5
Spac
e M
echa
nism
Act
iviti
esO
bjec
tive:
Dev
elop
tech
nolo
gies
to e
nabl
e du
rabl
e an
d hi
ghly
re
liabl
e sp
ace
mec
hani
sms
for c
urre
nt a
nd fu
ture
spa
ce e
xplo
ratio
nve
hicl
esA
ppro
ach:
•Lev
erag
e G
RC
mec
hani
cal s
yste
ms
and
tribo
logy
exp
ertis
ew
ith th
at fr
om o
ther
cen
ters
•Util
ize
exte
nsiv
e m
echa
nica
l com
pone
nt fa
cilit
ies
at G
RC
to
valid
ate
new
tech
nolo
gies
Stat
us /
Plan
s:•C
ontin
ue s
uppo
rt fo
r shu
ttle
RTF
dith
er /
wea
r tes
ting
of g
ears
faul
t tol
eran
ce te
stin
g of
gea
rsad
apt /
dev
elop
sin
gle
toot
h be
ndin
g fix
ture
for g
ear l
oad
capa
city
inve
stig
atio
n•P
lan
/ ini
tiate
Cod
e T
mec
hani
sms
/ trib
olog
y ta
sk
Sum
mar
y
•Fo
ur m
ain
focu
s ar
eas
in th
e dr
ive
syst
em a
rea:
* Th
erm
al B
ehav
ior o
f Hig
h-S
peed
Gea
ring
* H
ealth
and
Usa
ge M
onito
ring
* A
dvan
ced
Com
pone
nt R
esea
rch
* S
pace
Mec
hani
sms
•C
urre
ntly
con
duct
/ m
anag
e re
sear
ch w
ithin
our
cen
ter
as w
ell a
s at
con
tract
or a
nd u
nive
rsity
loca
tions
•In
volv
ed in
ana
lytic
al a
nd e
xper
imen
tal d
evel
opm
ents
•W
ork
clos
ely
with
the
aero
spac
e in
dust
ry, o
ther
go
vern
men
t age
ncie
s / N
AS
A c
ente
rs, N
ES
C…
.