ai-aerospace/ams_data_full_2000-2020 huggingface dataset:
483   Figure 10.  No-Load Test Setup  and Run In Test Results  

Friction Test under Load  The goal of the second test was determination of the input torque under different loads  in ambient  and  vacuum  conditions .  

At ambient temperature t he mechanism was test ed to an output torque of up to  200 N -m (limit of the test  setup) without any  problem s. As such high torque levels are not the target application , the high test was  only performed once. The nominal t est was performed up to 70 N-m output load, which covers the nominal  applications. For the torque test at ambient condition,  the actuator was integrated in the torque test s etup  (Figure 11) where the load was generated by a SARA21  model  connected with a gear stage. The gear  stage allows testing the unit without going to the limit of the SARA21. During the test , the test item was  operated at different speeds and the resistive torque was continuously  increased. This step was repeated  several times for both rotation al directions and at different speeds , as the resistive torque of the doub lestage Harmonic Drive® g ear at cold temperature is very important for the motor selection. The friction test  was also performed in vacuum at cold and hot temperature. For this test , again the SARA21 test  infrastructure was used (Figure 13). For the TV test , the Future Actuator test setup had to be adapted in  order to keep the motor and torque sensor temperature in the specified range.  

Figure 11.  Torque Test Setup    The test results showed, as expected, a linear increase of the input torque vs. output torque ( Figure 12).  Over the temperature the input torque increases in a non- linear way.  

Start Torque Test   The start torque also called break -out torque [4] is the torque at the beginning of a rotation which can be  higher than the nominal running torque. The goal of the test was to measure the star t torque behavior of  the double- stage strain wave gear at different temperatures.      The tests, performed under TV, showed that the Future Actuator start torque behavior is very similar to a normal Harmonic Drive® gear and the start torque is temperature dependent. At hot temperature it is almost
484 not present and at cold temperature the effect was stronger. For the Future Actuator the start toque reached  a maximum of 15% above the nominal running torque.  

   Figure 12.  Input Torque vs. Output Torque  Figure 13.  TV Test Setup      Hysteresis  and Transmission Accuracy Test   Strain wave gears made by Harmonic Drive ® AG are backlash free and have the highest position accuracy.  Due to internal friction the gear shows a hysteresis loss . Therefore,  a specific test setup was designed to  derive the very small hysteresis of the Future Actuator configuration. The goal of the configuration was to exclude disturbance effects coming from outside the gearbox . The main contributor is the test motor and  its attached gearbox  and the second effect is the accuracy of the motor  controller. Therefore, the motor  was replaced with a mechanical hand- driven lever. The lever was moved along a grid- type disc (Figure 14)  which ensured that the lever could be repeatedly  positioned at specific positions. With this the input was  position controlled and not speed controlled. The lever allowed to repeat the input position with a very high  accuracy  and the error was calculated based on the difference between the measured and theoretical  position of  the output flange.  The encoder on the output side was  a 28- bit reference encoder with enough  resolution for this test. The test was repeated several times with different  start directions . The test was then  repeated at different input angles. All tests  showed a very similar result , in the range of 9x 10 -6 rad.  

The transmission accuracy test was performed with the same test setup used for the hysteresis test. For  the test, the lever was rotated several times in the same direction about a specific angle.  The deviation  between the theoretical and the measured position then was calculated. This test was performed in both rotation directions and at different input angles.    The conclusion from the transmission accuracy test is that the accuracy is generally very high and the  accuracy improves with the reduction of the actuation angle. For fine pointing angles the test has shown an average transmission accuracy of below 2*10 -6 rad in the unloaded condition.
485   Figure 14.  Hysteresis Test Setup  

Stiffness Test   The stiffness of the actuator is important for the attached equipment . There are two contributors for the  actuator stiffness :  the gear stage for the rotational stiffness and the main bearing for the other stiffness  directions . Due to the rotation symmetry of the actuator , four stiffness parameters  remain:   axial and r adial  translational stiffness,  the bending stiffness and the rotational stiffness around the rotation axis . The  stiffness test was  performed with the SARA21 test rig  and therefore the test could be easily performed. The  test ri g had to be reinforced due to the higher loads of  the Future Actuator. The stiffness test itself confirmed  the values resulting from the analysis performed dur ing the development.  

Table 3.  Future Actuator  stiffness    Stiffness   Torsion  > 2.5 E+04  Nm/rad   Bending  > 3.0 E+05  Nm/rad   Radial  > 9.3 E+08 N/m  Axial  > 1.4 E+08  N/m 

Documentation  

Documentation makes a large contribution to the Future Actuator development cost efficiency . In the frame  of the breadboard development the documentation was tailored to the needs and the important information.  Key findings, test results and development steps were thoroughly documented but t he development was  not overloaded with standard documentation.  

Conclusion  

The Future Actuator development approach was entirely new within the mechanism domain of RUAG. It  can be seen as a major success as it resulted in a very attractive new product which was developed by a  small team, a small budget and within short duration. It thus demonstrated the suitability of the lean  development approach. In a nutshell , the lean development approach can be summarized in the following  sequence:
486 1. Define challenging development goals for the product including top level requirements   2. Prepare a basic concept and  select key suppliers   3. Allow suppliers to bring in the best product with minimum restrictions   4. Build concept s around supplier components and refine requirements   5. Finalise the concept   6. Test the concept   7. Based on test result , initiate Phase 3 with the customer  

Particularly,  the early involvement of the suppliers was a key element of the development. Together with  the early supplier involvement the technical requirements were kept open in order to allow the development  of the best possible solution. This  however require d an intensive collaboration with the supplier and the  openness to adapt the concept to the benefit of key components . It was important to stay as long as possible  in the concept phase until the best possible solution was found. This is different from developments with a frozen milestone plan which does not allow such a flexibility.    The development with small teams allow ed a fast and direct development but it require d the regular  consultation of the internal expertise to ensure maximum benefit of all existing know -how. General  recommendations are:  development tools as design thinking and concurrent engineering shoul d be used  whenever possible; and t he documentation efforts should be reduced as far as possible but  of course it has  to be ensured that  key information is documented.    Testing of  critical technologies or elements should be performed as early as possible. The testing should   be kept simple and limited to the mitigation of the identified risks. The t est program  should be defined  flexible in order that modifications of the test program  can be easily made during the test s. For  developments like the Future Actuator internal funding should be preferred to external funding as the needed development flexibility might not fully be given in programmes having fixed milestones and  customer expectations. For the Future Actuator design approach as presented in this paper , the final result  would certainly not have been achieved  with fixed and detailed requirements from the beginning.      The Future Actuator  design  is now being refined together with the main/launch customer  based on the test  results and updated c ustomer needs. The next steps are the finali zation of the design and the qualification  program.    RUAG will make further use of the lean development approach for specific product developments. Further  projects are al ready initiated and running.  

Figure 15.  RUAG’s Future Actuator Breadboard Model
487 References  

[1]  E. W. Roberts, 'A review of harmonic drives for space applications' ESA -ESTL -TM-0103, 2012.   [2]  M. Jansson, H. Koenen, M. Brizuela, J. -L. Viviente and A. Merstallinger, Harmles - Development of  dry lubricated Harmonic Drive® gears for space applications, Bilbao, Spain: Proc. '16th European  Space Mechanisms and Tribology Symposium 2015', 2015.   [3]  E. W. Roberts, P. Bridgeman, M. Jansson, M. Schulke and A. Tvaruzka, The performance and life of  fluid-lubricated Harmonic® Drive gears, Bilbao, Spain: Proc. '16th European Space Mechanisms and  Tribology Symposium 2015', 2015.   [4] E. W. Roberts, 'TV asse ssment of grease -lubricated compact harmonic drive gear boxes' ESA -ESTL - TM-0031, 2006.   [5] Klaus L. Schulte: Kleine Geschichte der PT6. K.L.S. Publishing, 2007.
TheNASA STIProgram Office... inProfile Sinceitsfounding, NASA hasbeendedicated to tileadvancement ofaeronautics andspace science. TheNASA Scientific andTechnical Information (STI)Program Office playsakeypart inhelping NASA maintain thisimportant role. TheNASA STIProgram Officeisoperated by Langley Research Center, theLeadCenter for NASA's scientific andtechnical information. The NASA STIProgram Officeprovides access tothe NASA STIDatabase, thelargest collection of aeronautical andspacescience STIintheworld. TileProgram OfficeisalsoNASA's institutional mechanism fordisseminating theresults ofits research anddevelopment activities. Theseresults arepublished byNASA intheNASA STIReport Series, which includes thefollowing report types: TECHNICAL PUBLICATION. Reports of completed research oramajorsignificant phaseofresearch thatpresent theresults of NASA programs andinclude extensive data ortheoretical analysis. Includes compilations ofsignificant scientific andtechnical dataand information deemed tobeofcontinuing reference value. NASA's counterpart ofpeerreviewed formal professional papers but haslessstringent limitations onmanuscript length andextent ofgraphic presentations. TECHNICAL MEMORANDUM. Scientific andtechnical findings thatarepreliminary or ofspecialized interest, e.g.,quickrelease reports, working papers, andbibliographies thatcontain minimal annotation. Doesnot contain extensive analysis. CONTRACTOR REPORT. Scientific and technical findings byNASA-sponsored contractors andgrantees.CONFERENCE PUBLICATION. Collected papers fromscientific andtechnical conferences, symposia, seminars, orother meetings sponsored orcosponsored by NASA. SPECIAL PUBLICATION. Scientific, technical, orhistorical information from NASA programs, projects, andmissions, oftenconcerned withsubjects having substantial public interest. TECHNICAL TRANSLATION. Englishlanguage translations offoreign scientific andtechnical material pertinent toNASA's mission. Specialized services thatcomplement theSTI Program Office's diverse offerings include creating custom thesauri, building customized databases,organizing andpublishing research results.., evenproviding videos. Formoreinformation abouttheNASA STI Program Office, seethefollowing: •Access theNASA STIProgram Home Page athttp://www.sti.nasa.gov •E-mail yourquestion viatheInternet to help@sti.nasa.gov •Faxyourquestion totheNASA Access HelpDeskat301-621-0134 •Telephone theNASAAccess HelpDeskat 301-621-0390 Writeto: NASA Access HelpDesk NASA Center forAeroSpace Information 7121Standard Drive Hanover, MD21076
NASA/CP--2002-211506 Proceedings ofthe36thAerospace Mechanisms Symposium Proceedings ofaconference heldatthe Sheraton CityCentre Hoteland cosponsored bytheNASA Glenn Research Center and Lockheed Martin SpaceSystems Company and organized bytheMechanisms Education Association Cleveland, Ohio May15-17, 2002 National Aeronautics and SpaceAdministration Glenn Research Center April2002
Acknowledgments Thehighquality ofthissymposium isaresultoftheworkofmanypeople, andtheireffortsaregratefully acknowledged. Thisextends tothevoluntary members ofthesymposium organizing committee representing the eightNASAfieldcenters, LMSSC, andtheEuropean SpaceAgency. Appreciation isalsoextended tothesession chairs, theauthors, andparticularly thepersonnel atGRCresponsible forthesymposium arrangements andthepublication oftheseproceedings. Asincere thankyoualsogoestothesymposium executive committee whoisresponsible forthe year-to-year management oftheAMS,including paperprocessing andpreparation oftheprogram. Tradenames ormanufacturers' names areusedinthisreportfor identification only.Thisusagedoesnotconstitute anofficial endorsement, eitherexpressed orimplied, bytheNational Aeronautics andSpaceAdministration. NASA Center forAerospace Information 7121Standard Drive Hanover, MD21076Available from National Technical Information Service 5285PortRoyalRoad Springfield, VA22100 Available electronically athttp://gltrs.grc.nasa.gov/GLTRS
Preface TheAerospace Mechanisms Symposium (AMS)provides aunique forumforthoseactivein thedesign, production, anduseofaerospace mechanisms. Amajorfocusisthereporting of problems andsolutions associated withthedevelopment andflightcertification ofnew mechanisms. Organized bytheMechanisms Education Association, theNational Aeronautics andSpaceAdministration andLockheed MartinSpaceSystems Company (LMSSC) sharethe responsibility forhosting theAMS.Nowinits36thyear,theAMScontinues tobewellattended, attracting participants fromboththeUnited Statesandabroad. The36thAMS,hosted bytheGlennResearch Center (GRC)inCleveland, Ohio,washeld May15,16,and17,2002.Duringthese3days,32papers werepresented. Topics included deployment mechanisms, tribology, actuators, pointing andoptical mechanisms, International SpaceStation mechanisms, release mechanisms, andtestequipment. Hardware displays during thesupplier exhibit gaveattendees anopportunity tomeetwithdevelopers ofcurrent andfuture mechanism components. NASA/C P--2002-211506 iii
TableofContents Agenda ............................................................................................................................................. ix Organizing andAdvisory Committees ............................................................................................. xiv Asteroid Sampling Mechanism forMUSES-C KenHiguchi, Jun'ichiro Kawaguchi, AkiraFujiwara, TheInstitute ofSpaceandAstronautical Science; Toshiaki Okudaira, NECTOSHIBA SpaceSystems; andSatoru Yajima, Sumitomo Heavy Industries ......................................................................................................... 1 ADescription ofMechanisms UsedintheLowResolution Airglow andAurora Spectrograph andSpecial Sensor Ultraviolet LimbImager PhilipKalmanson andRussell Starks, Praxis, Inc.;andStefanThonnard and Kenneth Dymond, NavalResearch Laboratory ......................................................................... 13 TheIRACShutter Mechanism: Residual Magnetism andtheRotary Solenoid ScottSchwinger, ClaefHakun, GaryBrown, andKenBlumenstock, NASAGoddard Space FlightCenter........................................................................................ 15 ACryogenic Half-Wave PlateModule toMeasure Polarization atMultiple FIRPassbands Timothy S.Rennick, JohnE.Vaillancourt, RogerH.Hildebrand, andStephen J.Heimsath, TheUniversity ofChicago ........................................................................................................ 27 Tape-Spring Rolling Hinges AlanM.WattandSergio Pellegrino, University ofCambridge .................................................. 37 Material Property Effects onCoaxial CableMechanical Failure R.B.Pan,J.B.Chang, C.C.Wan,Y.R.Takeuchi, TheAerospace Corporation; R.McVey, Boeing Satellite Systems; andI.Chen,Raytheon Systems ..................................... 51 Design andTesting oftheCRISP Tracking MirrorCoverandRelease Mechanism Jeffrey LeesandEdSchaefer, JohnsHopkins University Applied Physics Laboratory ............... 63 ZeroDeadband, Multiple StrutSynchronized HingeforDeployable Structures Matthew Botke, DavidMurphy, Thomas Murphey, AEC-Able Engineering; andPeterSorensen, Kollabra ................................................................................................... 77 DCMotorSelection forSpaceMechanisms DavidB.MarksandRichard A.Fink,MoogInc......................................................................... 89 Design andManufacturing ofExtremely LowMassFlightSystems Michael R.Johnson, JetPropulsion Laboratory ...................................................................... 103 Design ofaRobotic WristandTool-Exchange Mechanism forSatellite Servicing Russell D.Howard, University ofMaryland .............................................................................. 117 Operational Improvements ofaPyrotechnic UltraLowShockSeparation Nut Alexander Luna,Hi-Shear Technology Corporation ............................................................... 131 NASA/CP--2002-211506 v
Alternatives toPyrotechnics--Nitinol ReleaseMechanisms AndrewTuszynski, Hi-ShearTechnology Corporation ............................................................. 137 SystemCharacterization andMotorStepVerification ThroughRotaryAcceleration Signals ScottStarinandFredCrosno,CDAInterCorp......................................................................... 141 HighResolution StandardProximitySensor RogerBlaser,Vibro-Meter SA................................................................................................. 147 Qualification oftheInflatableSunshieldInSpace(ISIS)Mast DavidJ.Rohweller, TRWAstroAerospace ............................................................................. 155 ISSS/ADeployment--The HighsandLowsofEVAContingency Capability, ADesigner's Perspective BertHaugen,MalcolmFerry,andKevinKlein,LockheedMartinSpaceSystemsCompany.. 169 TheLightweight Deployable AntennafortheMARSISExperiment ontheMarsExpress Spacecraft GeoffreyW.MarksandMichaelT.Reilly,TRWAstroAerospace; andRichardL.Huff, UniversityofIowa.................................................................................................................... 183 MABE:High-Precision Tip/TiltMechanism BasedonMagneticBearingTechnology N.LoixandJ.Ph.Verschueren, Micromega Dynamics; andL.Scolamiero, ESA/ESTEC ......197 Development ofaFineSteeringMirrorAssembly RubenNalbandian andJeffWilliams,MoogInc.................................................................... 207 ADescription andPerformance ofMechanisms UsedintheHighResolution Ionospheric Thermospheric Spectrograph PhillipKalmanson, PraxisInc.;HsiungChou,AtlanticOnline;RussellStarks,PraxisInc.; andKennethDymondandStefanThonnard, NavalResearchLaboratory.............................. 215 DesignofanEVA-Capable Four-Point RestraintSystem ArmondAsadurianandJimHammond, MoogChatsworth Operations; KazuoHamadaand HiroshiIrikado,NECTOSHIBASpaceSystems;andMichioItoandMihoEndo,NASDA.......229 IntricaciesofUsingKevlarCordandThermalKnivesinaDeployable ReleaseSystem: IssuesandSolutions AlphonsoC.StewartandJasonH.Hair,NASAGoddardSpaceFlightCenter........................ 243 ReleaseMechanisms ontheGravityProbe-BRelativityMission SeanMcCullyandDennisSt.Clair,LockheedMartinSpaceSystemsCompany................... 257 Conceptualization andDesignofaMechanical DockingSystem TroyNilsonandMitchWiens,StarsysResearchCorporation ................................................... 265 Automating Separation SystemReliabilityTesting RyanL.Perroy,PlanetarySystemsCorporation ...................................................................... 279 RandomVibrationFailureMechanism ofaConradBearingUsingCrownBali-Retainer KlausEngel,COMDEVInternational; ReginaKwiatkowska, COMDEVSpaceGroup; andMihaiVladimirescu, COMDEVInternational .................................................................. 291 NASA/CP--2002-211506 vi
Comparison ofSeveralDifferentSputteredMolybdenum DisulfideCoatingsforUseinSpace Applications RobertL.Fusaro,NASAGlennResearchCenter;andMarkSiebert,UniversityofToledo.....305 SpaceBallBearingLoadCapacityWithDryLubrication A.Borrien,J.B.Mondier,andE.Conde,CNES...................................................................... 319 Tribological Properties ofaPennzane®-Based LiquidLubricant(Disubstituted Alkylated Cyclopentane) forLowTemperature SpaceApplications CliffordVenier,PennzoiI-Quaker StateCompany;EdwardW.Casserly,PenrecoCompany; WilliamR.Jones,Jr.,andMarioMarchetti,NASAGlennResearchCenter;MarkJ.Jansen, Sest,Inc.;andRoamerE.Predmore, NASAGoddardSpaceFlightCenter............................. 331 ISSSGANTGroupLevelOffloading TestMechanism XilinZhang,EMSTechnologies Canada,Ltd........................................................................ 339 Relationship BetweentheDifficultyIndexandtheEvaluation AccuracyofGroundDeployment Testing HironoriIshikawaandAkiraMeguro,NTTCorporation ............................................................ 353 NASA/CP--2002-211506 vii
Agenda WEDNESDAY, 15MAY2002 8:00 WEDNESDAY PRESENTERS' BREAKFAST--Hope Roomon7thFloor 8:00 CHECK-IN ANDREFRESHMENTS--Registration OfficeandEastBallroom on6thFloor 9:00 INTRODUCTORY REMARKS FredOswald, HostChairman NASAGlennResearch Center, Cleveland, OH StuartH.Loewenthal, General Chairman Lockheed MartinSpaceSystems Company, Sunnyvale, CA CENTER WELCOME Dr.Donald Campbell, Center Director NASAGlennResearch Center, Cleveland, OH 9:30 SESSION InlNSTRUMENT MECHANISMS LucioScolamiero, Session Chair ESA/ESTEC, Noordwijk, TheNetherlands •Asteroid Sampling Mechanism forMUSES-C KenHiguchi, Jun'ichiro Kawaguchi andAkiraFujiwara, TheInstitute ofSpaceand Astronautical Science, Sagamihara, Japan; Toshiaki Okudaira, NECTOSHIBA Space Systems, Yokohama, Japan; Satoru Yajima, Sumitomo Heavy Industries, Niihama, Japan •ADescription ofMechanisms usedintheLowResolution Airglow andAurora Spectrograph andSpecial Sensor Ultraviolet LimbImager PhilipKalmanson, Russell StarksandKenneth Dymond, Praxis, Inc.,Alexandria, VA;Stefan Thonnard, NavalResearch Laboratory, Washington, D.C. •TheIRACShutter Mechanism: Residual Magnetism andtheRotary Solenoid ScottSchwinger, ClaefHakun, GaryBrownandKenBlumenstock, NASAGoddard Space FlightCenter, Greenbelt, MD •ACryogenic Half-Wave PlateModule toMeasure Polarization atMultiple FIRPassbands Timothy Rennick, JohnVaillancourt, RogerHildebrand andStephen Heimsath, University ofChicago, Chicago, IL 11:30 LUNCH BREAK 12:45 SESSION IInDEPLOY BertHaugen, Session Chair Lockheed MartinSpaceSystems, Sunnyvale, CA •Tape-Spring Rolling Hinges AlanWattandSergio Pellegrino, University ofCambridge, Cambridge, United Kingdom •Material Property Effects onCoaxial CableMechanical Failure Robert Pan,J.B.Chang, C.C.WanandY.R.Takeuchi, TheAerospace Corporation, ElSegundo, CA;R.McVey, Boeing Satellite Systems, ElSegundo, CA;I.Chen, Raytheon Systems, ElSegundo, CA •Design andTesting oftheCRISP Tracking MirrorCoverandRelease Mechanism Jeffrey LeesandEdSchaefer, JohnsHopkins University Applied Physics Laboratory, Laurel, MD •ZeroDeadband, Multiple StrutSynchronized HingeforDeployable Structures Matthew Botke,DavidMurphy andThomas Murphey, AEC-ABLE Engineering, Goleta, CA; PeterSorensen, Kollabra, PaloAlto,CA 2:45 BREAK NASA/C P--2002-211506 ix