high flexibility rotorcraft driveshafts using flexible matrix ：使用灵活的矩阵的高弹性旋翼机传动轴

High Flexibility Rotorcraft Driveshafts using Flexible Matrix Composites and Active Bearing ControlPrincipal InvestigatorsKon-Well Wang, Ph.D.Diefenderfer Chaired Professor in Mechanical EngineeringCharles Bakis, Ph.D.Professor of Engineering Science and MechanicsEdward Smith, Ph.D.Professor of Aerospace EngineeringGraduate Student supported by RCOEBryan Mayrides (M.S. student)Other Team MembersHans DeSmidt (Ph.D. student)Ying Shan (Ph.D. student),PS 2.2,Issues of Current Driveline Systems Problem Statement and Technical Barriers,Current DrivelinesSegmented shafting with significant # of flex couplings/bearings for misalignment compensationPassive dampers needed for supercritical speed shaftsHigh Maintenance and CostComponent (bearings, couplings, dampers) wearShaft balancing and alignmentStrict shaft eccentricity tolerances,Issues applicable to both helicopter and tiltrotor,Program Goal and Ideas,To address the issues with current systems and overcome the technical barriers for achieving a simple, high performance, low vibration, low cost, and low maintenance driveline of rotary-wing aircraftReduce number of mechanical contact componentsReduce maintenance needSuppress vibration and ensure stability,IDEAS ?,Develop and utilize newly emerging materials and active control technologies - a combination of Flexible matrix composite (FMC) materials and Active magnetic bearings (AMB),Ideas,Flexible matrix composite (FMC) materials with tailored ply orientations for shaftingSoft in flexure and stiff in torsion to accommodate for large misalignment and effectively transmit power Without multi-segment shafting and large # of bearings/couplings - reduce cost and maintenance need,Ideas (cont.),Active magnetic bearings for low maintenance and vibration controlWhile highly flexible composite driveshaft systems have many advantages, their vibration behavior could be issues that need to be addressed before realizing the idea Penn State researchers have explored the feasibility of active vibration control of tailrotor-drivetrain structure via active magnetic bearings (AMB) by proper controller design, the AMB actuator could be a good candidate for helicopter driveline control (size, weight, power) DeSmidt, Wang, and Smith, Proc of 54th AHS Forum, 1998,Non-contact - no frictional wear Large frequency range - ideal for active vibration control in rotorcraft setting Light backup roller bearings (only contact with active failure) for fail-safe purpose,2004 Review Comments and Actions,Assess Potential Payoffs We have examined payoffs for supercritical driveline in previous studies; this year we expanded the study to show potential payoffs (weight and component reductions) for subcritical drivelines via system designAssess Cost Benefit Qualitatively, reducing components/maintenance = reducing cost;To quantify cost benefit requires development on specific drive system with manufacturers and users (future RITA project)Examine Practicality of Magnetic Bearing Have achieved another successful demonstration of AMB controller for FMC shafting with uncertaintiesIn the process of examining AMB design (weight, size, power) in rotorcraft setting via NASA Glenn design code (On-going effort)Have generated new ideas of hybrid active-passive failsafe devices as future basic research topicsAddress Failure ModesThorough study beyond scope of current program Have generated ideas/plan to examine this issue as a future basic research topic,Research Issues and Task Objectives,Materials and Composite IssuesStructural Mechanics and Dynamics IssuesSystems and Controls Issues,Research Issues and Task Objectives,Materials and Composite IssuesRationale: Traditional barrier to higher strain operation of fiber composites is matrix crackingFlexible, low-modulus matrix can potentially avoid cracking,Technical Objectives: Select a trial flexible matrix system (carbon/polyurethane)Develop filament winding processCharacterize stiffness & damping behavior and validate models over range of temperatures, frequencies, and strainsBuild lab-scale shafts for experimental validation of self-heating, structural dynamics, and to investigate fatigue behavior,Matrix Cracking,Materials and Composite Sub-Task,Achievements 2001-2003/04Developed wet filament winding technique for trial flexible matrix composite shafts (carbon/polyurethane)Developed test apparatus & method for characterizing frequency and temperature dependent damping & stiffness of FMC laminas and laminatesDeveloped & validated models for frequency and temperature dependent damping & stiffness of FMC laminas and laminatesDeveloped model and test method to investigate self-heating behavior of rotating misaligned FMC shafts,Summary of Accomplishments in 2004/05: Refined and experimentally validated self-heating model of rotating misaligned FMC shafts,Input to the temperature model: frequency and temperature dependent lamina properties of FMC material; misalignment strain; shaft speed The misalignment strain and rotation speed can be controlled. The stand can spin FMC shafts at up to 1.25% misalignment strain, and at speed up to 2500 RPM,Internal Self-Heating Model and Experimental Validation Method for Misaligned Rotating FMC Shafts,0.75%, RMC,0.75%, FMC,Model Results and Experimental Validation,(45) deg. FMC,Model capable of predicting self heating behavior of FMC materials and providing guidance for design and control of FMC shaft,Self-heating of FMC shaft is insignificant compared to RMC,Effect of Temperature on Shaft Properties,Laminate design affects temperature sensitivity of shaftTool developed can predict temperature effect on shaft properties provide design and control guidance,Shaft Longitudinal Modulus,+60/-60/+25/-25s,+45/-45/+45/-45s,Research Issues and Task Objectives,Materials and Composite IssuesStructural Mechanics and Dynamics IssuesDevelop analysis tools for driveshaft dynamic loads/ deformation characterization (e.g., strain level, buckling, stability, damping effect on temperature & property variation)FMC materials selection and structural tailoring/optimization to satisfy design desires (e.g., maximum allowable misalignment, minimum weight, and minimum internal damping)Systems and Controls Issues,Structural Mechanics and Dynamics Sub-Task,Summary of Previous Work (2001-2003/04)FE model and analysis tools have been developed to analyze driveline static and dynamic characteristics (deformation,stress level,natural frequency, etc.)Utilizing the model and tools developed, Performed study to provide information regarding parameter effects on system (durability, stability, etc.)System parameters were tailored to achieve satisfactory system performance for supercritical driveline,Structural Mechanics and Dynamics Sub-Task,Summary of Current Work (2004/05)Examined feasibility of designing FMC driveshafts for subcritical applications Maintain advantages of current supercritical driveline (light weight, fewer bearings) but without the shortcomings (high vibration, whirl instability, and external damper requirements)Performed optimization study where shaft parameters were tailored to find minimum weight and/or component driveline that meets performance requirementsExamined applications for model/analysis toolReducing weight in subcritical driveline (Blackhawk, Chinook)Design a driveline for a minimum number of components,InputsHelicopter properties (shaft geometry, speed, power)Applied loads (torque, misalignment, imbalance)Design variables (ply sequence, ply angles, # bearings, outer diameter)Inputs used to iteratively calculate temperature dependent laminate properties and steady state temperatureAccounts for self-heating (misaligned rotation) and considers atmospheric heating and rotor downwash coolingLaminate properties (at steady state temperature) to calculate performance indicesCritical speed ratio (ensures subcritical)Tsai Wu strength factor (measure of strength)Torsional buckling safety factorTorsional yield safety factorDriveline with minimum weight/components is “optimum” design,Design Approach/Model Outline,Minimum Weight Design Study Results - Blackhawk,Blackhawk: current driveline specifications5 segments4 midspan flex couplings, 4 midspan bearingsDriveline mass = 31.3 kg (69 lbs)Blackhawk: optimum FMC driveline specifications1 segment with 60/-60/-25/25S layup0 midspan couplings, 3 midspan bearings Driveline mass = 21.6 kg (47.6 lbs),Conventional Alloy,Input Torque 734 Nm,(reduction of 5 components),(reduction of 29.5%),Minimum Weight Design Study Results - Chinook,Chinook: current driveline specifications7 segments6 midspan flex couplings, 6 midspan bearingsDriveline mass = 60.4 kg (133 lbs)Chinook: optimum FMC driveline specifications1 segment with 50/-50/-20/20S layup0 midspan couplings, 5 midspan bearingsDriveline mass = 44.4 kg (97.9 lbs),Input Torque 4067 Nm,Conclusion: Designers go from subcritical to supercritical to reduce weight, but weight savings (even component reduction) can also be realized by using FMC drivelines while maintaining subcritical operation,(reduction of 25.5%),(reduction of 7 components),Minimum Component Design Study,Model & analysis tool applied to re-design driveline for minimum components (reduce maintenance needs) instead of minimum weightCan we still achieve weight savings when minimizing driveline components?One example: Blackhawk with q1/-q1/-q2/q2s layup,Observations:Always eliminate all midspan couplings for FMC designs (both methods)The number of bearing components can be further reduced even with subcritical speed requirement Weight still saved for this case as compared to current design,Materials and Composite IssuesStructural Mechanics and Dynamics IssuesSystems and Controls IssuesEffective vibration and stability control methodologyVibration suppression - Shaft imbalance with uncertain magnitude and distributionStability issues for supercritical shafting - whirl instability due to shaft internal damping Adaptive control to compensate for operating condition uncertainty and shaft property variationsActuator/system design in rotorcraft setting (size, weight, power),Research Issues and Task Objectives,Systems and Controls Sub-Task- Achievement Summary,Achievements (2001- 2003/04)Preliminary study to identify issues and feasibility of AMB actuators/control in rotorcraft setting Developed state equation and uncertainty function formulation for the AMB-FMC driveshaft systemSynthesized hybrid robust feedback/adaptive feed-forward control law for AMB driveline system and developed robust controller design methodology Analytically and experimentally evaluated and validated closed-loop controller performance on AMB-driveline testrig (on conventional segmented Alloy shaft),Summary of New Achievements (2004/05)Developed H/Synchronous Adaptive Feed-Forward controller for AMB/FMC driveline systemSuppress imbalance vibrationSuppress whirl instability (if supercritical) Account for FMC shaft stiffness and damping uncertainties due to operating temperature variationsConcurrent optimal design of control parameters and AMB locations to maximize closed-loop robustnessAnalytically and experimentally evaluated AMB/FMC driveline closed-loop performance on testrigStability and vibration suppression performance and robustnessMultiple operating conditions (various shaft speeds, load torques, and operating temperatures),Systems and Controls Sub-Task,AMB-FMC Driveline System with Hybrid H /Adaptive Control,Hybrid H/AVC Control LawRobust H feedback - Levitates driveline & ensures stabilityAdaptive feed-forward - Adapts to suppress driveline vibration,Non-Contact Active Magnetic Bearing,AMB-FMC Driveline System,One-Piece FMC shaft with rigid couplings supported by Active Magnetic Bearings (AMB)Driveline subjected to shaft imbalance, misalignment, torque & ambient temperature variations,AMB-FMC Driveline SystemClosed-Loop Robustness & Performance,Due to FMC stiffness and damping temperature sensitivity, H/AVC designed to be robust to variations about nominal temperatureClosed-loop system has significant temp. robustness -20F T 190F,Limited sensor information requiredOnly uses collocated AMB sensorsNo knowledge of shaft imbalance or operating temperature required,Test Results,Plan for rest of 2005,Structural Mechanics and Dynamics IssuesUse structural dynamics model to select an “optimum” matrix materialIncorporate a safety factor in the model to design against fatigue failure,Materials and Composite IssuesEvaluation of FMC fatigue behavior,Systems and Controls IssuesEvaluate design issues (size, weight, power) of AMB actuator in rotorcraft setting via NASA Glenn AMB codeCompare weight/size with conventional bearing system,The feasibility and advantages of utilizing FMC and AMB technologies to improve current rotorcraft driveline systems have been demonstrated for both super- and sub-critical drivelinesTools have been developed which can be utilized for specific driveline system development applications Manufacturing and characterization processesAnalytical and experimental methodsDesign and control algorithms,Overall Project Accomplishments & Conclusions,We have shown, while maintaining torque transmitting capabilityFMC shafting Eliminates segments and flexible couplings/bearings reduces components and maintenance needsReduces strict requirements for alignmentReduces weight AMBs Eliminate contact bearings reduce maintenanceReduce vibration level with robust performance w.r.t. uncertainties (temperature, operating conditions, etc.)Reduce strict requirements for balancing, alignment, and tolerance,Overall Project Future Directions,Application and development work (RITA type projects)The analytical and experimental tools developed can be utilized for the development and evaluation of specific future drivelines with FMC shafting and/or AMB technologyBasic research possibilitiesFMCs with materials enhancement (environment, fatigue, failure modes, etc.) for advanced rotorcraft applicationsActive-passive hybrid non-contact bearings Enhance driveline fail-safety and stability while retaining merits of AMBsDistributed auto-balancing techniques Enhance vibration reduction of driveline without active action,Publications,Shan, Y., and Bakis, C.E., “Static and Dynamic Characterization of a Flexible Matrix Composite Material,” Proc. 58th American Helicopter Society Annual Forum, Montreal, Quebec, June 2002.Shan, Y., and Bakis, C.E., “Frequency and Temperature Dependent Damping Behavior of Flexible Matrix Composite Tubes,” 35th International SAMPE Technical Conference, Dayton, OH, Sept. 28 Oct. 2, 2003.Shin, E., Wang, K.W., and Smith, E.C., “Characterization of Flexible Matrix Composite Rotorcraft Driveshafts,” Proc. 59th American Helicopter Society Annual Forum, Phoenix, AZ, May 2003.DeSmidt, H.A., Wang, K.W., Smith, E.C., and Provenza, A.J., “Stability Control of Driveline System with Internal Damping and Non-Constant Velocity Couplings,” Proc. ISCORMA-2 Conference, Gdansk, Poland, Aug. 2003.,Publications (Cont.),DeSmidt, H.A., Wang, K.W., and Smith, E.C., “Multi-Harmonic Adaptive Vibration Control of AMB-Driveline Systems with Non-Constant Velocity Couplings,” Proc. ASME Design Technical Conference-19th Biennial Conference on Mechanical Vibration and Noise, Chicago, IL, Sept. 2003.DeSmidt, H.A., Wang, K.W., and Smith, E.C., “Multi-Harmonic Adaptive Vibration Control of Magnetic Bearing-Driveshaft with Auxiliary Feedback: Theory and Experiment,” Proc. 45th AIAA Structures, Structural Dynamics and Materials Conference, Palm Springs, CA, April 2004.DeSmidt, H.A., Wang, K.W., and Smith, E.C., ”Stability of a Segmented Supercritical Driveline with Non-Constant Velocity Couplings Subjected to Misalignment and Torque,” Journal of Sound and Vibration Vol. 277, No. 4-5, pp. 895-918, 2004.DeSmidt, H.A., Wang, K.W., and Smith, E.C., “Adaptive Control of Flexible Matrix Composite Rotorcraft Drivelines,” Proc. 60th American Helicopter Society Annual Forum, Baltimore, MD, June 2004.,Publications (Cont.),DeSmidt, H.A., Wang, K.W., Smith, E.C., and Provenza, A.J., ”On the Robust Stability of Segmented Driveshafts with Active Magnetic Bearing Control,” Journal of Vibration and Control, Vol. 11 pp.317-329, 2005.Shan, Y., and Bakis, C.E., “Internal Heating Behavior of Flexible Matrix Composite Driveshafts,” Proc. 61st American Helicopter Society Annual Forum, Grapevine, Texas, 1-3 June 2005.Mayrides, B., Wang, K.W., and Smith, E.C., “Analysis and Synthesis of Highly Flexible Helicopter Drivelines with Flexible Matrix Composite Shafting,” Proc. 61st American Helicopter Society Annual Forum, Grapevine, Texas, 1-3 June 2005.DeSmidt, H.A., Wang, K.W., and Smith, E.C., “Multi-Harmonic Adaptive Vibration Control of Misaligned Driveshaft Systems An Experimental Study,” Proc. of the 12th International Congress on Sound and Vibration, Lisbon, Portugal, July 2005.,External Interactions, Leveraging and Technology Transfer,Have had discussions with Army NASA Glenn (Bill, Provenza), Bell (Brunken, Riley), Boeing Philadelphia (Robuck, Gabrys), Boeing Mesa (Hansen), Lord Corporation (Potter), and UTRC (Davis) on various aspects of this projectHave worked with Army NASA Glenn on designing and fabricating test fixtures as well as Magnetic Bearing setup and calibration Have visited Bell and discussed with Brunken and Riley addressing temperature effect based on their suggestions; have continued discussion since thenMark Robuck (Boeing Philadelphia) has visited Penn State in 2003 and discussed future collaboration possibilities in joining efforts for government contracts in this area have continued to follow upLeveraged upon Army/NASA Glenn GSRP Fellowship, Army DURIP, Weiss Fellowship, and internal funds from the Structural Dynamics and Controls Lab,Questions?,The End,Schedule and Milestones,Tasks,2001,2002,2004,2005,Refinement of driveline model Perform analysis on driveline model to provide info for FMCFMC selection/ synthesisFMC material characterizationStructure tailoring/optimizationAMB control law synthesis a