Thrust stand for vertically oriented electric propulsion performance evaluation

A variation of a hanging pendulum thrust stand capable of measuring the performance of an electric thruster operating in the vertical orientation is presented. The vertical orientation of the thruster dictates that the thruster must be horizontally offset from the pendulum pivot arm, necessitating the use of a counterweight system to provide a neutrally stable system. Motion of the pendulum arm is transferred through a balance mechanism to a secondary arm on which deflection is measured. A noncontact light-based transducer is used to measure displacement of the secondary beam. The members experience very little friction, rotating on twisting torsional pivots with oscillatory motion attenuated by a passive, eddy-current damper. Displacement is calibrated using an in situ thrust calibration system. Thermal management and self-leveling systems are incorporated to mitigate thermal and mechanical drifts. Gravitational force and torsional spring constants associated with flexure pivots provide restoring moments. An analysis of the design indicates that the thrust measurement range spans roughly four decades, with the stand capable of measuring thrust up to 12 N for a 200 kg thruster and up to approximately 800 mN for a 10 kg thruster. Data obtained from calibration tests performed using a 26.8 lbm simulated thruster indicated a resolution of 1 mN on 100 mN level thrusts, while those tests conducted on a 200 lbm thruster yielded a resolution of roughly 2.5 mN at thrust levels of 0.5 N and greater.     

Development of a two-dimensional dual pendulum thrust stand for Hall thrusters

A two-dimensional dual pendulum thrust stand was developed to measure thrust vectors [axial and horizontal (transverse) direction thrusts] of a Hall thruster. A thruster with a steering mechanism is mounted on the inner pendulum, and thrust is measured from the displacement between inner and outer pendulums, by which a thermal drift effect is canceled out. Two crossover knife-edges support each pendulum arm: one is set on the other at a right angle. They enable the pendulums to swing in two directions. Thrust calibration using a pulley and weight system showed that the measurement errors were less than 0.25 mN (1.4%) in the main thrust direction and 0.09 mN (1.4%) in its transverse direction. The thrust angle of the thrust vector was measured with the stand using the thruster. Consequently, a vector deviation from the main thrust direction of +/-2.3 degrees was measured with the error of +/-0.2 degrees under the typical operating conditions for the thruster.     

Non-contact thrust stand calibration method for repetitively pulsed electric thrusters

A thrust stand calibration technique for use in testing repetitively pulsed electric thrusters for in-space propulsion has been developed and tested using a modified hanging pendulum thrust stand. In the implementation of this technique, current pulses are applied to a solenoid to produce a pulsed magnetic field that acts against a permanent magnet mounted to the thrust stand pendulum arm. The force on the magnet is applied in this non-contact manner, with the entire pulsed force transferred to the pendulum arm through a piezoelectric force transducer to provide a time-accurate force measurement. Modeling of the pendulum arm dynamics reveals that after an initial transient in thrust stand motion the quasi-steady average deflection of the thrust stand arm away from the unforced or "zero" position can be related to the average applied force through a simple linear Hooke's law relationship. Modeling demonstrates that this technique is universally applicable except when the pulsing period is increased to the point where it approaches the period of natural thrust stand motion. Calibration data were obtained using a modified hanging pendulum thrust stand previously used for steady-state thrust measurements. Data were obtained for varying impulse bit at constant pulse frequency and for varying pulse frequency. The two data sets exhibit excellent quantitative agreement with each other. The overall error on the linear regression fit used to determine the calibration coefficient was roughly 1%.     

High-accuracy displacement metrology and control using a dual Fabry-Perot cavity with an optical frequency comb generator

A displacement metrology and control system using an optical frequency comb generator and a dual Fabry-Perot cavity is developed with sub-nm accuracy. The optical frequency comb generator has expanded the displacement measurement range and the dual cavity system has suppressed the environmental fluctuation. We evaluated the absolute uncertainty of the developed displacement measurement system to be approximately 190 pm for the displacement of 14 μm and the accurate displacement control using a phase-locked loop was demonstrated with a resolution of approximately 24 pm.     

Impact of plasma noise on a direct thrust measurement system

In order to evaluate the accuracy and sensitivity of a pendulum-type thrust measurement system, a linear variable differential transformer (LVDT) and a laser optical displacement sensor have been used simultaneously to determine the displacement resulting from an applied thrust. The LVDT sensor uses an analog interface, whereas the laser sensor uses a digital interface to communicate the displacement readings to the data acquisition equipment. The data collected by both sensors show good agreement for static mass calibrations and validation with a cold gas thruster. However, the data obtained using the LVDT deviate significantly from that of the laser sensor when operating two varieties of plasma thrusters: a radio frequency (RF) driven plasma thruster, and a DC powered plasma thruster. Results establish that even with appropriate shielding and signal filtering the LVDT sensor is subject to plasma noise and radio frequency interactions which result in anomalous thrust readings. Experimental data show that the thrust determined using the LVDT system in a direct current plasma environment and a RF discharge is approximately a factor of three higher than the thrust values obtained using a laser sensor system for the operating conditions investigated. These findings are of significance to the electric propulsion community as LVDT sensors are often utilized in thrust measurement systems and accurate thrust measurement and the reproducibility of thrust data is key to analyzing thruster performance. Methods are proposed to evaluate system susceptibility to plasma noise and an effective filtering scheme presented for DC discharges.     

Uncertainty evaluation of a 10N·m dead weight torque standard machine and comparison with a 1kN·m dead weight torque standard machine

A 10N·m dead weight torque standard machine (10-N·m-DWTSM) has been developed and evaluated since 2006 at the National Metrology Institute of Japan (NMIJ), a part of the National Institute of Advanced Industrial Science and Technology (AIST). Previously, the lengths of a moment arm, made of a low-thermal-expansion alloy (Super Invar), and the sensitivity limit of the fulcrum were evaluated. However, it is known that mechanical parts made of Super Invar vary in size with time. Therefore, the sensitivity limit of the fulcrum should be investigated under real calibration conditions. In this study, the moment arm lengths and the sensitivity limit of the fulcrum were re-evaluated. The moment arm lengths were found to have increased by an average of 6.3 μm in five years. The relative combined standard uncertainty of the moment arm length, w_arm, was re-evaluated in consideration of the uncertainty of the secular length change and was found to be 1.8 × 10⁻⁵. The sensitivity limit of the fulcrum was investigated by using a highly accurate, small-rated-capacity torque measuring device. The relative combined standard uncertainty due to the sensitivity limit of the fulcrum was 2.5 × 10⁻⁵ in the 0.1–10N·m torque range. The uncertainty budget table of the 10-N·m-DWTSM was completed. The relative expanded uncertainty of torque realized by the 10-N·m-DWTSM, W_tsm, was evaluated in the 0.1–10N·m torque range and was found to be 6.6 × 10⁻⁵, with a coverage factor, k, being equal to 2. In addition, the 10-N·m-DWTSM was compared with the existing 1-kN·m-DWTSM at NMIJ by using small-rated-capacity torque measuring devices at 5N·m and 10N·m torque steps. Two loading conditions were adopted in this comparison. The comparison results showed good agreement within the uncertainties in all cases. Thus, the torque realized by the 10-N·m-DWTSM was shown to be equivalent to that achieved by the 1-kN·m-DWTSM.     

Influence of tube wall longitudinal heat conduction on temperature measurement of cryogenic gas with low mass flow rates

Longitudinal heat conduction is an important parameter in the cryogenic field, especially in cryogenic heat exchangers. In the present study, the parasitic effect of tube wall longitudinal heat conduction on temperature measurement within the tube has been studied for cryogenic gas with low mass flow rates by finite element method and experimental tests. The effects of various parameters such as tube outlet temperature, tube wall thermal conductivity, mass flow rate, and tube wall thickness have been investigated. Axial positioning errors of temperature sensor due to tube wall longitudinal heat conduction were higher for lower gas flow rates. The results showed that the tube wall thermal conductivity leads to axial heat conduction within the tube wall, but the higher tube wall thermal conductivity does not lead to bigger axial positioning error of temperature sensor at tube outlet. According to data obtained from simulations and experiments, sensor with distance of 5 mm from tube outlet had 14.92% and 8.51% temperature measurement error (with respect to gas flow temperature at tube outlet) for tube wall thermal conductivities of 16 and 400 W m⁻¹ K⁻¹, respectively.     

Quasi-constant rotational stiffness characteristic for cross-spring pivots in high precision measurement of unbalance moment

This paper proposes a design method for cross-spring pivots with quasi-constant rotational stiffness in the field of unbalanced moment measurement. To achieve high precision measurement of unbalance moment, the relationship between instrument sensitivity and the rotational stiffness of the cross-spring pivot is revealed. In order to eliminate the impacts of payload changes on instrument sensitivity, the relationship between geometric parameters and the rotational stiffness of the pivot is studied. Further, cross-spring pivots with quasi-constant rotational stiffness are designed as the rotation unit of a static balancing instrument, while the center shift of pivot takes the minimum value. Certain amount of unbalance moments is measured by the instrument. Experimental studies of the instrument show that the maximum measurement errors of unbalance moments 0.162 g mm, 0.319 g mm and 1.300 g mm are 0.068 g mm, 0.086 g mm and 0.053 g mm, respectively, when the payload ranges from 0 g to 7000 g. The instrument can achieve a relatively high precision measurement and the instrument sensitivity is almost not affected by the changes of payloads. The effectiveness of the method and the stiffness property of the pivot are verified by the experiments. So this kind of pivot has good prospects in unbalance moment measurement.     

Design and experimental validation of an ultra-precision Abbe-compliant linear encoder-based position measurement system

The design and development of an Abbe-compliant linear encoder-based measurement system for position measurement with a targeted 20 nm uncertainty (k = 2) in machine tools and CMMs is presented. It consists of a linear scale and a capacitive sensor, mounted in line on an interface which is guided in the scale's measurement direction and driven by a linear motor based on the output signal of the capacitive sensor. The capacitive sensor measures the displacement of a target surface on the workpiece table. The functional point, which is the center of a tool or touch probe, is always aligned with the scale and capacitive sensor such that this configuration is compliant with the Abbe principle. Thermal stability is achieved by the application of a thermal center between the scale and capacitive sensor at the tip of the latter, which prevents both components to drift apart. Based on this concept, a prototype of a one-DOF measurement system was developed for a measurement range of 120 mm, together with an experimental setup aimed at verifying the reproducibility of the system for changing ambient conditions of ±0.5 °C and ±5%rh and the repeatability during tracking of a target surface over a short period of time. These experiments have shown that the measurement uncertainty of the one-DOF system is below 29 nm with a 95% confidence level.     

A signal interpolation method for Fabry–Perot interferometer utilized in mechanical vibration measurement

In this investigation, a self-developed signal processing method for Fabry–Perot interferometer is proposed which can be utilized for high-speed dynamic displacement measurements, e.g. mechanical vibration measurements. The lookup table (LUT) integrated with the interference intensity equation has been employed for the interpolation processing of interference signals. With the aid of this method, the interpolation error has been reduced by 40% in comparison with that resulting from the commercial sinusoidal signal processing module. By operations of Fast Fourier Transform (FFT), the displacement measurement distribution can be converted into the frequency spectrum diagram. The interpolation resolution of the proposed interferometric displacement measurement system is about 0.1 nm. Experimental results demonstrate that this interferometer system is available for measuring frequencies till 2 kHz where its corresponding amplitude is 0.15 μm.     

Measurement method and pipe wall misalignment adjustment algorithm of the pipe butting machine

This paper presents a runout measurement method and a novel finite grouping method to predict and optimize the rotational angle and translational displacement of butting pipes to minimize pipe wall misalignment (PWM). This study develops a method to minimize the PWM of the pipes excluding the positions of welding seams. In this method, the measurement data are divided into finite groups and the criteria are created to identify the positions of welding seams and eliminate the effect of the welding seams. Finally, the rotational angle and translational displacement of the butting pipes are optimized to minimize the PWM. A butting machine is designed to implement this method. The machine is benchmarked by a standard smooth pipe to minimize system errors. Three butting experiments have been performed with welded pipes of diameter 406 mm. The comparison shows that the computation results agree with the experimental results very well. The maximum PWMs in three experiments are less than 1.87 mm, which satisfies the butting requirements, that is, a PWM of less than 2.0 mm. Then, the uncertainties of the measurement results are discussed.     

A laser-based machine vision measurement system for laser forming

Laser forming continues to be a promising technology in manufacturing due to its fast speed, flexibility, and low-cost. Measurement of deformation after laser forming is widely needed to verify its convergence to the intended shape in academic research. With the development of laser forming, high requirements on the measurement of the deformed work-piece have been sought such as a 3D profile of the deformed surface, a large measuring range, and measuring convenience. In this paper, a laser-based machine vision measurement system was developed to measure the 3D profile of deformed surface by a one-off scanning process. Based on the 3D profile data, the vertical displacement of the deformed plate was calculated for bending analysis. In addition, as one of the important feature parameters, transverse shrinkage was automatically determined through a novel image-based method during the scanning process. A measuring accuracy of 0.03 mm for vertical displacement measurement and 0.0125 mm for transverse shrinkage were achieved in the developed measurement system. This measurement performance is acceptable in most of the laser forming processes currently studied.     

A long-stroke 3D contact scanning probe for micro/nano coordinate measuring machine

This paper presents a long-stroke contact scanning probe with high precision and low stiffness for micro/nano coordinate measuring machines (micro/nano CMMs). The displacements of the probe tip in 3D are detected by two plane mirrors supported by an elastic mechanism, which is comprised of a tungsten stylus, a floating plate and two orthogonal Z-shaped leaf springs fixed to the outer case. A Michelson interferometer is used to detect the vertical displacement of the mirror mounted on the center of the floating plate. An autocollimator based two dimensional angle sensor is used to detect the tilt of the other plane mirror located at the end of the arm of the floating plate. The stiffness and the dynamic properties are investigated by simulation. The optimal structural parameters of the probe are obtained based on the force-motion model and the constrained conditions of stiffness, measurement range and horizontal size. The results of the performance tests show that the probe has a contact force gradient within 0.5 mN/μm, a measuring range of (±20 μm), (±20 μm), and 20 μm, respectively, in X, Y and Z directions, and a measurement standard deviation of 30 nm. The feasibility of the probe has preliminarily been verified by testing the curved surface of a convex lens.     

A new approach for geo-monitoring using modern total stations and RGB + D images

The objective of this study is to present a new approach to geo-monitoring. The approach is based on a combination of different existing as well as established methods while resolving present disadvantages. Herein, RGB + D images are used for a fused data analysis of scan and image data acquired by a single instrument. The used Image Assisted Total Station (IATS) – a multi-sensor system – is presented in detail, with particular focus on the integrated camera system. This includes an improved matrix based notation for the pixel angle relation.The main feature of the analysis is a combination of point cloud and image data, which complement each other very well for monitoring tasks. The data is acquired in subsequent measurement epochs wherein RGB + D images are generated. As a result, any pixel position can be expressed as a polar measurement and transformed into a 3D world coordinate. With the help of image matching algorithms corresponding points/regions of two epochs can be found and displacement vectors calculated.The single processing steps are explained and the practical usage is demonstrated by an application example.     

Development and precise positioning control of a thin and compact linear switched reluctance motor

This paper describes the development and precise positioning control of a thin and compact linear switched reluctance motor (LSRM). The LSRM that has been developed has a mover that is easy to fabricate and can be disposable. The mover can be easily separated from the stator, allowing it to be changed frequently or discarded in a hazardous application. The prototyped LSRM mover is only 0.128 mm thick with the stator measuring 2.0 mm at its thickest point. These features are highly desirable for space savings while being cost-effective. However, the LSRM has a strong nonlinear driving characteristic that presents a challenge with respect to precision control. In order to overcome this problem and achieve precision positioning, a linearizer unit was designed and integrated into the controller to compensate for the nonlinear relationships among the effective thrust force, mover position, and excitation current. The usefulness of the designed controller was examined experimentally. The experimental positioning results show that the steady-state errors were all less than 1 μm in the working range of the LSRM. In addition, the redesign for the improvement of thrust characteristic and easy fabrication of the LSRM is explained.     

Gas Oil Piston Prover,primary reference values for Gas-Volume

The paper describes the design, measurement results and uncertainty analyses of the hydraulic driven piston-prover system which has been in operation at VSL since 2008. The 12-meter long, 0.6 m bore piston-prover is used for the realization of Reference Values for Gas-Volume at pressures between 1 and 65 bar(a) at several gases. The principle is based on the displacement of a piston acting as a Gas–Oil separator. The standard has a flow-rate range from 5 to 230 m³/h. The system is designed to calibrate reference meters. The Calibration and Measurement Capability (CMC) of the system is proven to be smaller than 0.1% (k=2). The paper also explains the coherence between the Gas–Oil piston-prover and other traceability generators and ‘flow rate bootstrapper systems’.     

Application of blue laser direct-writing equipment for manufacturing of periodic and aperiodic nanostructure patterns

This study presents the novel development of low cost, highly efficient blue laser direct-writing equipment for using mask-less laser lithography to manufacture periodic and aperiodic nanostructure patterns. The system includes a long-stroke linear motor precision stage (X, Y), a piezoelectric nano-precision stage (Y, θz), a 3-DOF (degrees of freedom) laser interferometer measurement system, and a blue laser direct-writing optical system. The 3-DOF laser interferometer measurement system gives the control system feedback for displacement (X, Y, θz) of the equipment. The laser processing equipment consists of a blue laser direct-writing optical head, a field-programmable gate array (FPGA) alignment interface, and an optical head servo controller. The optical head operates at a wavelength of 405 nm. Processing the nanostructures on thermo-reaction inorganic resists with precise control of the laser intensity, taking advantage of the threshold effect to exceed the limitations of optical diffraction, and reduces the nanostructure hole size. The equipment can be used to fabricate various periodic nanostructure patterns, aperiodic nanostructure patterns, and two-dimensional patterns. The equipment positioning accuracy is within 50 nm at a speed of 50 mm/s, and the minimum critical dimension can be achieved about 100 nm or so.     

Micro-drilling of Ti–6Al–4V alloy: The effects of cooling/lubricating

This paper presents a series of experimental investigations of the effects of various machining conditions [dry, flooded, minimum quantity lubrication (MQL), and cryogenic] and cutting parameters (cutting speed and feed rate) on thrust force, torque, tool wear, burr formation, and surface roughness in micro-drilling of Ti–6Al–4V alloy. A set of uncoated carbide twist drills with a diameter of 700 μm were used for making holes in the workpiece material. Both machining conditions and cutting parameters were found to influence the thrust force and torque. The thrust force and torque are higher in cryogenic cooling. It was found that the MQL condition produced the highest engagement torque amplitude in comparison to the other coolant–lubrication conditions. The maximum average torque value was obtained in the dry drilling process. There was no substantial effect of various coolant–lubrication conditions on burr height. However, it was observed that the burr height was at a minimum level in cryogenic drilling. Increasing feed rate and decreasing spindle speed increased the entry and exit burr height. The minimum surface roughness values were obtained in the flood cooling condition. In the dry drilling process, increased cutting speed resulted in reduced hardness on the subsurface of the drilled hole. This indicates that the surface and subsurface of the drilled hole were subject to softening in the dry micro-drilling process. The softening at the subsurface of drilled holes under different cooling and lubrication conditions is much smaller compared to the dry micro-drilling process.     

On reliable measurement of micro drilling forces and identification of different phases

Mechanical micro-drilling process is often used in the manufacture of miniature components and molds. Frequent breakage of micro-drill is a major problem necessitating a thorough investigation into the process. One of the important responses measured during micro-drilling process is variation of thrust force and torque. Since the values of thrust force and torque are very low in micro-drilling, reliable measurements have to be carried out using high-resolution dynamometer. In the present work, micro-drilling is carried out using 0.5 mm diameter drill on Al 6061-T6 sheet of 3 mm thickness. The measurement results obtained from multi-component dynamometer are discussed first. Subsequently, a torque sensor mounted on the multi-component dynamometer is used to measure the torque, while the thrust force is acquired from latter. Since it is practically impossible to start acquiring the signals at a given time instant, the signals have to be synchronized in time domain using a novel signal processing technique. Different phases in micro-drilling, namely entry, full penetration and dwell are identified uniquely.     

Uncertainty analysis for a phase-detector based phase noise measurement system

Phase noise is an important parameter to characterise the frequency stability of oscillators and synthesised signal generators. Accurate measurement of phase noise is required for various applications in radar, communication and navigation systems. A single-channel phase-detector based phase noise measurement system is described. The system’s measurement errors and uncertainties have been analysed in details. The expanded uncertainty is about 2.7 dB for calibrating phase noise of a signal generator at 0.001–1.6 GHz for frequency offsets from 1 Hz to 100 kHz. The uncertainty budget for measuring a signal generator’s phase noise at 640 MHz is also presented.