Verification of Space System Dynamics Using the MATLAB Identification Toolbox in Space Qualification Test

This article presents an approach with regards to the Functional Testing of Space System (SS) that could be a space vehicle (spacecraft-S/C) and/or its equipment and components – S/C subsystems. This test should finalize the Space Qualification Tests (SQT) campaign. It could be considered as a generic test and used for a wide class of SS that, from the point of view of System Dynamics and Control Theory, may be described by the ordinary differential equations. The suggested methodology is based on using semi-natural experiment laboratory stand that does not require complicated, precise and expensive technological control-verification equipment. However, it allows for testing totally assembled system during Assembling, Integration and Testing (AIT) activities at the final phase of SQT, involving system hardware (HW) and software (SW). The test physically activates system input (sensors) and output (actuators) and requires recording their outputs in real time. The data are then inserted in a laboratory computer, where it is post-experiment processed by the MATLAB/Simulink Identification Toolbox. It allows for estimating the system dynamics in the form of estimation of its differential equation coefficients through the verification experimental test and comparing them with expected mathematical model, prematurely verified by mathematical simulation during the design process. Mathematical simulation results presented in the article show that this approach could be applicable and helpful in SQT practice. Further semi-natural experiments should specify detail requirements for the test laboratory equipment and test-procedures.

Effect of Needle Height on Discharge Coefficient and Cavitation Number

Cavitation inside diesel injector nozzle is investigated using Reynolds-Stress-Navier stokes equations. Schnerr-Sauer cavitation model is used for modeling cavitation inside diesel injector nozzle. The carrying fluid utilized in the current study is diesel fuel. The flow is verified at the beginning by comparing with the previous experimental data and it was found that K-Epsilon turbulent model could lead to a better accuracy comparing to K-Omega turbulent model. Moreover, mass flow rate obtained numerically is compared with the experimental value and discrepancy was found to be less than 5% - which shows the accuracy of the current results. Finally, a real-size four-hole nozzle is investigated and the flow inside it is visualized based on velocity profile, discharge coefficient and cavitation number. It was found that the mesh density could be reduced significantly by utilizing periodic boundary condition. Velocity contour at the mid nozzle showed that maximum value of velocity occurs at the end of the needle before entering the orifice area. Last but not least, at the same boundary conditions, when different needle heights were utilized, it was found that as needle height increases with an increase in cavitation number, discharge coefficient increases, while the mentioned increases is more tangible at smaller values of needle heights.

Effect of Different Diesel Fuels on Formation of the Cavitation Phenomena

Cavitation inside a diesel injector nozzle is investigated numerically in this study. The Reynolds Stress Navier Stokes set of equations (RANS) are utilized to investigate flow behavior inside the nozzle numerically. Moreover, K-ε turbulent model is found to be a better approach comparing to K-ω turbulent model. The Winklhofer rectangular shape nozzle is also simulated in order to verify the current numerical scheme, and with the mass flow rate approach, the current solution is verified. Afterward, a six-hole real size nozzle was simulated and it was found that among the different fuels used in this study with the same condition, diesel fuel provides the largest length of cavitation. Also, it was found that at the same boundary condition, rapeseed methyl ester (RME) fuel leads to the highest value of discharge coefficient and mass flow rate.

Electrostatic Cleaning System Integrated with Thunderon Brush for Lunar Dust Mitigation

Detrimental effects of lunar dust on space hardware, spacesuits, and astronauts’ health have been already identified during Apollo missions. Developing effective dust mitigation technologies is critically important for successful space exploration and related missions in NASA applications. In this study, an electrostatic cleaning system (ECS) integrated with a negatively ionized Thunderon brush was developed to mitigate small-sized lunar dust particles with diameters ranging from 0.04 µm to 35 µm, and the mean and median size of 7 µm and 5 µm, respectively. It was found that the frequency pulses of the negative ion generator caused particles to stick to the Thunderon bristles and repel between the pulses. The brush was used manually to ensure that particles were removed from areas where the ECS failed to mitigate the lunar simulant. The acquired data demonstrated that the developed system removed over 91-96% of the lunar dust particles. The present study was performed as a proof-of-concept to enhance the cleaning performance of ECSs by integrating a brushing process. Suggestions were made to further improve the performance of the developed technology through future research.

Fatigue Life Prediction on Steel Beam Bridges under Variable Amplitude Loading

Steel bridges are normally subjected to random loads with different traffic frequencies. They are structures with dynamic behavior and are subject to fatigue failure process, where the nucleation of a crack, growth and failure can occur. After locating and determining the size of an existing fault, it is important to predict the crack propagation and the convenient time for repair. Therefore, fracture mechanics and fatigue concepts are essential to the right approach to the problem. To study the fatigue crack growth, a computational code was developed by using the root mean square (RMS) and the cycle-by-cycle models. One observes the variable amplitude loading influence on the life structural prediction. Different loads histories and initial crack length were considered as input variables. Thus, it was evaluated the dispersion of results of the expected structural life choosing different initial parameters.

IntelligentLogger: A Heavy-Duty Vehicles Fleet Management System Based on IoT and Smart Prediction Techniques

Both daily and long-term management of a heavy-duty vehicles and construction machinery fleet is an extremely complicated and hard to solve issue. This is mainly due to the diversity of the fleet vehicles – machinery, which concerns not only the vehicle types, but also their age/efficiency, as well as the fleet volume, which is often of the order of hundreds or even thousands of vehicles/machineries. In the present paper we present “InteligentLogger”, a holistic heavy-duty fleet management system covering a wide range of diverse fleet vehicles. This is based on specifically designed hardware and software for the automated vehicle health status and operational cost monitoring, for smart maintenance. InteligentLogger is characterized by high adaptability that permits to be tailored to practically any heavy-duty vehicle/machinery (of different technologies -modern or legacy- and of dissimilar uses). Contrary to conventional logistic systems, which are characterized by raised operational costs and often errors, InteligentLogger provides a cost-effective and reliable integrated solution for the e-management and e-maintenance of the fleet members. The InteligentLogger system offers the following unique features that guarantee successful heavy-duty vehicles/machineries fleet management: (a) Recording and storage of operating data of motorized construction machinery, in a reliable way and in real time, using specifically designed Internet of Things (IoT) sensor nodes that communicate through the available network infrastructures, e.g., 3G/LTE; (b) Use on any machine, regardless of its age, in a universal way; (c) Flexibility and complete customization both in terms of data collection, integration with 3rd party systems, as well as in terms of processing and drawing conclusions; (d) Validation, error reporting & correction, as well as update of the system’s database; (e) Artificial intelligence (AI) software, for processing information in real time, identifying out-of-normal behavior and generating alerts; (f) A MicroStrategy based enterprise BI, for modeling information and producing reports, dashboards, and alerts focusing on vehicles– machinery optimal usage, as well as maintenance and scraping policies; (g) Modular structure that allows low implementation costs in the basic fully functional version, but offers scalability without requiring a complete system upgrade.

Parametric Study of 3D Micro-Fin Tubes on Heat Transfer and Friction Factor

One area of special importance for the surface-level study of heat exchangers is tubes with internal micro-fins (< 0.5 mm tall). Micro-finned surfaces are a kind of extended solid surface in which energy is exchanged with water that acts as the source or sink of energy. Significant performance gains are possible for either shell, tube, or double pipe heat exchangers if the best surfaces are identified. The parametric studies of micro-finned tubes that have appeared in the literature left some key parameters unexplored. Specifically, they ignored three-dimensional (3D) micro-fin configurations, conduction heat transfer in the fins, and conduction in the solid surface below the micro-fins. Thus, this study aimed at implementing a parametric study of 3D micro-finned tubes that considered micro-fine height and discontinuity features. A 3D conductive and convective heat-transfer simulation through coupled solid and periodic fluid domains is applied in a commercial package, ANSYS Fluent 19.1. The simulation is steady-state with turbulent water flow cooling the inner wall of a tube with micro-fins. The simulation utilizes a constant and uniform temperature on the tube outer wall. Performance is mapped for 18 different simulation cases, including a smooth tube using a realizable k-ε turbulence model at a Reynolds number of 48,928. Results compared the performance of 3D tubes with results for the similar two-dimensional (2D) one. Results showed that the micro-fine height has a greater impact on performance factors than discontinuity features in 3D micro-fin tubes. A transformed 3D micro-fin tube can enhance heat transfer, and pressure drops up to 21% and 56% compared to a 2D one, respectfully.

Rolling Element Bearing Diagnosis by Improved Envelope Spectrum: Optimal Frequency Band Selection

The Rolling Element Bearing (REB) vibration diagnosis is worth of special interest by the variety of REB and the wide necessity of those elements in industrial applications. The presence of a localized fault in a REB gives rise to a vibrational response, characterized by the modulation of a carrier signal. Frequency content of carrier signal (Spectral Frequency –f) is mainly related to resonance frequencies of the REB. This carrier signal is modulated by another signal, governed by the periodicity of the fault impact (Cyclic Frequency –α). In this sense, REB fault vibration response gives rise to a second-order cyclostationary signal. Second order cyclostationary signals could be represented in a bi-spectral map, where Spectral Coherence –SCoh are plotted against f and α. The Improved Envelope Spectrum –IES, is a useful approach to execute REB fault diagnosis. IES could be applied by the integration of SCoh over a predefined bandwidth on the f axis. Approaches to select f-bandwidth have been recently exposed by the definition of a metric which intends to evaluate the magnitude of the IES at the fault characteristics frequencies. This metric is represented in a 1/3-binary tree as a function of the frequency bandwidth and centre. Based on this binary tree the optimal frequency band is selected. However, some advantages have been seen if the metric is changed, which in fact tends to dictate different optimal f-bandwidth and so improve the IES representation. This paper evaluates the behaviour of the IES from a different metric optimization. This metric is based on the sample correlation coefficient, detecting high peaks in the selected frequencies while penalizing high peaks in the neighbours of the selected frequencies. Prior results indicate an improvement on the signal-noise ratio (SNR) on around 86% of samples analysed, which belong to IMS database.

Fatigue Failure Analysis in AISI 304 Stainless Wind Turbine Shafts

Wind turbines are equipment of great importance for generating clean energy in countries and regions with abundant winds. However, complex loadings fluctuations to which they are subject can cause premature failure of these equipment due to the material fatigue process. This work evaluates fatigue failures in small AISI 304 stainless steel turbine shafts. Fractographic analysis techniques, chemical analyzes using energy dispersive spectrometry (EDS), and hardness tests were used to verify the origin of the failures, characterize the properties of the components and the material. The nucleation of cracks on the shafts' surface was observed due to a combined effect of variable stresses, geometric stress concentrating details, and surface wear, leading to the crack's propagation until the catastrophic failure. Beach marks were identified in the macrographic examination, characterizing the probable failure due to fatigue. The sensitization phenomenon was also observed.