1、 Standard ANSI/AIA S-096-204 AIA standards are copyrighted by the American Institute of Aeronautics and Astronautics (AIA), 1801 Alexander Bel Drive, Reston, VA 20191-434 USA. Al rights reserved. AIA grants you a license as folows: The right to download an electronic file of this AIA standard for te
2、mporary storage on one computer for purposes of viewing, and/or printing one copy of the AIA standard for individual use. Neither the electronic file nor the hard copy print may be reproduced in any way. In adition, the elctronic file may not be distributed elsewhere over computer networks or otherw
3、ise. The hard copy print may only be distributed to other employees for their internal use within your organization. Space Systems Flywhel Rotor Asemblies ANSI/AIA S-096-204 American National Standard Space Systems Flywhel Rotor Assemblies Sponsored by American Institute of Aeronautics and Astronaut
4、ics Aproved 30 November 204 American National Standards Institute Abstract This standard establishes baseline requirements for the design, fabrication, test, inspection, storage, and transportation of a flywhel rotor asembly used in a spaceflight flywhel system for energy storage and/or atitude cont
5、rol. These requirements when implemented on a particular system wil asure a high level of confidence in achieving safe and reliable operation. ANSI/AIA S-096-204 i Aproval of an American National Standard requires verification by ANSI that the requirements for due proces, consensus, and other criter
6、ia have ben met by the standards developer. Consensus is established when, in the judgment of the ANSI Board of Standards Review, substantial agrement has ben reached by directly and materialy afected interests. Substantial agrement means much more than a simple majority, but not necesarily unanimit
7、y. Consensus requires that al views and objections be considered, and that a concerted efort be made toward their resolution. The use of American National Standards is completely voluntary; their existence does not in any respect preclude anyone, whether he has aproved the standards or not, from man
8、ufacturing, marketing, purchasing, or using products, proceses, or procedures not conforming to the standards. The American National Standards Institute does not develop standards and wil in no circumstances give an interpretation of any American National Standard. Moreover, no person shal have the
9、right or authority to isue an interpretation of an American National Standard in the name of the American National Standards Institute. Requests for interpretations should be adresed to the secretariat or sponsor whose name apears on the title page of this standard. CAUTION NOTICE: This American Nat
10、ional Standard may be revised or withdrawn at any time. The procedures of the American National Standards Institute require that action be taken to afirm, revise, or withdraw this standard no later than five years from the date of aproval. Purchasers of American National Standards may receive curent
11、 information on al standards by caling or writing the American National Standards Institute. Library of Congres Cataloging-in-Publication Data American national standard space systems : flywhel rotor asemblies / sponsored by American Institute of Aeronautics and Astronautics. p. cm. ISBN 1-56347-741
12、-6 (hardcopy) - ISBN 1-56347-742-4 (electronic) 1. Space vehicles-Atitude control systems-Equipment and suplies-Standards-United States. 2. Space vehicles-Auxiliary power suply-Equipment and suplies-Standards-United States. 3. Flywhels-Standards-United States. 4. Rotors-Standards-United States. I. A
13、merican Institute of Aeronautics and Astronautics. TL3260.A45 204 629.474-dc2 204027019 Published by American Institute of Aeronautics and Astronautics 1801 Alexander Bel Drive, Reston, VA 20191 Copyright 204 American Institute of Aeronautics and Astronautics Al rights reserved No part of this publi
14、cation may be reproduced in any form, in an elctronic retrieval system or otherwise, without prior writen permision of the publisher. Printed in the United States of America American National Standard ANSI/AIA S-096-204 ii Contents Forewordv 1 Scope.1 2 Aplicable Documents1 3 Vocabulary.1 3.1 Abrevi
15、ations and Acronyms.1 3.2 Terms and Definitions.2 4 General Requirements5 4.1 Design Requirements.5 4.1.1 System Analysis.5 4.1.2 Loads, Speds and Environments.6 4.1.3 Strength6 4.1.4 Static Stifnes6 4.1.5 Rotor Dynamics.6 4.1.6 Thermal7 4.1.7 Static Strength Margin of Safety7 4.1.8 Fracture Control
16、*.7 4.1.9 Fatigue Life.8 4.1.10 Time Dependent Behavior.8 4.1.1 Stres-Rupture Life.8 4.1.12 Corosion and Stres Corosion Control and Prevention.8 4.1.13 Outgasing.8 4.2 Materials Requirements.9 4.2.1 Metalic Materials9 4.2.2 Composite Materials9 4.2.3 Ceramic Materials.10 4.2.4 Polymeric Materials.1
17、4.3 Fabrication and Proces Control.1 4.4 Quality Asurance.12 4.4.1 Inspection Plan.12 4.4.2 Inspection Techniques.12 4.4.3 Inspection Data.12 4.4.4 Traceability*.12 4.5 Repair and Refurbishment13 4.6 Storage Requirements.13 4.7 Transportation Requirements13 ANSI/AIA S-096-204 iv 5 Verification Requi
18、rements13 5.1 Design Requirements Verification13 5.1.1 System Analysis Verification13 5.1.2 Loads, Speds and Environments Verification14 5.1.3 Strength Verification.14 5.1.4 Static Stifnes Verification14 5.1.5 Rotor Dynamics Verification.14 5.1.6 Thermal Verification.15 5.1.7 Static Strength MoS Ver
19、ification.15 5.1.8 Fracture Control Verification*16 5.1.9 Fatigue Life Verification17 5.1.10 Time Dependent Behavior Verification17 5.1.1 Stres-Rupture Life Verification17 5.1.12 Corosion and Stres Corosion Control and Prevention Verification17 5.1.13 Outgasing Verification.17 5.2 Aceptance Tests.17
20、 5.2.1 Inspection.18 5.2.2 Prof Spin Test.18 5.2.3 Modal Test.18 5.3 Qualification Tests18 5.3.1 Inspection.19 5.3.2 Prof Spin Test.19 5.3.3 Thermal Vacum Tests19 5.3.4 Vibration and Shock Tests19 5.3.5 Damage Tolerance (Safe-Life) Test*19 5.3.6 Modal Test.19 5.3.7 Ultimate Load Test19 Tables Table
21、1 Design Requirements Verification Matrix.15 ANSI/AIA S-096-204 v Foreword This Standard establishes baseline requirements for the design, fabrication, test, inspection, storage, and transportation of a flywhel rotor asembly used in a spaceflight flywhel system for energy storage and/or atitude cont
22、rol. These requirements when implemented on a particular system wil asure a high level of confidence in achieving safe and reliable operation. The development efort of this Standard was one of the major activities of the Flywhel Rotor Safety and Longevity (FRSL) Working Group which was formed in Jun
23、e 200 with the emphasis on inclusion of aerospace prime companies, flywhel rotor supliers, university researchers and al interested government agencies. James Chang is the Chairman of this Working Group. Jenifer Ratner is the Secretary and David Christopher is the Technical Advisor. Kery McLalin and
24、 Jery Fausz are the government sponsors. At the time of document preparation, the members of the AIA Flywhel Rotor Safe-Life Standards Working Group were: James B. Chang, Chair The Aerospace Corporation Charles Bakis Pen State Univ Norman Bracket Beacon Power Corporation John Coyner AFS Trinity Powe
25、r Corp Dean Flanagan Flywhel Energy Systems, Inc. Yaser Gowayed Auburn University Joseph Klupar Honeywel Kevin Kono NASA Glen Research Center Kery McLalin NASA Glen Research Center Jenifer Ratner The Aerospace Corporation James Schindler Boeing Phantomworks Carlos Stevens Honeywel Satelite Systems R
26、ichard Thompson University of Texas - Center for Electromechanics Jerome Tzeng U.S. Army Research Lab Jef Welsh AFRL, Space Vehicles Directorate David Zimcik National Research Council Canada The above consensus body aproved this document in June 204. The AIA Standards Executive Council (Mr. Phil Che
27、ney, chairman) acepted the document for publication in October 204. The AIA Standards Procedures dictates that al aproved Standards, Recomended Practices, and Guides are advisory only. Their use by anyone engaged in industry or trade is entirely voluntary. There is no agrement to adhere to any AIA s
28、tandards publication and no comitment to conform to or be guided by standards reports. In formulating, revising, and aproving standards publications, the comites on standards wil not consider patents that may aply to the subject mater. Prospective users of the publications are responsible for protec
29、ting themselves against liability for infringement of patents or copyright or both. ANSI/AIA S-096-204 1 1 Scope This document establishes a top level certification standard for the design, analysis, material selection and characterization, fabrication, test and inspection of the flywhel rotor asemb
30、ly (FRA) in a flywhel used for energy storage and/or atitude control in maned and unmaned space systems. This standard, when implemented on an FRA in a particular flywhel system, can asure a high level of confidence in achieving safe and reliable operation. This document may also be aplicable to fly
31、whel systems used in aircraft, mobile, stationary and subteranean aplications if apropriate changes are agred to betwen the responsible authority and the flywhel developer. This document aplies specificaly to FRAs in flywhels used in space flight aplications. The standard is aplicable to the parts i
32、n the FRA, which rotate under normal operating conditions. Included are rim, hub and/or shaft, and other asociated rotating parts such as the rotating bearing components and the motor generator rotor. This document does not include verification requirements aplicable to the system level of the flywh
33、el. At the flywhel system level, the qualification and aceptance test requirements specified in MIL-STD-1540 are aplicable. 2 Aplicable Documents The folowing documents contain provisions which, through reference in this text, constitute provisions of this standard. For dated references, subsequent
34、amendments to, or revisions of, any of these publications do not aply. However, parties to agrements based on this standard are encouraged to investigate the posibility of aplying the most recent editions of the normative documents indicated below. For undated references, the latest edition of the n
35、ormative document refered to aplies. MIL-STD-1540 Military Standard, Test Requirements for Launch, Uper-Stage, and Space Vehicle MIL-STD-1629 Failure Modes and Efects Criticality Analysis MIL-HDBK-5 Military Handbok, Metalic Material and Elements for Aerospace Vehicle Structures MIL-HDBK-17 Defense
36、Department Handbok, Polymer Matrix Composites MIL-HDBK-340 Military Handbok, Test Requirements For Launch, Uper Stage or of low released energy; or if the part is failsafe; or if there is only a remote posibility of significant crack growth on the part to begin with. Fracture Mechanics an enginering
37、 discipline which describes the behavior of cracks or crack-like defects in materials under stres Fracture Toughnes a generic term for measurements of resistance to extension of a crack Impact Damage damage in a non-metalic part within the FRA that is caused by an object striking on the part or the
38、part striking on an object ANSI/AIA S-096-204 4 Impact Damage Tolerance the ability of the fracture critical non-metalic parts in the FRA to resist strength degradation due to the impact damage event Initial Flaw A local discontinuity or a crack-like defect in the parts of a FRA before the aplicatio
39、n of load and/or deleterious environment. Key Proces Parameter (KP) the critical proces parameters that afect key design and product characteristics Life Factor the factor by which the service life is multiplied to obtain total fatigue life or safe-life NOTE Life Factor is often refered to as a scat
40、er factor that is normaly used to acount for the scater of materials fatigue or crack growth data. Limit Load the maximum load or combination of loads a rotating part is expected to experience at any time during its intended operation and expected environment Margin of Safety (MoS) MoS= Alowable Loa
41、d/(Limit Load X Design Safety Factor) 1 NOTE Load may mean stres or strain. Maximum Expected Operating Sped (MEOS) the maximum spining sped that a part in a FRA is expected to experience during its normal operation NOTE MEOS is synonymous with limit sped. Maximum Design Sped (MDS) the highest posibl
42、e operating sped based on a combination of credible failures NOTE NASA requires maned systems to acomodate any combination of two credible failures that wil afect sped. Non-Destructive Evaluation (NDE) a proces or procedure for determining the quality or characteristics of a material, part, or asemb
43、ly without permanently altering the subject or its properties NOTE In this document, this term is synonymous with non-destructive inspection (NDI), and non-destructive testing (NDT). Operating Environments al environments experienced during service life of FRA Prof Spin Test a spin test that is run
44、on a flight FRA at a pre-selected spining sped that is higher than MEOS Polymeric Materials an organic material composed of molecules characterized by the repetition of one or more types of monomeric units Qualification Tests the required formal tests used to prove that the design, manufacturing, an
45、d asembly have resulted in hardware conforming to specification requirements and is aceptable for the intended usage NOTE Qualification test is synonymous with certification test. ANSI/AIA S-096-204 5 Service Life the period of time (or cycles) starting with the manufacturing of a specific part in a
46、 FRA and continuing through al aceptance testing, handling, storage, transportation, normal operation, refurbishment, re-testing, and reuse that may be required or specified for that part Stres-Rupture Life the time during which the composite maintains structural integrity considering the combined e
47、fects of stres level(s), time at stres level(s), and asociated environments Touchdown Bearings bearings required to act as the rotor suspension system in the non-operating mode and/or the backup suspension system in the operating mode during main suspension system failure Touchdown Event an event in
48、 which the rotor is forced onto its touchdown bearings due to malfunction of primary bearings, overload or other anomaly Ultimate Load the product of the limit load and the design ultimate safety factor; the load that the parts in a FRA must withstand without catastrophic failure in the expected env
49、ironment Ultimate Strength the ultimate load that the parts in a FRA withstand without catastrophic failure in the aplicable operating environment Visual Damage Threshold (VDT) an impact energy level shown by test(s) that creates an indication that is detectable by a trained inspector using an unaided visual technique 4 General Requirements This section presents the general requirements for the design; material selection and characterization; fabrication and proces control; quality asurance; repair and refurbishment; and storage for the parts in the FRA. Most of the requirements
