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Active periodic struts for a gearbox support system

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INSTITUTE OF PHYSICS PUBLISHING SMART MATERIALS AND STRUCTURES
Smart Mater. Struct. 15 (2006) 1707–1714 doi:10.1088/0964-1726/15/6/024

Active periodic struts for a gearbox

support system
S Asiri1 , A Baz1 and D Pines2
1
Department of Mechanical Engineering, University of Maryland, College Park,
MD 20742, USA
2
Department of Aerospace Engineering, University of Maryland, College Park,
MD 20742, USA

Received 22 July 2005, in final form 30 August 2006

Published 10 October 2006
Online at stacks.iop.org/SMS/15/1707
Abstract
Active periodic structures exhibit unique dynamic characteristics that make
them act as tunable mechanical filters for wave propagation. As a result,
waves can propagate along the periodic structures only within specific
frequency bands called the ‘pass bands’ and wave propagation is completely
blocked within other frequency bands called the ‘stop bands’. The spectral
width of these bands can be tuned according to the nature of the external
excitation.
In this paper, the emphasis is placed on developing a new class of these
periodic structures called active periodic struts (APS) which can be used to
support gearbox systems on the airframes of helicopters. When designed
properly the APS can stop the propagation of vibration from the gearbox to
the airframe within critical frequency bands and consequently minimize the
effects of transmission of undesirable vibration and sound radiation to the
helicopter cabin. The theory governing the operation of this class of APS is
presented and their tunable filtering characteristics are demonstrated
experimentally as a function of their design parameters.
The presented concept of the APS can be easily employed in many
applications to control the wave propagation and the force transmission in
an attempt to stop/confine the propagation of undesirable disturbances.
(Some figures in this article are in colour only in the electronic version)

Nomenclature Ki j Appropriately partitioned matrices of the stiffness

Kp Total stiffness of the piezo-insert
A Cross-section area L Element length
b Width of piezo-insert La Length of cell a
CD Elastic modulus Lb Length of cell b
Dp Electrical displacement of the piezo-insert Mi j Appropriately partitioned matrices of the mass
E Young’s modulus N Number of cells
Ep Electrical field intensity of the piezo-insert Qp Electrical charge
F Force Sp Strain of the piezo-insert
FI Total interface force tp Thickness of piezo-insert
fN Excitation harmonic force at the end of strut T Transfer matrix of the unit cell
Fp Piezo-force Tk Transfer matrix of the k th cell
hp Piezo-coupling constant Tp Stress of the piezo-insert
kpc Active piezo-stiffness due to the control gain K u Longitudinal deflection
kps Structural piezo-stiffness V Applied voltage
Kd Dynamic stiffness matrix Y State vector = {u L FL }T
Kg Control gain Yk Eigenvector of transfer matrix of the unit cell

0964-1726/06/061707+08$30.00 © 2006 IOP Publishing Ltd Printed in the UK 1707

S Asiri et al

Yk Eigenvector of the transpose of transfer matrix of the unit gearbox using hydraulic actuators. Sutton et al (1997) used an
cell actual helicopter strut set up under realistic loading conditions.
α Logarithmic decay of amplitude of state vector They showed that attenuations of 30–40 dB are possible in
β Phase difference between the adjacent cells the kinetic energy transmitted to the fuselage over a range of
εS Electrical permittivity frequencies between 250 and 1250 Hz.
λ Eigenvalue of transfer matrix of the unit cell Sikorsky Aircraft Corporation has been engaged in the
ρ Density development of an active noise control (ANC) for the S-76
μ Propagation constant helicopter. For that research activity, Millott et al (1998)
ω Excitation frequency investigated an active pseudo chock-point isolation using point
force actuators surrounding the gearbox mounts to actively
cancel the gear-mesh vibrations before they are transmitted to
1. Introduction the fuselage. Unlike the conventional helicopter (e.g. EH101),
a Sikorsky Aircraft helicopter such as the UH-60 has the main
Helicopter gearbox support struts act as the transmission
gearbox bolted directly to the airframe instead of using struts.
paths of the vibration from the rotor blades and gearbox to
As a consequence, dual point actuators are not applicable.
the fuselage and cabin. Therefore, proper design of these
Therefore, Millott and Welsh (1999) utilized single-point
struts is essential to the attenuation of the vibration of and
inertial actuators mounted at various locations in the helicopter
the noise radiated into the helicopter cabin. Accordingly,
fuselage. They showed that an active vibration control (AVC)
extensive efforts have been devoted to the design of various
system on a UH-60 aircraft achieved significant reduction of
configurations of passive and active struts in order to ensure
a quiet cabin environment. For example, Loewy (1984) the main rotor vibration which is transmitted to the helicopter
presented a comprehensive account of the different passive cabin and cockpit. Pelinescu and Balachandran (1998)
strut designs that are augmented with arrays of springs and investigated analytically and experimentally an active control
dampers to dissipate the vibration energy. Distinct among these system to control the longitudinal and flexural vibrations
designs is the design of Brennan et al (1992), whereby simple transmitted through a cylindrical strut using piezoelectric
flexible elements are added in series with the passive struts to actuators over the frequency range 10–6000 Hz.
serve as vibration absorber. Many control systems use inertial actuators but their
Examples of various active control strategies that are concept is difficult to integrate into the strut design because
considered by the helicopter industry are presented by Kretz the available space around the struts is restricted or sometimes
and Larche (1980) and King (1988). Such active control not available. For this reason, Gembler et al (1998) introduced
systems offer the potential to meet increasingly stringent smart struts as an isolator of the vibration transmitted from
comfort requirements over significant areas of the aircraft the gearbox to the fuselage and cabin. Gembler et al (1999)
structure. In principle, these techniques generate secondary showed that the innovative use of smart struts provides a high
forces that oppose the existing forces causing fuselage capability to reduce the noise in the BK117 Helicopter ground
vibration. They can be applied at the rotor, as in the runs.
case of higher harmonic control (HHC) to cancel vibration In the present study, a radically different concept is
at the source or can be applied at the rotor to fuselage presented, whereby periodic struts are considered because
interface as in the case of active isolation. Because of the these struts exhibit unique dynamic characteristics that make
limitations of HHC and active isolation techniques in terms them act as mechanical filters for wave propagation. As
of power requirements, limited high-speed performance, and a result, waves can propagate along the periodic struts
high weight requirements, Westland Helicopter Ltd developed only within specific frequency bands called the ‘pass bands’
a unique technique called active control of structural response and wave propagation is completely blocked within other
(ACSR) (Staple and Wells 1990). In that technique, hydraulic frequency bands called the ‘stop bands’. The spectral width
actuators are fitted into the main rotor gearbox supporting and location of these bands are fixed for passive periodic struts
struts and are used to isolate the fuselage from low-frequency (Asiri et al 2002), but tunable in response to the structural
excitation (17.5 Hz). The ACSR technique is based on vibration for active periodic struts (Baz 2001).
applying secondary forces at the structure to cancel the effect The theory of periodic structures was originally developed
of vibration generated by primary uncontrolled excitations for solid state applications (Brillouin 1946) and extended, in
from the main rotor. Driving the shakers to minimize airframe the early 1970s, to the design of mechanical structures. Since
vibration as measured by accelerometers, the active controller then, the theory has been extensively applied to a wide variety
reduced average vibration levels by around 75%. of structures such as spring–mass systems, periodic beams,
At the much higher frequencies of the gear meshing tones stiffened plates, ribbed shells and space structures.
(500–1000 Hz) such hydraulic actuators are less effective. As This paper is organized in four sections. In section 1,
a result, Brennan et al (1992) described a set of laboratory we have given a brief introduction. Section 2 presents
experiments with three magnetostrictive actuators designed the theoretical background of passive and active struts
to attenuate the vibration of a single strut. Elliott et al and section 3 demonstrates the performance characteristics
(1994) extended that study and demonstrated that there was of the struts alone as well as the struts and gearbox
a significant improvement in vibration isolation in the range system assembly. Comparisons between the theoretical and
from 200 to 1000 Hz. Kawaguchi et al (1996) presented experimental characteristics are also presented in section 3.
an active vibration reduction (AVR) system to reduce the Section 4 summarizes the findings and the conclusions of the
longitudinal and lateral vibrations of a BK117 helicopter present study. It also outlines the direction for future research.

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 Active periodic struts for a gearbox support system

Piezoelectric inserts 2.2.2. Active sub-cell. The constitutive equations of the

active piezoelectric insert are given by Baz (2001)
    
Ep 1/εS −h p Dp
= (3)
Tp −h p C D Sp
Cell
where E p , Dp , Tp and Sp are the electrical field intensity,
Figure 1. Typical example of an active periodic strut.
electrical displacement, stress and strain of the piezo-insert.
Also, ε S , h p and C D define the electrical permittivity, piezo-
2. Modeling of the active periodic struts coupling constant and elastic modulus.
Equation (3) can be rewritten in terms of applied voltage
2.1. Overview
Vp , piezo-force Fp , electrical charge Q p and net deflection
In this section, the emphasis is placed on studying the (u R − u I ) as follows:
dynamics of one-dimensional periodic struts in their active     
and passive modes of operation in order to demonstrate their Vp /tp 1/εS −h p Q p /bL p
= . (4)
unique filtering capabilities. The dynamics of one-dimensional Fp /btp −h p C D (u R − u I )/L p
periodic struts are determined using the transfer matrix
method. The basic characteristics of the transfer matrices Eliminating the charge Q p from equation (4) gives
of periodic struts are presented and related to the physics of
Fp = −h p εS bVp + [btp (C D − h 2p εS )/L p ] (u R − u I ). (5)
wave propagation along these struts. The methodologies for
determining the pass and stop bands as well as the propagation Let the piezo-voltage Vp be generated according to the
parameters are presented. following control law:
In this paper, the focus is placed on active periodic
struts consisting of a straight rod with periodically placed Vp = −K g (u R − u I ). (6)
piezoelectric inserts as shown in figure 1.
Then, equation (5) reduces to
2.2. Dynamics of the struts Fp = {h p εS bK g + [btp (C D − h 2p εS )/L p ]} (u R − u I )
 
Consider now the dynamics of the periodic strut which consists u1
of a passive sub-cell and an active piezoelectric sub-cell as = (kpc + kps ) { −1 1 } (7)
uR
shown in figure 2.
where kpc = h p εS bK g and kps = [btp (C D − h 2p εS )/L p ] with
kpc and kps denote the active piezo-stiffness due to the control
2.2.1. Passive sub-cell. The dynamics characteristics of the
gain K g and the structural piezo-stiffness respectively.
passive sub-cell (a) can be described as follows:
Equation (7) can be used to generate the force vector
        { FIp FR }T acting on the piezo-insert rewritten as
MLLa MLIa ü L K LLa K LIa uL FL
+ =      
MILa MIIa ü I K ILa K IIa uI FIa FIp −1 uI
(1) = (kpc + kps ) { −1 1 }
FR 1 uR
where Mi ja and K i ja are appropriately partitioned matrices of   
kp −kp uI
the mass and stiffness matrices of sub-cell a. Also, u and F = (8)
−kp kp uR
define the deflection and force vectors, with subscripts L and I
denoting the left and interface sides of the passive sub-cell. with kp = (kpc + kps ) the total stiffness of the piezo-insert.
For a sinusoidal excitation at a frequency ω, equation (1) Hence, the dynamic equations of sinusoidal motions of the
reduces to active sub-cell are given by
         
K LLa − MLLa ω2 K LIa − MLIa ω2 uL FL kp − MIIb w2 −kp − MIRb w2 uI FIb
= , =
K ILa − MILa ω2 K IIa − MIIa ω2 uI FIa −kp − MRIb w2 kp − MRRb w2 uR FR
         
K dLLa K dLIa uL FL K dIIb K dIRb uI FIb
or = (2) or = (9)
K dILa K dIIa uI FIa K dRIb K dRRb uR FR
where K d is the dynamic stiffness matrix of the sub-cell.

Sub-cells ro d a piezo-insert b rod a Piezo-insert b

FL FIa FIb FR

La Lb uL uI uI uR

Left (L) Interface (I) Right (R)

(a) Complete cell (b) passive sub-cell (c) – active sub -cell

Figure 2. Unit cell of the active periodic strut.

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S Asiri et al

Cell 1 Cell 2 Cell k Cell k+1 Cell N-1 Cell N

(a) – Periodic strut with N cells

u Lk u Rk u Lk +1 u R k +1
Cell k Cell k+1
FLk FR k FLk +1 FR k +1
Interface I
(b) – Interaction between two consecutive cells

Figure 3. One-dimensional periodic strut.

where Mi jb and K i jb are appropriately partitioned matrices of Piezoelectric Actuators

the mass and stiffness matrices of sub-cell b. 1.6 in
1/2 in
3/4 in
2.2.3. Dynamics of the entire cell. The dynamics of the entire
cell, as shown in figure 2, can be determined by the assembly
6 in
of the dynamic equations of the passive and active sub-cells
which are given by equations (2) and (9) respectively. This 19 in
yields the following dynamic equations:
    
FL K dLLa K dLIa 0 uL Figure 4. Geometrical parameters of the active struts.
FI = K dILa K dIIa + K dIIb K dIRb uI (10)
FR 0 K dRIb K dRRb uR
where FI = FIa + FIb denotes the total interface force. Considering now the compatibility and equilibrium
Using Guyan’s reduction (Paz 1997) to condense the conditions at the interface between the k th and the k + 1th cells
interface degree of freedom u I yields the following condensed yields the following expressions:
dynamic equations
     u Rk = u Lk+1 and FRk = −FLk+1 . (13)
K dLL K dLR u Lk FLk
= (11)
K dRL K dRR u Rk FRk Substituting these conditions into equation (13), it reduces
for the k th cell with to
    
K dLL = C −1 (−K ILa + C K LLa ), K dLR = −C K IRb , u Lk+1 −K d−LR1 K dLL K d−LR1
u Lk
= .
FLk+1 K dRR K d−LR1 K dLL − K dRL −K dRR K d−LR1
FLk
−1 (14)
K RL = K RIb K LI a
(K LL − K LLa ),
In a more compact form, equation (14) can be rewritten as
−1     
K RR = K RIb K LI K LR + K RRb ,
a
uL t t uL
= 11 12 or Yk+1 = [Tk ]Yk
and
FL k+1 t21 t22 FL k
−1
C = (K IIa + K IIb )K LI . (15)
a
where Y and [Tk ] denote the state vector { u L FL }T and the
Hence, equation (11) directly relates the deflections u Lk transfer matrix of the k th cell. Note that the transfer matrix
and u Rk of the left and right sides of the k th unit cell to the relates the state vector at the left end of the k + 1th cell to
forces acting on these two sides FLk and FRk . In this manner, that at the left end of the k th cell. For exactly periodic struts,
it is easy to study the interactions between neighboring cells [Tk ] = [T ] and the eigenvalue problem of [T ] can be written
using a reduced order model. Note that in the reduced order as
model, the interface degree of freedom u I is condensed and not [T ]Yk = λYk . (16)
eliminated. Combining equations (15) and (16) gives

2.2.4. Dynamics of the entire active periodic strut. The Yk+1 = λYk (17)
assembly of the cells of the entire periodic strut can be
represented as shown in figure 3. The undamped dynamics of indicating that the eigenvalue λ of the matrix [T ] is the ratio
the k th cell as determined from equation (11) can be rearranged between the state vectors at two consecutive cells.
to take the following form: Hence, one can reach the following conclusions.
    
u Rk −K d−LR1 K dLL K d−LR1 u Lk (a) If |λ| = 1, then Yk+1 = Yk and the state vector propagates
= .
FRk −K dRR K d−LR1 K dLL + K dRL K dRR K d−LR1 FLk along the strut as is. This condition defines a pass band
(12) condition and

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 Active periodic struts for a gearbox support system

Strut
4 4
Signal Conditioner
6

Accelerometers
Phase Shifter 6

2 2

1 Shaker
Power Amplifier 5

FFT Analyzer
3 4

Figure 5. Test setup for evaluating the vibration transmission characteristics of the struts.

Accelerometer
Power Amplifier
block A
Block Phase Shifter B
Block B
A
Signal Conditioner

Block A
Block Block
A B

Accelerometer Motor

Power Amplifier

Signal Conditioner
Signal Signal
Conditioner Conditioner
Block B

FFT
Analyzer

Figure 6. Experimental setup used to measure vibration transmission from a gearbox supported by active periodic struts.

(b) If |λ| < 1, then Yk+1 < Yk and the state vector is 3. Performance of the active struts
attenuated as it propagates along the strut. This condition
defines a stop band condition. 3.1. Overview

A further explanation of the physical meaning of the In order to demonstrate the feasibility of the theoretical con-
eigenvalue λ can be extracted by rewriting it as cepts presented, experimental investigations were conducted.
These investigations were carried out in two main stages. In
λ = eμ = eα+iβ (18) the first stage, the vibration attenuation characteristics of the
active strut with two actuators on the shaker were studied and
where μ is defined as the ‘propagation constant’ which is a evaluated. In the second stage, a gearbox was supported by
complex number whose real part (α ) represents the logarithmic four active periodic struts which are integrated to evaluate their
decay of the state vector and its imaginary part (β ) defines the performance as a means for attenuating the vibration transmis-
phase difference between the adjacent cells. sion from the gearbox to the airframe.

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S Asiri et al

(a) 3.2. Experimental facilities

Figure 4 shows the dimensions of the periodic strut considered

in this experimental study. The frequency response of such a
strut was obtained both in its passive (open-loop) and active
(closed-loop) modes of operation.
Two experimental test rigs have been employed in this
study to evaluate the performance of the passive periodic struts.
The first test rig aims at monitoring the vibration transmission
(b)
characteristics of the struts alone as influenced by geometrical
and material discontinuities. Figure 5 shows the details of the
employed test facility.
The experimental setup shown in figure 6 is used to
measure the vibration transmission from the gearbox to the
airframe through a set of four active periodic support struts.
The setup is used also to study the effect of the periodicity of
the struts in active mode on the vibration transmitted through
Figure 7. The transfer functions of the plain, passive periodic, and these struts.
active periodic struts with the propagation factor in both passive and In all the experiments, the phase shifters are adjusted to
shifter
active modes. produce 90◦ phase shift at the lowest frequency of 160 Hz, and 90
hence the controller becomes simply a derivative controller.

In the present study, piezo actuators model 712A02 from 3.3. Experimental results
PCB Piezotronics, Inc. (Depew, NY) were used. The actuator
has flat frequency response characteristics in the range between 3.3.1. Struts alone. Figure 7 shows the magnitude of the
150 and 5000 Hz with a sensitivity of 0.015 pound V−1 and a transfer functions of plain, passive periodic, and active periodic
peak excitation voltage of 100 V. struts when they are subjected to white noise excitation. These
0.015
clamped force
Strut Plain PPS APS Plain PPS APS

(a) – 160 Hz (in pass band) (b) – 800 Hz (in stop band)
Strut Plain PPS APS Plain PPS APS

(c) - 1520 Hz (in stop band) (d) – 2600 Hz (in stop band)

Figure 8. The vibration of plain, passive periodic (PPS) and active periodic (APS) struts at different frequencies.

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 Active periodic struts for a gearbox support system

Figure 9. The control voltage of the lower and upper actuators.

Figure 10. The system response in the case of a collocated sensor/actuator arrangement with broadband excitation from the gearbox.

transfer functions quantify the response of the free end of the the active periodic strut outperforming the plain and the passive
struts to input excitations at the other end of the struts. periodic struts.
Figure 7(a) indicates clearly that the passive periodic strut In all the reported results, the active strut has provided a 0
4000Hz
exhibits experimentally a broad stop band between 650 and viable means for extending the width of the stop band between
4000 Hz whereby the vibration transmission through the strut 0 and 4000 Hz. Also, attenuations of more than 20 dB are
is eliminated completely. Furthermore, figure 7(a) indicates obtained with control voltages less than 5 V as shown in
that the active strut provides an effective means for stopping the figure 9 for the two control actuators. Note that a frequency 4000Hz

vibration transmission over a very broad frequency range. It is range higher than 4000 Hz was not considered because of the
particularly effective for stopping the low-frequency vibration limitation imposed by the actuator bandwidth.
in the range below 600 Hz and up to 150 Hz where the It is important here to note that the observed stop band
passive periodic strut has been ineffective. This result is characteristics which are predicted theoretically and confirmed
particularly important in using a hybrid strut that combines experimentally are obtained with only two periodic cells.
both the passive and active strategies to stop high-frequency Better attenuation performance would be expected with more
as well as low-frequency wave propagation. In this manner, periodic cells.
the active strut increases the spectral width of the stop band
over that of the passive strut. This experimental characteristics 3.3.2. Struts supporting a gearbox. Figure 10 shows the
conforms with the theoretical prediction of the real part of transfer function of the support system with plain, passive
the propagation parameter shown in figure 7(b) for both the periodic, and active periodic struts when the system is
passive and active struts. Note that the theoretical predictions subjected to broadband excitations from the gearbox. Figure 11
are obtained by dividing each unit cell into ten elements in shows the corresponding control voltage of the control
order to accurately capture the dynamics expressed by the finite actuators.
element equation (1).
Figure 8 displays the vibration distribution over plain, 4. Conclusions
passive periodic, and active periodic struts at four different
frequencies using a scanning laser vibrometer. It is clear This paper has presented a new class of periodic strut for
from the figures that the vibration transmission is completely isolating the vibration transmission from helicopter gearboxes
blocked whenever the frequencies lie inside the stop band with to the airframe in an attempt to produce a quiet cabin

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S Asiri et al

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Excellence (RCOE) at the University of Maryland, College isolation of multiple structural waves on a helicopter gearbox
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