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Stacking Connectors & Nickel Underplating
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Internal electrostatic discharge tests of Micro-D connectors for planned Europa mission
UNKNOWN
ESD Analysis/Evaluation of Orion Crew Survival Systems (OCSS) Umbilical Interface Connector (UIC) & Umbilical
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Spline screw payload fastening system
A system for coupling an orbital replacement unit (ORU) to a space station structure via the actions of a robot and/or astronaut is described. This system provides mechanical and electrical connections both between the ORU and the space station structure and between the ORU and the ORU and the robot/astronaut hand tool. Alignment and timing features ensure safe, sure handling and precision coupling. This includes a first female type spline connector selectively located on the space station structure, a male type spline connector positioned on the orbital replacement unit so as to mate with and connect to the first female type spline connector, and a second female type spline connector located on the orbital replacement unit. A compliant drive rod interconnects the second female type spline connector and the male type spline connector. A robotic special end effector is used for mating with and driving the second female type spline connector. Also included are alignment tabs exteriorally located on the orbital replacement unit for berthing with the space station structure. The first and second female type spline connectors each include a threaded bolt member having a captured nut member located thereon which can translate up and down the bolt but are constrained from rotation thereabout, the nut member having a mounting surface with at least one first type electrical connector located on the mounting surface for translating with the nut member. At least one complementary second type electrical connector on the orbital replacement unit mates with at least one first type electrical connector on the mounting surface of the nut member. When the driver on the robotic end effector mates with the second female type spline connector and rotates, the male type spline connector and the first female type spline connector lock together, the driver and the second female type spline connector lock together, and the nut members translate up the threaded bolt members carrying the first type electrical connector up to the complementary second type connector for interconnection therewith.
Evaluation of Small Form Factor Fiber Optic Interconnects for the NASA Electronics Parts and Packaging Program (NEPP)
The Diamond AVIM optical fiber connector has been used for over a decade in flight environments. AVIM which stands for Aviation Intermediate Maintenance is always referenced as a fiber optic connector type from the DIN (Deutsches Institut fur Normung) family of optical fiber connectors. The newly available Mini AVIM and DMI (Definition Multimedia Interface) connectors also by Diamond provide similar features as the high performance AVIM with the added benefits of being small form factor for board mount and internal box use where long connectors and strain relief can not be accommodated. Transceiver, fiber laser technology and receiver optic technology based on small sized constraints will benefit the most by the reduction in connector form factor. It is for this reason that the Mini AVIM is being evaluated for multimode and single mode optical fiber use in both fiber based and cable based packaging configurations. In a fiber based termination, there are no cable materials to bond to the connector. The only bonding that is conducted is the mounting of the fiber with epoxy to the connector ferrules (which are called DMI ferrules). In a cable configuration, the compatibility of the connector subcomponents along with the upjacketing materials of the cable around the fiber needs to be considered carefully for termination fabrication. Cabled terminations will show greater insertion loss and high probability of failures during thermal cycling testing. This is due to the stressing of the combination of materials that each have different Coefficients of Thermal Expansion (CTE's) and that are bonded together to the connector subcomponents. As the materials flex during thermal excursions, forces are applied to the termination and can make the system fail if the grouping of materials (per their CTE's) are not compatible and this includes cable materials, epoxies, ferrule and connector body components. For this evaluation, multimode 100 micron core step index fiber was used for the fiber terminated condition, and single mode SMF-28 upjacketed with W.L. Gore Flexlite was used for the cabled configuration. For background purposes, a comparison is presented here for information purposes between the high performance AVIM connector features and the Mini AVIM small form factor connectors. Basic connector features are described here.
Correction for Thermal EMFs in Thermocouple Feedthroughs
A straightforward measurement technique provides for correction of thermal-electromotive-force (thermal-EMF) errors introduced by temperature gradients along the pins of non-thermocouple-alloy hermetic feedthrough connectors for thermocouple extension wires that must pass through bulkheads. This technique is an alternative to the traditional technique in which the thermal-EMF errors are eliminated by use of custom-made multipin hermetic feedthrough connectors that contain pins made of the same alloys as those of the thermocouple extension wires. One disadvantage of the traditional technique is that it is expensive and time-consuming to fabricate multipin custom thermocouple connectors. In addition, the thermocouple-alloy pins in these connectors tend to corrode easily and/or tend to be less rugged compared to the non-thermocouple-alloy pins of ordinary connectors. As the number of thermocouples (and thus pins) is increased in a given setup, the magnitude of these disadvantages increases accordingly. The present technique is implemented by means of a little additional hardware and software, the cost of which is more than offset by the savings incurred through the use of ordinary instead of thermocouple connectors. The figure schematically depicts a typical measurement setup to which the technique is applied. The additional hardware includes an isothermal block (made of copper) instrumented with a reference thermocouple and a compensation thermocouple. The reference thermocouple is connected to an external data-acquisition system (DAS) through a two-pin thermocouple-alloy hermetic feedthrough connector, but this is the only such connector in the apparatus. The compensation thermocouple is connected to the DAS through two pins of the same ordinary multipin connector that connects the measurement thermocouples to the DAS.
Umbilical mechanism assembly for the international space station
Mechanisms for engaging and disengaging electrical and fluid line connectors are required to be operated repeatedly in hazardous or remote locations on space station, nuclear reactors, toxic chemical and undersea environments. Such mechanisms may require shields to protect the mating faces of the connectors when connectors are not engaged and move these shields out of the way during connector engagement. It is desirable to provide a force-transmitting structure to react the force required to engage or disengage the connectors. It is also desirable that the mechanism for moving the connectors and shields is reliable, simple, and the structure as lightweight as possible. With these basic requirements, an Umbilical Mechanism Assembly (UMA) was originally designed for the Space Station Freedom and now being utilized for the International Space Station.
Adhesive Bubble Removal Method and Apparatus for Fiber Optic Applications
An assembly for supporting a fiber optic termination or connector in a centrifuge and comprising a cylindrical body member having a top portion adapted to receive the ferrule body portion of a fiber optic termination or connector and a bottom portion for receiving a cylindrical piston/sealing unit is presented. The piston portion of the piston/sealing unit includes a compressible tip which is adapted to a butt up against the outer end of the ferrule body portion of the fiber optic termination or connector. A cylindrical end cap fits over the upper end of the body member for holding the fiber optic termination in place on the body member and causing a seal to be formed between the termination or connector and the upper portion of the body member adjacent the compressible tip of the plunger. The parts, when fitted together, are placed in a centrifuge which is operated for a predetermined spin cycle, so as to cause any bubbles in the uncured liquid adhesive to be vented outwardly from the termination through the end cap. Subsequent removal of the fiber optic termination or connector from the centrifuge and assembly is "bubble free" and ready to be joined with an optical fiber which is inserted in the ferrule end of the termination or connector.
Umbilical mechanism
Apparatus is described for automatically mating a pair of connectors and protecting them prior to mating, which minimizes weight and uses relatively simple and reliable mechanisms. Lower and upper connectors (24, 26) are held in lower and upper parts (14, 16) of a housing, with the upper connector mounted on a carrier (32) that is motor driven to move down and mate the connectors. A pair of movable members (36, 38) serve as shields, as coarse alignment aids, and as force transmitters. The movable members are pivotally mounted at the bottom of the upper housing, and as the carrier moves down it pivots the members out of the way. The movable members have socket elements (116) that closely receive pin elements (120) on the lower housing part, to coarsely align the connectors and to react mating and unmating forces between the housings. The carrier has a pair of plate portions (60, 62) with slots (64), and the movable members have cam followers engaged with the slot walls, to move the members with precision. The carrier plate-like portions engage follower members (82) that pivot open lower shield parts (44, 46) covering the lower connector, which is mounted on four stacks of Belleville washers (142).
Adhesive bubble removal method and apparatus for fiber applications
An assembly for supporting a fiber optic termination or connector in a centrifuge and comprising a cylindrical body member having a top portion adapted to receive the ferrule body portion of a fiber optic termination or connector and a bottom portion for receiving a cylindrical piston/sealing unit. The piston portion of the piston/sealing unit includes a compressible tip which is adapted to a butt up against the outer end of the ferrule body portion of the fiber optic termination or connector. A cylindrical end cap fits over the upper end of the body member for holding the fiber optic termination in place on the body member and causing a seal to be formed between the termination or connector and the upper portion of the body member adjacent the compressible tip of the plunger. The parts, when fitted together, are placed in a centrifuge which is operated for a predetermined spin cycle, so as to cause any bubbles in the uncured liquid adhesive to be vented outwardly from the termination through the end cap. Subsequent removal of the fiber optic termination or connector from the centrifuge and assembly is bubble free and ready to be joined with an optical fiber which is inserted in the ferrule end of the termination or connector.
Dust-Tolerant Intelligent Electrical Connection System
Faults in wiring systems are a serious concern for the aerospace and aeronautic (commercial, military, and civilian) industries. Circuit failures and vehicle accidents have occurred and have been attributed to faulty wiring created by open and/or short circuits. Often, such circuit failures occur due to vibration during vehicle launch or operation. Therefore, developing non-intrusive fault-tolerant techniques is necessary to detect circuit faults and automatically route signals through alternate recovery paths while the vehicle or lunar surface systems equipment is in operation. Electrical connector concepts combining dust mitigation strategies and cable diagnostic technologies have significant application for lunar and Martian surface systems, as well as for dusty terrestrial applications. The dust-tolerant intelligent electrical connection system has several novel concepts and unique features. It combines intelligent cable diagnostics (health monitoring) and automatic circuit routing capabilities into a dust-tolerant electrical umbilical. It retrofits a clamshell protective dust cover to an existing connector for reduced gravity operation, and features a universal connector housing with three styles of dust protection: inverted cap, rotating cap, and clamshell. It uses a self-healing membrane as a dust barrier for electrical connectors where required, while also combining lotus leaf technology for applications where a dust-resistant coating providing low surface tension is needed to mitigate Van der Waals forces, thereby disallowing dust particle adhesion to connector surfaces. It also permits using a ruggedized iris mechanism with an embedded electrodynamic dust shield as a dust barrier for electrical connectors where required.
Mechanical Design and Configuration of Penetrations for the Europa Clipper Avionics Vault Structure
The main purpose of the Avionics Vault is to shield radiation sensitive electronics for the Europa Clipper Spacecraft. The vault is a box structure made out of aluminum panels. The panels are roughly 10 mm thick in order to shield the electronics from the orbital total ionizing radiation around Jupiter. The vault requires an electromagnetic interference (EMI) shielding effectiveness (SE) of at least 70 dB in order to mitigate EMI with the spacecraft radar receiver. Overall, the vault accommodates four main types of penetrations: receptacle connectors, pass-through cables, fluid lines, and vent holes. More than 150 cables penetrate the vault panels to connect to electronic boxes inside. Fluid pipes enter and exit the vault to transfer heat to the rest of the spacecraft. Vent holes provide a path for air to escape from the vault during launch. Several novel penetrations designs were created to meet EMI and radiation shielding requirements. Receptacle connectors interface to the vault panels using 1.3 mm thick Ta10W plates. Pass-through cables penetrate the vault using aluminum clamshells after being wrapped with Teflon cushion tape, Kapton tape, and copper tape. Vent hole penetrations consist of a copper mesh for EMI shielding and an aluminum radiation shield bracket to direct air out of the vault during launch. Fluid lines terminate at the vault wall using mechanical fittings that resemble a nut and bolt interface. In addition, most mechanical seams and penetrations utilize EMI gaskets to ensure proper EMI shielding. To reduce risk and confirm that the vault penetration designs were appropriate for EMI shielding, an EMI chamber at the Jet Propulsion Laboratory (JPL) was used to test a mock-up vault panel with multiple variations of all four main types of vault penetrations. This EMI SE test also incorporated different methods for bundling pass-through cables, and a comparison of flange mounted connectors versus jam nut connectors. A low noise preamplifier and a Rohde & Schwarz spectrum analyzer measured E-field levels transmitting through the mock-up vault panel. The results showed a shielding effectiveness of 77 dB for the mock-up vault panel, which exceeds the 70 dB target for Europa Clipper. Both the flange mounted connectors and jam nut connectors exhibited similar EMI SE results at the measured frequencies, and all variations of vault penetrations showed favorable EMI SE levels. Since the flight panels will be much larger and include many more penetrations, there will be testing of the flight vault to confirm its EMI SE is compliant with environmental requirements.
Analytical study of electrical disconnect system for use on manned and unmanned missions
The program to survey existing electrical connector availability, and establish an optimum connector design for maintainable spacecraft substation interfaces is reported. Functional and operational requirements are given along with the results of the documentation survey, which disclosed that the MSFC series connectors have the preferred features of current connector technology. Optimum design concepts for EVA tasks, modules serviced by manipulators, and for manipulators independent of other servicing units are presented. It is concluded that separate connector designs are required for spacecraft replaceable modules, and for crewman EVA.
System for connecting fluid couplings
A system for mating fluid transfer couplings is constructed having a male connector which is provided with a pair of opposed rollers mounted to an exterior region thereof. A male half of a fluid transfer coupling is rotatably supported in an opening in an end of the connector and is equipped with an outwardly extending forward portion. The forward portion locks into an engagement and locking region of a female half of the fluid transfer coupling, with female half being rotatably supported in a receptacle. The receptacle has an opening aligned with locking region, with this opening having a pair of concentric, annularly disposed ramps extending around an interior portion of opening. These ramps are inclined toward the interior of the receptacle and are provided with slots through which rollers of the connector pass. After the connector is inserted into the receptacle (engaging forward portion into engagement region), relative rotation between the connector and receptacle causes the rollers to traverse ramps until the rollers abut and are gripped by retainers. This axially forces the forward portion into locked, sealed engagement with the engagement region.
SiC Multi-Chip Power Modules as Power-System Building Blocks
The term "SiC MCPMs" (wherein "MCPM" signifies "multi-chip power module") denotes electronic power-supply modules containing multiple silicon carbide power devices and silicon-on-insulator (SOI) control integrated-circuit chips. SiC MCPMs are being developed as building blocks of advanced expandable, reconfigurable, fault-tolerant power-supply systems. Exploiting the ability of SiC semiconductor devices to operate at temperatures, breakdown voltages, and current densities significantly greater than those of conventional Si devices, the designs of SiC MCPMs and of systems comprising multiple SiC MCPMs are expected to afford a greater degree of miniaturization through stacking of modules with reduced requirements for heat sinking. Moreover, the higher-temperature capabilities of SiC MCPMs could enable operation in environments hotter than Si-based power systems can withstand. The stacked SiC MCPMs in a given system can be electrically connected in series, parallel, or a series/parallel combination to increase the overall power-handling capability of the system. In addition to power connections, the modules have communication connections. The SOI controllers in the modules communicate with each other as nodes of a decentralized control network, in which no single controller exerts overall command of the system. Control functions effected via the network include synchronization of switching of power devices and rapid reconfiguration of power connections to enable the power system to continue to supply power to a load in the event of failure of one of the modules. In addition to serving as building blocks of reliable power-supply systems, SiC MCPMs could be augmented with external control circuitry to make them perform additional power-handling functions as needed for specific applications: typical functions could include regulating voltages, storing energy, and driving motors. Because identical SiC MCPM building blocks could be utilized in a variety of ways, the cost and difficulty of designing new, highly reliable power systems would be reduced considerably. Several prototype DC-to-DC power-converter modules containing SiC power-switching devices were designed and built to demonstrate the feasibility of the SiC MCPM concept. In anticipation of a future need for operation at high temperature, the circuitry in the modules includes high-temperature inductors and capacitors. These modules were designed to be stacked to construct a system of four modules electrically connected in series and/or parallel. The packaging of the modules is designed to satisfy requirements for series and parallel interconnection among modules, high power density, high thermal efficiency, small size, and light weight. Each module includes four output power connectors two for serial and two for parallel output power connections among the modules. Each module also includes two signal connectors, electrically isolated from the power connectors, that afford four zones for signal interconnections among the SOI controllers. Finally, each module includes two input power connectors, through which it receives power from an in-line power bus. This design feature is included in anticipation of a custom-designed power bus incorporating sockets compatible with snap-on type connectors to enable rapid replacement of failed modules.
Development of the Orion Crew-Service Module Umbilical Retention and Release Mechanism
The Orion CSM umbilical retention and release mechanism supports and protects all of the cross-module commodities between the spacecrafts crew and service modules. These commodities include explosive transfer lines, wiring for power and data, and flexible hoses for ground purge and life support systems. The mechanism employs a single separation interface which is retained with pyrotechnically actuated separation bolts and supports roughly two dozen electrical and fluid connectors. When module separation is commanded, either for nominal on-orbit CONOPS or in the event of an abort, the mechanism must release the separation interface and sever all commodity connections within milliseconds of command receipt. There are a number of unique and novel aspects of the design solution developed by the Orion mechanisms team. The design is highly modular and can easily be adapted to other vehiclesmodules and alternate commodity sets. It will be flight tested during Orions Exploration Flight Test 1 (EFT-1) in 2014, and the Orion team anticipates reuse of the design for all future missions. The design packages fluid, electrical, and ordnance disconnects in a single separation interface. It supports abort separations even in cases where aerodynamic loading prevents the deployment of the umbilical arm. Unlike the Apollo CSM umbilical which was a destructive separation device, the Orion design is resettable and flight units can be tested for separation performance prior to flight.Initial development testing of the mechanisms separation interface resulted in binding failures due to connector misalignments. The separation interface was redesigned with a robust linear guide system, and the connector separation and boom deployment were separated into two discretely sequenced events. These changes addressed the root cause of the binding failure by providing better control of connector alignment. The new design was tuned and validated analytically via Monte Carlo simulation. The analytical validation was followed by a repeat of the initial test suite plus test cases at thermal extremes and test cases with imposed mechanical failures demonstrating fault tolerance. The mechanism was then exposed to the qualification vibration environment. Finally, separation testing was performed at full speed with live ordnance.All tests of the redesigned mechanism resulted in successful separation of the umbilical interface with adequate force margins and timing. The test data showed good agreement with the predictions of the Monte Carlo simulation. The simulation proved invaluable due to the number of variables affecting the separation and the uncertainty associated with each. The simulation allowed for rapid assessment of numerous trades and contingency scenarios, and can be easily reconfigured for varying commodity sets and connector layouts.