SEARCH · Engineering Papers
Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.
Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.
Large arrays are rapidly assembled from individual solar cells by automated production line developed for NASA's Jet Propulsion Laboratory. Apparatus positions cells within array, attaches interconnection tabs, applies solder flux, and solders interconnections. Cells are placed in either straight or staggered configurations and may be connected either in series or in parallel. Are attached at rate of one every 5 seconds.
Solar cells are oriented and fluxed automatically at first work station along solar-array assembly line. In under 2 seconds rotary drive rotates cell into proper position for applying solder flux to bus pad on collector side. When contact bus pad is in correct position, capstan drive is disengaged, and vacuum holddown beneath cell is turned on. Flux system lowers and applies preset amount of solder flux to bus pad. Two interconnect tabs are soldered to fluxed areas.
Final work station along walking-beam conveyor of solar-array assembly line turns each pretabbed solar cell over, depositing it back-side-up onto landing pad, which centers cell without engaging collector surface. Solar cell arrives at inverting work station collector-side-up with two interconnect tabs attached to collector side. Cells are inverted so that second soldering operation takes place in plain view of operator. Inversion protects collector from damage when handled at later stages of assembly.
Vacuum "lance" picks up assembled chain of solar cells from string conveyor without disturbing cells or interconnecting tabs. Lance has 2 vacuum pickups per cell, for total of up to 32 pickups. Positions and number of pickups can be varied. Lance can be adjusted for range of cell sizes, shapes, and spacings.
A leading edge flap design for highly swept wings, called a vortex flap, was tested on an arrow wing model in a low speed wind tunnel. A vortex flap differs from a conventional plain flap in that it has a leading edge tab which is counterdeflected from the main portion of the flap. This results in intentional separation at the flap leading edge, causing a vortex to form and lie on the flap. By trapping this vortex, the vortex flap can result in significantly improved wing flow characteristics relative to conventional flaps at moderate to high angles of attack, as demonstrated by the flow visualization results of this tests.
Yaw control surfaces were developed for a jet propelled aircraft. A thrust augmented rudder is disposed above the jet exhaust stream and a thrust rudder tab extends downward into the jet exhaust stream. These components are cooperatively deflected to generate yawing moments for directional control of the aircraft.
The technical readiness of a cost effective process sequence that has the potential for the production of flat plate photovoltaic modules which met the price goal in 1986 of $.70 or less per Watt peak was demonstrated. The proposed process sequence was reviewed and laboratory verification experiments were conducted. The preliminary process includes the following features: semicrystalline silicon (10 cm by 10 cm) as the silicon input material; spray on dopant diffusion source; Al paste BSF formation; spray on AR coating; electroless Ni plate solder dip metallization; laser scribe edges; K & S tabbing and stringing machine; and laminated EVA modules.
The purpose of this program is to demonstrate the technical readiness of a cost effective process sequence that has the potential for the production of flat plate photovoltaic modules which met the price goal in 1986 of $.70 or less per watt peak. Program efforts included: preliminary design review, preliminary cell fabrication using the proposed process sequence, verification of sandblasting back cleanup, study of resist parameters, evaluation of pull strength of the proposed metallization, measurement of contact resistance of Electroless Ni contacts, optimization of process parameter, design of the MEPSDU module, identification and testing of insulator tapes, development of a lamination process sequence, identification, discussions, demonstrations and visits with candidate equipment vendors, evaluation of proposals for tabbing and stringing machine.
Hexagonnally-close-packed round solar cells are interconnected in series strings. Parallel contacts between cells at equipotential in adjacent series strings insure redundant current paths to relieve adverse effects of cell failures and mismatches. Parallel connections carry no current if cells are matched and functioning normally. If cell fails, tabs carry current to bypass inoperative cell.
Tests were conducted in the Langley 12-foot low-speed wind-tunnel to determine the longitudinal and lateral-directional aerodynamic effects of plain and tabbed vortex flaps on a flat-plate, highly swept arrow-wing model. Flow-visualization studies were made using a helium-bubble technique. Static forces and moments were measured over an angle-of-attack range from 0 deg to 50deg for sideslip angles of 0 deg and + or - 4 deg.
Both mean flow and turbulence measurements were investigated using the resonant Doppler velocimeter in a Mach 3.2 nitrogen flow. Data are presented showing velocity, temperature and pressure measured point by point across the flow field. This data is compared with conventional pitot and temperature surveys. Turbulence was induced by a small metal tab in the flow and observed by both hot wire and RDV techniques. Photographs of the flow field demonstrate the utility of the RDV for quantitative flow field visualization.
The feasibility of applying wing tip extensions, winglets, and active control wing load alleviation to the Boeing 747 is investigated. Winglet aerodynamic design methods and high speed wind tunnel test results of winglets and of symmetrically deflected ailerons are presented. Structural resizing analyses to determine weight and aeroelastic twist increments for all the concepts and flutter model test results for the wing with winglets are included. Control law development, system mechanization/reliability studies, and aileron balance tab trade studies for active wing load alleviation systems are discussed. Results are presented in the form of incremental effects on L/D, structural weight, block fuel savings, stability and control, airplane price, and airline operating economics.
Multiwall insulating sandwich panels are provided for thermal protection of hypervelocity vehicles and other enclosures. In one embodiment, the multiwall panels are formed of alternate layers of dimpled and flat metal (titanium alloy) foil sheets and beaded scarfed edge seals to provide enclosure thermal protection up to 1000 F. An additional embodiment employs an intermediate fibrous insulation for the sandwich panel to provide thermal protection up to 2000 F. A third embodiment employs a silicide coated columbium waffle as the outer panel skin and fibrous layered intermediate protection for thermal environment protection up to 2500 F. The use of multiple panels on an enclosure facilitate repair and refurbishment of the thermal protection system due to the simple support provided by the tab and clip attachment for the panels.
The far field acoustic data base generated in studies of broadband shock noise from supersonic jets is presented. Both conical and contoured nozzles of exit Mach numbers 1.0, 1.5, and 2.0 were tested using unheated air at pressure ratios ranging from 1.9 to 14. Tests were performed both with and without screech suppression tabs. Overall sound pressure variations and representative 1/3-octave and narrowband spectra are presented. The mean static pressure measured within these jets is also surveyed.
The scanning laser acoustic microscope (SLAM) has been evaluated for non-destructive examination of solar cells and interconnector bonds. Using this technique, it is possible to view through materials in order to reveal regions of discontinuity such as microcracks and voids. Of particular interest is the ability to evaluate, in a unique manner, the bonds produced by parallel gap welding. It is possible to not only determine the area and geometry of the bond between the tab and cell, but also to reveal any microcracks incurred during the welding. By correlating the SLAM results with conventional techniques of weld evaluation a more confident weld parameter optimization can be obtained.
Threaded hooks retract bracket arms holding element. Tool uses three hooks with threaded shanks mounted in ring-shaped holder to pull on tabs to release optical element. One person can easily insert or remove optical element (such as prism or lens) from spring holder or bracket with minimal risk of damage.
Resistance welds of solar cell interconnect tabs were evaluated. Both copper-silver and silver-silver welds were made with various heat inputs and weld durations. Parallel gap and annular gap weld electrode designs were used. The welds were analyzed by light microscope, electron microprobe and scanning laser acoustic microscope. These analyses showed the size and shape of the weld, the relationship between the acoustic micrographs, the visible electrode footprint, and the effect of electrode misalignment. The effect of weld heat input on weld microstructure was also shown.
An investigation was conducted in the Langley 6- by 28-Inch Transonic Tunnel to determine the two dimensional aerodynamic characteristics of a 10-percent-thick helicopter rotor airfoil at Mach numbers from 0.33 to 0.87 and respective Reynolds numbers from 4.9 x 10 to the 6th to 9.8 x 10 to the 6th. This airfoil, designated the RC-10(N)-1, was also investigated at Reynolds numbers from 3.0 x 10 to the 6th to 7.3 x 10 to the 6th at respective Mach numbers of 0.33 to 0.83 for comparison wit the SC 1095 (with tab) airfoil. The RC-10(N)-1 airfoil was designed by the use of a viscous transonic analysis code. The results of the investigation indicate that the RC-10(N)-1 airfoil met all the design goals. At a Reynolds number of about 9.4 x 10 to the 6th the drag divergence Mach number at zero normal-force coefficient was 0.815 with a corresponding pitching-moment coefficient of zero. The drag divergence Mach number at a normal-force coefficient of 0.9 and a Reynolds number of about 8.0 x 10 to the 6th was 0.61. The drag divergence Mach number of this new airfoil was higher than that of the SC 1095 airfoil at normal-force coefficients above 0.3. Measurements in the same wind tunnel at comparable Reynolds numbers indicated that the maximum normal-force coefficient of the RC-10(N)-1 airfoil was higher than that of the NACA 0012 airfoil for Mach numbers above about 0.35 and was about the same as that of the SC 1095 airfoil for Mach numbers up to 0.5.