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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.

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At least 37 records · Page 2

All sources NASA NTRS DOE OSTI

NASA NTRS1989

Usability testing and requirements derivation for EMU-compatible electrical connectors

On-orbit servicing of payloads is simplified when a spacecraft has been designed for serviceability. A key design criterion for a serviceable spaceraft is standardization of electrical connectors. This paper investigates the effects of extravehicular mobility unit (EMU) glove size, connector size, and connector type on usability of electrical connectors. An experiment was conducted exploring participants' ability to mate and demate connectors in an evacuated glovebox. Independent variables were two EMU glove-sizes, five connector size groups, and seven connector types. Significant differences in performance times and heart rate changes during mate and demate operations were found. Subjective assessments of connectors were collected from participants with a usability questionnaire. The data were used to derive design recommendations for a NASA-recommended EMU-compatible electrical connector.

Reaux, Ray A.↗

NASA NTRS2000

High-Speed Automated Tester for Vacuum Chamber Feedthrough Connectors and Cables

The Goddard Space Flight Center's thermal vacuum laboratory has developed a high-speed automated system for testing the integrity of 37-pin MIL-C-5015 cylindrical electrical feedthrough connectors used on penetration plates of thermal vacuum chambers. The system consists of a desktop PC driving a data acquisition front end. The latter measures the resistance through each pin of the connector and the resistance from each pin to all other pins and the connector shell. In addition to identifying unacceptable feedthroughs, the system is also used for testing cables. In the special case of Type T thermocouples (used almost exclusively at the lab), the difference in resistance between the copper and constantan wires provides positive proof of accidentally reversed connector wiring. Data acquisition time to completely test a cable or feedthrough connector is less than thirty seconds. The system provides a hardcopy printout of the resistance readings. Connectors or cables with fewer wires are tested using simple adapter cables. Initial tests indicate that the performance of a given feedthrough connector can be predicted on the basis of measured resistance readings, reducing ongoing cost of connector replacement. The opportunity to positively certify the integrity of cables, cable connectors and feedthroughs before the start of a thermal vacuum test minimizes the likelihood of a circuit problem that would require returning the chamber to ambient conditions for repair. This system has two principal advantages for the Goddard thermal vacuum laboratory. Its only significant cost was the labor to fabricate the test cable and shorting cable -- about 40 man-hours total. The system was built around a computer and data acquisition unit that were already on hand. The second advantage is that it very quickly tests both of the parameters that are essential.

Swope, Robert H.↗

DOE OSTI2011

Photovoltaic module kit including connector assembly for non-penetrating array installation

A PV module kit for non-penetrating rooftop installation, including a plurality of PV modules and a plurality of connectors. Each of the PV modules includes a PV laminate and a frame forming a mounting region assembled thereto. The connectors include a male connector having a male fastener extending from a head, and a female connector having a female fastener assembled within a head. The heads are entirely formed of plastic. The kit provides a mounted array state including a junction at which the mounting region of at least two of the PV modules are aligned and interconnected by engagement of the male connector with the female connector. The so-formed junction is substantially electrically insulated. The plurality of connectors can further include a spacer connector including a head forming a bore sized to slidably receive the male fastener, with all of the connector heads being identical.

14 SOLAR ENERGY↗

DOE OSTI2012

Photovoltaic module kit including connector assembly for non-penetrating array installation

14 SOLAR ENERGY↗

DOE OSTI2013

Photovoltaic module kit including connector assembly for non-penetrating array installation

A PV module kit for non-penetrating rooftop installation, including a plurality of PV modules and a plurality of connectors. Each of the PV modules includes a PV laminate and a frame forming a mounting region assembled thereto. The connectors include a male connector having a male fastener extending from a head, and a female connector having a female fastener assempbled within a head. The heads are entirely formed of plastic. The kit provides a mounted array state including a junction at which the mounting regions of at least two of the PV modules are aligned and interconnected by engagement of the male connector with the female connector. The so-formed junction is substantially electrically insulated. The plurality of connectors can further include a spacer connector including a head forming a bore sized slidably receive the male fastener, with all of the connector heads being identical.

14 SOLAR ENERGY↗

DOE OSTI2025

Rapid characterization and failure analysis of 6276 rooftop-harvested photovoltaic connectors

Photovoltaic (PV) connectors, which link modules in series and connect PV strings in parallel, have increasingly been recognized as a primary contributor to PV system failures and a source of numerous fire incidents. However, publicly available data on the rates and types of connector failures are scarce, primarily due to the proprietary nature of the information and the need for comprehensive analysis. This study represents the first large-scale investigation of harvested PV connectors, drawing from a dataset of 6276 connectors from residential rooftop solar systems across the United States. The outcome of this work is twofold: 1) we have established a rapid characterization method for large populations of harvested connectors, incorporating visual inspection, resistance measurements, and X-ray imaging; and 2) the analysis made possible by our rapid-processing method has revealed, for a population of connector models provided by a single rooftop installer, failure statistics and insights for various connector makes and models, installation practices, operating currents, and internal component displacements. This research identifies common failure modes that could be considered in future connector designs standards, and operations and maintenance practices, to ultimately improve the reliability of this vital component of PV infrastructure.

MC4↗

NASA NTRS2008

Tool for Inspecting Alignment of Twinaxial Connectors

A proposed tool would be used to inspect alignments of mating twinaxial-connector assemblies on interconnecting wiring harnesses. More specifically, the tool would be used to inspect the alignment of each contact pin of each connector on one assembly with the corresponding socket in the corresponding connector on the other assembly. It is necessary to inspect the alignment because if mating of the assemblies is attempted when any pin/socket pair is misaligned beyond tolerance, the connection will not be completed and the dielectric material in the socket will be damaged (see Figure 1). Although the basic principle of the tool is applicable to almost any type of mating connector assemblies, the specific geometry of the tool must match the pin-and-socket geometry of the specific mating assemblies to be inspected. In the original application for which the tool was conceived, each of the mating assemblies contains eight twinaxial connectors; the pin diameter is 0.014 in. (.0.35 mm), and the maximum allowable pin/socket misalignment is 0.007 in. (.0.18 mm). Incomplete connections can result in loss of flight data within the functional path to the space shuttle crew cockpit displays. The tool (see Figure 2) would consist mainly of a transparent disk with alignment clocking tabs that can be fitted onto either connector assembly. Sets of circles or equivalent reference markings are affixed to the face of the tool, located at the desired positions of the mating contact pairs. An inspector would simply fit the tool onto a connector assembly, engaging the clocking tabs until the tool fits tightly. The inspector would then align one set of circles positioning a line of sight perpendicular to one contact within the connector assembly. Mis alignments would be evidenced by the tip of a pin contact straying past the inner edge of the circle. Socket contact misalignments would be evidenced by a crescent-shaped portion of the white dielectric appearing within the circle. The tool could include a variable magnifier plus an illuminator that could be configured so as not to cast shadows.

Smith, Christopher R.↗

NASA NTRS2004

Tool for Insertion of a Fiber-Optic Terminus in a Connector

A tool has been developed for the special purpose of inserting the terminus of an optical fiber in a cable connector that conforms to NASA Specification SSQ- 21635. What prompted the development of the tool was the observation that because of some aspects of the designs of fiber-optic termini and of springs, sealing rings, and a grommet inside the shell of such a connector, there is a tendency for the grommet to become damaged and detached from the sealing rings during installation. It is necessary to ensure the integrity of the grommet for proper sealing and proper functioning of the connector. The special-purpose tool provides the needed protection for the grommet. The grommet-protection tool resembles a funnel into which an axial slit has been cut (see figure). Prior to insertion, the grommet-protection tool is rolled so that one side of the slit overlaps the other side. The rolled-up grommet-protection tool is inserted in one of the connector holes that accommodate the fiber-optic termini and is pushed in until the flange (the wider of the two conical portions) of the tool becomes seated on the connector grommet. Then a special-purpose installation tool is inserted in the flange of the grommet-protection tool and pressed in until it becomes seated in the flange. This operation expands the narrower of the two conical portions of the grommet-protection tool. The installation tool is removed and the grommet-protection tool remains expanded due to the flat surfaces on the axial slit. By use of a standard contact-insertion tool, a fiber-optic terminus is inserted, through the grommet-protection tool, into the connector cavity. By use of a pair of forceps or needle-nose pliers, the grommet-protection tool is then pulled out of the cavity. Finally, the grommet-protection tool is removed from around the installed fiber-optic cable by pulling the cable through the axial slit. Unlike in some prior procedures for installing the fiber-optic termini in the connector, the procedure that involves the use of the present grommet-protection tool does not include the use of lubricants that can contaminate the interior of the connector. The grommet-protection tool is made of a fluoropolymer, taking advantage of the flexibility of such polymers and further taking advantage of the inherent slipperiness of fluoropolymers. Although the tool is designed primarily for insertion of a fiber-optic terminus, it might also be useful for extracting a previously installed fiber-optic terminus.

King, Wes↗

NASA NTRS2017

Dust and Debris Tolerant Retractable Cover Connector

A debris exclusion and removal apparatus for connectors which have retractable cover configurations which include internal wafers that clean the connectors prior to mating. XXXX connectors. More particularly, embodiments relate to dust tolerant connectors. Some embodiments also relate to an intelligent connector system capable of detecting damage to or faults within a conductor and then rerouting the energy to a non-damaged spare conductor. Discussion Connectors of the present invention may be used to transfer electrical current, fluid, and gas in a wide variety of environments containing dust and other debris, wherein that debris may present substantial challenges. For example, lunar/Martian dust intrusion and/or accumulation in connectors used to transfer oxygen, hydrogen, nitrogen, etc., may lead to larger system failures as well as loss of life in extraterrestrial human exploration endeavors. Additionally, embodiments of the present invention may also be suitable for use where connectors must resist water intrusion, such as terrestrial deep water operations.

Lewis, Mark E.↗

DOE OSTI2026

Modeling the PV System Level Economic Impact of PV Connector Failure Modes

Photovoltaic (PV) connectors must maintain mechanical integrity for over 25 years while operating under UV exposure, elevated temperature, and mechanical loading. Connector degradation increases with electrical resistance, leading to energy losses, unplanned downtime, and higher operation and maintenance (O&M) costs and in severe cases, safety risks from overhearing or arcing. Connector related failures remain among the most frequent causes of disruption in utility-scale PV (UPV) systems, yet their lifetime economic impacts are poorly quantified. This work presents a techno-economic analysis (TEA) framework that links identified connector failure modes to system level energy losses and lifetime cost impacts using identified resistance measurements and failure rates from 6,2761 PV connectors inspected. Connector failures increase system level O&M costs, raising LCOE by roughly 5%. Downtime driven availability losses dominate economic impact. Resistance-driven I2R and IV-curve losses are secondary, but remain non-negligible. Thermal damage, bend-radius violations, and loose connections drive the majority of LCOE uplift Improving connector reliability through better installation quality, inspection, and design can meaningfully reduce lost energy, O&M costs, and LCOE.

14 SOLAR ENERGY↗

DOE OSTI2017

Structural health monitoring of compression connectors for overhead transmission lines

Two-stage aluminum conductor steel-reinforced (ACSR) compression connectors are extensively used in US overhead transmission lines. The connectors are made by crimping a steel sleeve onto a steel core and an aluminum sleeve over aluminum conductive strands. The connectors are designed to operate at temperatures up to 125 C, but their performance is increasingly degrading because of overloading of lines. Currently, electric utilities conduct routine line inspections using thermal and electrical measurements. However, information about the structural integrity of connectors cannot be obtained. In this work, structural health monitoring (SHM) of compression connectors was studied using electromechanical impedance (EMI) analysis. Lead zirconate titanate (PZT)-5A was identified as a smart material for SHM. A flexible high-temperature bonding layer was used to address challenges in PZT integration due to a significant difference in the coefficients of thermal expansion of PZT and the aluminum substrate. The steel joint on the steel core was investigated because it is responsible for the ultimate tensile strength of the connector. Tensile testing was used to create structural damage to the joint, or steel core pullout, and thermal cycling introduced additional structural perturbations. EMI measurements were conducted between the tests. The root mean square deviation (RMSD) of EMI was identified as a damage index. The use of steel joints has been shown to enable SHM under simulated conditions. The EMI signature is sensitive to variations in structural conditions. RMSD can be correlated to the structural health of a connector and has potential for use in the SHM and structural integrity evaluation.

compression connectors↗

DOE OSTI2022

Printed Microwave Connector

This paper describes the development of a printed, planar microwave connector operating from 1-7 GHz. The connector, which is based on a Grounded Coplanar Waveguide (GCPW) transmission line structure, is fabricated using 3D-printed thermoplastic material (PEEK) and conductive nanoparticle silver ink. Electromagnetic models were established to provide guidance on design tradeoffs and their impact on microwave performance. New mechanical designs were also developed to provide accurate alignment and robust connection of the two halves of the planar connector structure. Initial connector prototypes were fabricated to validate the new planar design using conventional double-sided copper laminates (Isola MT40). The designs were then implemented in an all-printed version of the connector. Electromagnetic models of the printed connectors were developed using the measured dielectric properties of printed PEEK. The insertion loss of the printed connectors was measured to be less than 1.7dB across the band.

Microwave Connector, printed electronics, additive↗

NASA NTRS2006

Tool for Coupling a Torque Wrench to a Round Cable Connector

A tool makes it possible to couple a torque wrench to an externally knurled, internally threaded, round cable connector. The purpose served by the tool is to facilitate the tightening of multiple such connectors (or the repeated tightening of the same connector) to repeatable torques. The design of a prior cable-connector/ torque-wrench coupling tool provided for application of the torque-wrench jaws to a location laterally offset from the axis of rotation of the cable connector, making it necessary to correct the torque reading for the offset. Unlike the design of the prior tool, the design of the present tool provides for application of the torque-wrench jaws to a location on the axis of rotation, obviating correction of the torque reading for offset. The present tool (see figure) consists of a split collet containing a slot that provides clearance for inserting and bending the cable, a collet-locking sleeve, a collet-locking nut, and a torque-wrench adaptor that is press-fit onto the collet. Once the collet is positioned on the cable connector, the collet-locking nut is turned to force the collet-locking sleeve over the collet, compressing the collet through engagement of tapered surfaces on the outside of the collet and the inside of the locking sleeve. Because the collet is split and therefore somewhat flexible, this compression forces the collet inward to grip the connector securely. The torque wrench is then applied to the torque-wrench adaptor in the usual manner for torquing a nut or a bolt.

Hacker, Scott C.↗

NASA NTRS2011

Electrical Connector Mechanical Seating Sensor

A sensor provides a measurement of the degree of seating of an electrical connector. This sensor provides a number of discrete distances that a plug is inserted into a socket or receptacle. The number of measurements is equal to the number of pins available in the connector for sensing. On at least two occasions, the Shuttle Program has suffered serious time delays and incurred excessive costs simply because a plug was not seated well within a receptacle. Two methods were designed to address this problem: (1) the resistive pin technique and (2) the discrete length pins technique. In the resistive pin approach, a standard pin in a male connector is replaced with a pin that has a uniform resistivity along its length. This provides a variable resistance on that pin that is dependent on how far the pin is inserted into a socket. This is essentially a linear potentiometer. The discrete approach uses a pin (or a few pins) in the connector as a displacement indicator by truncating the pin length so it sits shorter in the connector than the other pins. A loss of signal on this pin would indicate a discrete amount of displacement of the connector. This approach would only give discrete values of connector displacement, and at least one pin would be needed for each displacement value that would be of interest.

Arens, Ellen↗

DOE OSTI2015

High-density percutaneous chronic connector for neural prosthetics

A high density percutaneous chronic connector, having first and second connector structures each having an array of magnets surrounding a mounting cavity. A first electrical feedthrough array is seated in the mounting cavity of the first connector structure and a second electrical feedthrough array is seated in the mounting cavity of the second connector structure, with a feedthrough interconnect matrix positioned between a top side of the first electrical feedthrough array and a bottom side of the second electrical feedthrough array to electrically connect the first electrical feedthrough array to the second electrical feedthrough array. The two arrays of magnets are arranged to attract in a first angular position which connects the first and second connector structures together and electrically connects the percutaneously connected device to the external electronics, and to repel in a second angular position to facilitate removal of the second connector structure from the first connector structure.

42 ENGINEERING↗

DOE OSTI2020

Connector system for photovoltaic array

A photovoltaic assembly comprising; (a) at least two photovoltaic components that are adjacent to each other in a first direction, each photovoltaic component comprising (i) a partial recess in communication with the partial recess in an adjacent photovoltaic component and (ii) one or more connector receptors aligned in a second direction which is non-parallel to the first direction; (b) a connector located at feast partially in the partial recess of the photovoltaic component and at least partially in the partial recess of the adjacent photovoltaic component so that the connector connects the photovoltaic component to the adjacent photovoltaic component, the connector comprising: (i) a flexible housing having a first end and a second end; (ii) one or more connection ports at the first end; (iii) one or more connection ports at the second end; and (iv) one more flexible electrical conductors that extend from the one or more connection ports at the first end to the one or more connection ports at the second end; wherein the connector is flexible so that the first end and the second end are movable relative to each other in a plane, out of the plane, or both; wherein the one or more connection ports at the first end and the one or more connection ports at the second end form a connection with the one or more connector receptors of the photovoltaic component and the adjacent photovoltaic component so that the connector electrically connects the photovoltaic component to the adjacent photovoltaic component.

14 SOLAR ENERGY↗

NASA NTRS1990

The connector space reduction mechanism

The Connector Space Reduction Mechanism (CSRM) is a simple device that can reduce the number of electromechanical devices on the Payload Interface Adapter/Station Interface Adapter (PIA/SIA) from 4 to 1. The device uses simplicity to attack the heart of the connector mating problem for large interfaces. The CSRM allows blind mate connector mating with minimal alignment required over short distances. This eliminates potential interface binding problems and connector damage. The CSRM is compatible with G and H connectors and Moog Rotary Shutoff fluid couplings. The CSRM can be used also with less forgiving connectors, as was demonstrated in the lab. The CSRM is NASA-Goddard exclusive design with patent applied for. The CSRM is the correct mechanism for the PIA/SIA interface as well as other similar berthing interfaces.

Milam, M. Bruce↗

NASA NTRS2007

SpaceWire Cable and Connector Variations. Session: SpaceWire Components

This viewgraph presentation reviews issues about SpaceWire cable and connectors. Discussion in the talk concerned connector specifications and cable specifications. The Connector Specification issues are: (1) Not impedance matched to the cable (2) Handling (Mechanical) issues (3) Need space-qualified matched impedance connector (4) alternative space-qualified connector and Electrical Issues (5) Only a single ground pin which does not pass through (6) Near-end Crosstalk (NEXT) at the SpaceWire connector Cable Specification issue concerns the use of larger gauge cable in non-standard applications or to meet tight specifications

Allen, Shaune S.↗