Design and Verification Testing of a Multi-Sensor Package Assembly
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Engineering - Mechanical and civil engineering↗
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Advanced Sensor Arrays and Packaging
Novel sensor packaging elements were designed, fabricated, and tested in order to facilitate the transition of electrochemical mixed-potential sensors toward commercialization. Of the two designs completed, the first is currently undergoing field trials, taking direct measurements within vehicle exhaust streams, while the second is undergoing preliminary laboratory testing. The sensors’ optimal operating conditions, sensitivity to hydrogen, and long-term baseline stability were also investigated. The sensing capabilities of lanthanum chromite (La 0.8 Sr 0.2 CrO 3 ) and indium-doped tin oxide (ITO) working electrodes were compared, and the ITO devices were selected for pre-commercial field trials testing at a hydrogen fuel cell vehicle fueling station in California. Previous data from that fueling station were also analyzed, and the causes of anomalous baseline drift were identified.
47 OTHER INSTRUMENTATION↗
Algorithms and Sensors for Small Robot Path Following
Tracked mobile robots in the 20 kg size class are under development for applications in urban reconnaissance. For efficient deployment, it is desirable for teams of robots to be able to automatically execute path following behaviors, with one or more followers tracking the path taken by a leader. The key challenges to enabling such a capability are (l) to develop sensor packages for such small robots that can accurately determine the path of the leader and (2) to develop path following algorithms for the subsequent robots. To date, we have integrated gyros, accelerometers, compass/inclinometers, odometry, and differential GPS into an effective sensing package. This paper describes the sensor package, sensor processing algorithm, and path tracking algorithm we have developed for the leader/follower problem in small robots and shows the result of performance characterization of the system. We also document pragmatic lessons learned about design, construction, and electromagnetic interference issues particular to the performance of state sensors on small robots.
path following↗
The Virtual Tablet: Virtual Reality as a Control System
In the field of human-computer interaction, Augmented Reality (AR) and Virtual Reality (VR) have been rapidly growing areas of interest and concerted development effort thanks to both private and public research. At NASA, a number of groups have explored the possibilities afforded by AR and VR technology, among which is the IT Advanced Concepts Lab (ITACL). Within ITACL, the AVR (Augmented/Virtual Reality) Lab focuses on VR technology specifically for its use in command and control. Previous work in the AVR lab includes the Natural User Interface (NUI) project and the Virtual Control Panel (VCP) project, which created virtual three-dimensional interfaces that users could interact with while wearing a VR headset thanks to body- and hand-tracking technology. The Virtual Tablet (VT) project attempts to improve on these previous efforts by incorporating a physical surrogate which is mirrored in the virtual environment, mitigating issues with difficulty of visually determining the interface location and lack of tactile feedback discovered in the development of previous efforts. The physical surrogate takes the form of a handheld sheet of acrylic glass with several infrared-range reflective markers and a sensor package attached. Using the sensor package to track orientation and a motion-capture system to track the marker positions, a model of the surrogate is placed in the virtual environment at a position which corresponds with the real-world location relative to the user's VR Head Mounted Display (HMD). A set of control mechanisms is then projected onto the surface of the surrogate such that to the user, immersed in VR, the control interface appears to be attached to the object they are holding. The VT project was taken from an early stage where the sensor package, motion-capture system, and physical surrogate had been constructed or tested individually but not yet combined or incorporated into the virtual environment. My contribution was to combine the pieces of hardware, write software to incorporate each piece of position or orientation data into a coherent description of the object's location in space, place the virtual analogue accordingly, and project the control interface onto it, resulting in a functioning object which has both a physical and a virtual presence. Additionally, the virtual environment was enhanced with two live video feeds from cameras mounted on the robotic device being used as an example target of the virtual interface. The working VT allows users to naturally interact with a control interface with little to no training and without the issues found in previous efforts.
virtual control interface↗
Near Field Intensity Trends of Main Laser Alignment Images in the National Ignition Facility (NIF)
The National Ignition Facility (NIF) utilizes 192 high-energy laser beams focused with enough power and precision on a hydrogen-filled spherical, cryogenic target to potentially initiate a fusion reaction. NIF has been operational for six years; during that time, thousands of successful laser firings or shots have been executed. Critical instrument measurements and camera images are carefully recorded for each shot. The result is a massive and complex database or ‘big data’ archive that can be used to investigate the state of the laser system at any point in its history or to locate and track trends in the laser operation over time. In this study, the optical light throughput for more than 1600 NIF shots for each of the 192 main laser beams and 48 quads was measured over a three year period from January 2009 to October 2012. The purpose was to verify that the variation in the transmission of light through the optics over time performed within design expectations during this time period. Differences between average or integrated intensity from images recorded by the input sensor package (ISP) and by the output sensor package (OSP) in the NIF beam-line were examined. A metric is described for quantifying changes in the integrated intensity measurements and was used to view potential trends. Results are presented for the NIF input and output sensor package trends and changes over the three year time-frame.
42 ENGINEERING↗
Aircraft sensor analysis package system description
An overview of the capabilities of the Aircraft Sensor Analysis Package (ASAP) is presented. The approach is non-technical, and several output products are illustrated. The major features of the system are described in more detail than is found in the User's Guide to a potential user, or to a user looking for a specific capability to be incorporated in another system.
Forman, M. L.↗
APPLICATIONS OF CURRENT TECHNOLOGY FOR CONTINUOUS MONITORING OF SPENT FUEL
Advancements in technology have opened many opportunities to improve upon the current infrastructure surrounding the nuclear fuel cycle. Embedded devices, very small sensors, and wireless technology can be applied to Security, Safety, and Nonproliferation of Spent Nuclear Fuel. Security, separate of current video monitoring systems, can be improved by integrating current wireless technology with a variety of sensors including motion detection, altimeter, accelerometer, and a tagging system. By continually monitoring these sensors, thresholds can be set to sense deviations from nominal values. Then alarms or notifications can be activated as needed. Safety can be improved in several ways. First, human exposure to ionizing radiation can be reduced by using a wireless sensor package on each spent fuel cask to monitor radiation, temperature, humidity, etc. Since the sensor data is monitored remotely operator stay-time is decreased and distance from the spent fuel increased, so the overall radiation exposure is reduced as compared to visual inspections. The second improvement is the ability to monitor continuously rather than periodically. If changes occur to the material, alarm thresholds could be set and notifications made to provide advanced notice of negative data trends. These sensor packages could also record data to be used for scientific evaluation and studies to improve transportation and storage safety. Nonproliferation can be improved for spent fuel transportation and storage by designing an integrated tag that uses current infrastructure for reporting and in an event; tracking can be accomplished using the Iridium satellite system. This technology is similar to GPS but with higher signal strength and penetration power, but lower accuracy. A sensor package can integrate all or some of the above depending on the transportation and storage requirements and regulations. A sensor package can be developed using off the shelf technology and applying it to each specific need. There are products on the market for smart meters, industrial lighting control and home automation that can be applied to the Back End Fuel Cycle. With a little integration and innovation a cost effective solution is achievable.
12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
NASA Tech Briefs, September 2003
Topics include: Oxygen-Partial-Pressure Sensor for Aircraft Oxygen Mask; Three-Dimensional Venturi Sensor for Measuring Extreme Winds; Swarms of Micron-Sized Sensors; Monitoring Volcanoes by Use of Air-Dropped Sensor Packages; Capacitive Sensors for Measuring Masses of Cryogenic Fluids; UHF Microstrip Antenna Array for Synthetic- Aperture Radar; Multimode Broad-Band Patch Antennas; 164-GHz MMIC HEMT Frequency Doubler; GPS Position and Heading Circuitry for Ships; Software for Managing Parametric Studies; Software Aids Visualization of Computed Unsteady Flow; Software for Testing Electroactive Structural Components; Advanced Software for Analysis of High-Speed Rolling-Element Bearings; Web Program for Development of GUIs for Cluster Computers; XML-Based Generator of C++ Code for Integration With GUIs; Oxide Protective Coats for Ir/Re Rocket Combustion Chambers; Simplified Waterproofing of Aerogels; Improved Thermal-Insulation Systems for Low Temperatures; Device for Automated Cutting and Transfer of Plant Shoots; Extension of Liouville Formalism to Postinstability Dynamics; Advances in Thrust-Based Emergency Control of an Airplane; Ultrasonic/Sonic Mechanisms for Drilling and Coring; Exercise Device Would Exert Selectable Constant Resistance; Improved Apparatus for Measuring Distance Between Axles; Six Classes of Diffraction-Based Optoelectronic Instruments; Modernizing Fortran 77 Legacy Codes; Active State Model for Autonomous Systems; Shields for Enhanced Protection Against High-Speed Debris; Scaling of Two-Phase Flows to Partial-Earth Gravity; Neutral-Axis Springs for Thin-Wall Integral Boom Hinges.
Source record↗
Sensors Umbra Package v 1.0
This package contains modules that model sensors in Umbra. There is a mix of modalities for both accumulating and tracking energy sensors: seismic, magnetic, and radiation. Some modules fuss information from multiple sensor types. Sensor devices (e.g., seismic sensors), detect objects such as people and vehicles that have sensor properties attached (e.g., seismic properties).
Oppel, Fred J.↗
A Hermetic Package Technique for Multi-Functional Fiber Sensors through Pressure Boundary of Energy Systems Based on Glass Sealants
This paper presents a hermitic fiber sensor packaging technique that enables fiber sensors to be embedded in energy systems for performing multi-parameter measurements in high-temperature and strong radiation environments. A high-temperature stable Intrinsic Fabry–Perot interferometer (IFPI) array, inscribed by a femtosecond laser direct writing scheme, is used to measure both temperature and pressure induced strain changes. To address the large disparity in thermo-expansion coefficients (TECs) between silica fibers and metal parts, glass sealants with TEC between silica optical fibers and metals were used to hermetically seal optical fiber sensors inside stainless steel metal tubes. The hermetically sealed package is validated for helium leakages between 1 MPa and 10 MPa using a helium leak detector. An IFPI sensor embedded in glass sealant was used to measure pressure. The paper demonstrates an effective technique to deploy fiber sensors to perform multi-parameter measurements in a wide range of energy systems that utilize high temperatures and strong radiation environments to achieve efficient energy production.
Optics↗
Evaluation of the prototype dual-axis wall attitude measurement sensor
A prototype dual-axis electrolytic tilt sensor package for angular position measurements was built and evaluated in a laboratory environment. The objective was to investigate the use of this package for making wind tunnel wall attitude measurements for the National Transonic Facility (NTF) at NASA Langley Research Center (LaRC). The instrumentation may replace an existing, more costly, and less rugged servo accelerometer package (angle-of-attack package) currently in use. The dual-axis electrolytic tilt sensor package contains two commercial electrolytic tilt sensors thermally insulated with NTF foam, all housed within a stainless steel package. The package is actively heated and maintained at 160 F using foil heating elements. The laboratory evaluation consisted of a series of tests to characterize the linearity, repeatability, cross-axis interaction, lead wire effect, step response, thermal time constant, and rectification errors. Tests revealed that the total RMS errors for the x-axis sensor is 0.084 degree, and 0.182 degree for the y-axis sensor. The RMS errors are greater than the 0.01 degree specification required for NTF wall attitude measurements. It is therefore not a viable replacement for the angle-of-attack package in the NTF application. However, with some physical modifications, it can be used as an inexpensive 5-degree range dual-axis inclinometer with overall accuracy approaching 0.01 degree under less harsh environments. Also, the data obtained from the tests can be valuable for wind tunnel applications of most types of electrolytic tilt sensors.
Wong, Douglas T.↗
Single-Crystal Sapphire Optical Fiber Sensor Instrumentation
This report summarizes technical progress on the program “Single-Crystal Sapphire Optical Fiber Sensor Instrumentation,” funded by the National Energy Technology Laboratory of the U.S. Department of Energy, and performed by the Center for Photonics Technology of the Bradley Department of Electrical and Computer Engineering at Virginia Tech. This project was completed in three phases, each with a separate focus. Phase I of the program, from October 1999 to April 2002, was devoted to development of sensing schema for use in high temperature, harsh environments. Different sensing designs were proposed and tested in the laboratory. Phase II of the program, from April 2002 to April 2009, focused on bringing the sensor technologies, which had already been successfully demonstrated in the laboratory, to a level where the sensors could be deployed in harsh industrial environments and eventually become commercially viable through a series of field tests. Also, a new sensing scheme was developed and tested with numerous advantages over all previous ones in Phase II. Phase III of the program, September 2009 to December 2013, focused on development of the new sensing scheme for field testing in conjunction with materials engineering of the improved sensor packaging lifetimes. In Phase I, three different sensing principles were studied: sapphire air-gap extrinsic Fabry-Perot sensors; intensity-based polarimetric sensors; and broadband polarimetric sensors. Black body radiation tests and corrosion tests were also performed in this phase. The outcome of the first phase of this program was the selection of broadband polarimetric differential interferometry (BPDI) for further prototype instrumentation development. This approach is based on the measurement of the optical path difference (OPD) between two orthogonally polarized light beams in a single-crystal sapphire disk. At the beginning of Phase II, in June 2004, the BPDI sensor was tested at the Wabash River coal gasifier facility in Terre Haute, Indiana. Due to business conditions at industrial partner and several logistical problems, this field test was not successful. An alternative high-temperature sensing system using sapphire wafer-based extrinsic Fabry-Perot interferometry was then developed as a significant improvement over the BPDI solution. From June 2006 to June 2008, three consecutive field tests were performed with the new sapphire wafer sensors at the TECO coal gasifier in Tampa, Florida. One of the sensors survived in the industrial coal gasifier for 7 months, over which time the existing thermocouples were replaced twice. The outcome of these TECO field tests suggests that the sapphire wafer sensor has very good potential to be commercialized. However packaging and sensor protection issues need additional development. During Phase III, several major improvements in the design and fabrication process of the sensor have been achieved through experiments and theoretical analysis. Studies on the property of the key components in the sensor head, including the sapphire fiber and sapphire wafer, were also conducted, for a better understanding of the sensor behavior. A final design based on all knowledge and experience has been developed, free of any issues encountered during the entire research. Sensors with this design performed well as expected in lab long-term tests, and were deployed in the sensing probe of the final coal-gasifier field test. Sensor packaging and protection was improved through materials engineering through testing of packaging designs in two blank probe packaging tests at Eastman Chemical in Kingsport, TN. Performance analysis of the blank probe packaging resulted in improve package designs culminating in a 3rd generation probe packaging utilized for the full field test of the sapphire optical sensor and materials designed sensor packaging.
47 OTHER INSTRUMENTATION↗
Distributed Sapphire Fiber Bragg Gratings Based Thermal Profiling of Submerged Entry Nozzles
This research focuses on the application of sapphire fiber Bragg gratings (FBGs) for instrumentation in submerged entry nozzles (SEN) within the steelmaking industry. The SEN is pivotal for transferring molten steel from a tundish to a mold, while preventing the infiltration of oxygen and nitrogen from the surrounding environment. Maintaining optimal flow conditions in the mold is crucial for ensuring casting process stability and maintaining high quality steel. Sapphire FBG sensors have been instrumented in SENs to enable distributed thermal mapping for monitoring the health of the SEN. The optical sensor comprises three cascaded sapphire FBGs inscribed using femtosecond laser technology into a one-meter-long sapphire crystalline fiber. The sensor underwent characterization in a laboratory setting up to 1600°C and was tested for long-term stability over 40 hours under extreme environmental conditions. The coupling between silica and sapphire fibers was investigated and implemented during sensor packaging. Here, the sensor successfully captured the pre-heat sequence of the SEN in real-world steelmaking operations. Compared to conventional thermocouples, sapphire FBG sensors demonstrated exceptional efficiency and precision. They offer potential benefits such as increased productivity, reduced energy consumption, and minimized carbon footprint in the steel industry.
Sapphire Fiber Bragg Grating↗
Multipoint Pressure and Temperature Sensing Fiber Optic Cable for Monitoring CO 2 Sequestration
This report describes the work completed on contract DE-FE0010116. The goal of this two year project was to develop and demonstrate in the laboratory a highly accurate multi-point pressure measurement fiber optic cable based on MEMS pressure sensors suitable for downhole deployment in a CO 2 sequestration well. The sensor interrogator was also to be demonstrated in a remote monitoring system and environmental testing was to be completed to indicate its downhole survivability over a lengthy period of time (e.g., 20 years). An interrogator system based on a pulsed laser excitation was shown to be capable of multiple (potentially 100+) simultaneous sensor measurements. Two sensors packages were completed and spliced in a cable onto the same fiber and measured. One sensor package was subsequently measured at high temperatures and pressures in supercritical CO 2 , while the other package was measured prior and after being subjected to high torque stresses to mimic downhole deployment. The environmental and stress tests indicated areas in which the package design should be further improved.
47 OTHER INSTRUMENTATION↗
[MODIS Investigation]
The objective of the last six months were: (1) Continue analysis of Hawaii Ocean Time-series (HOT) bio-optical mooring data, and Southern Ocean bio-optical drifter data; (2) Complete development of documentation of MOCEAN algorithms and software for use by MOCEAN team and GLI team; (3) Deploy instrumentation during JGOFS cruises in the Southern Ocean; (4) Participate in test cruise for Fast Repetition Rate (FRR) fluorometer; (5) Continue chemostat experiments on the relationship of fluorescence quantum yield to environmental factors; and (6) Continue to develop and expand browser-based information system for in situ bio-optical data. We are continuing to analyze bio-optical data collected at the Hawaii Ocean Time Series mooring as well as data from bio-optical drifters that were deployed in the Southern Ocean. A draft manuscript has now been prepared and is being revised. A second manuscript is also in preparation that explores the vector wind fields derived from NSCAT measurements. The HOT bio-optical mooring was recovered in December 1997. After retrieving the data, the sensor package was serviced and redeployed. We have begun preliminary analysis of these data, but we have only had the data for 3 weeks. However, all of the data were recovered, and there were no obvious anomalies. We will add second sensor package to the mooring when it is serviced next spring. In addition, Ricardo Letelier is funded as part of the SeaWiFS calibration/validation effort (through a subcontract from the University of Hawaii, Dr. John Porter), and he will be collecting bio-optical and fluorescence data as part of the HOT activity. This will provide additional in situ measurements for MODIS validation. As noted in the previous quarterly report, we have been analyzing data from three bio-optical drifters that were deployed in the Southern Ocean in September 1996. We presented results on chlorophyll and drifter speed. For the 1998 Ocean Sciences meeting, a paper will be presented on this data set, focusing on the diel variations in fluorescence quantum yield. Briefly, there are systematic patterns in the apparent quantum yield of fluorescence (defined as the slope of the line relating fluorescence/chlorophyll and incoming solar radiation). These systematic variations appear to be related to changes in the circulation of the Antarctic Polar Front which force nutrients into the upper ocean. A more complete analysis will be provided in the next Quarterly report.
Abbott, Mark R.↗
Automated UF 6 Cylinder Enrichment Assay: Status of the Hybrid Enrichment Verification Array (HEVA) Project: POTAS Phase II
Pacific Northwest National Laboratory (PNNL) intends to automate the UF 6 cylinder nondestructive assay (NDA) verification currently performed by the International Atomic Energy Agency (IAEA) at enrichment plants. PNNL is proposing the installation of a portal monitor at a key measurement point to positively identify each cylinder, measure its mass and enrichment, store the data along with operator inputs in a secure database, and maintain continuity of knowledge on measured cylinders until inspector arrival. This report summarizes the status of the research and development of an enrichment assay methodology supporting the cylinder verification concept. The enrichment assay approach exploits a hybrid of two passively-detected ionizing-radiation signatures: the traditional enrichment meter signature (186-keV photon peak area) and a non-traditional signature, manifested in the high-energy (3 to 8 MeV) gamma-ray continuum, generated by neutron emission from UF 6 . PNNL has designed, fabricated, and field-tested several prototype assay sensor packages in an effort to demonstrate proof-of-principle for the hybrid assay approach, quantify the expected assay precision for various categories of cylinder contents, and assess the potential for unsupervised deployment of the technology in a portal-monitor form factor. We refer to recent sensor-package prototypes as the Hybrid Enrichment Verification Array (HEVA). The report provides an overview of the assay signatures and summarizes the results of several HEVA field measurement campaigns on populations of Type 30B UF 6 cylinders containing low-enriched uranium (LEU), natural uranium (NU), and depleted uranium (DU). Approaches to performance optimization of the assay technique via radiation transport modeling are briefly described, as are spectroscopic and data-analysis algorithms.
11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
Instrument for Achieving High Angular Resolution on the Infrared Telescope
Aberrations in stellar images caused by the atmosphere sets a significant limit on angular resolution in ground based astronomy. The largest of these aberrations is the image motion or wavefront tilt. Since the image motion is random it causes a blurring of the image, and this causes a blurring of the image from 0.3 arcseconds to about 0.7 arcseconds. The purpose of the tip-tilt project was to devise a system for the NASA Infrared Telescope Facility that would measure the image movement and correct it by rapidly tilting a mirror in two axes (tip and tilt). The system would involve building a CCD sensor package to measure the image motion, a new top end for the telescope to hold the tip-tilt mirror, a control system, and software. The system was designed to correct images for the facility camera, NSFCAM, and for the facility spectrometer, SPEX. Both of these instruments are equipped with a cold beamsplitter to feed the sensor package.
Hall, Donald N. B.↗
Initial Process Planning of a Hybrid Multi-Tasking Platform
Abstract Applications of hybrid technology are expanding from refurbishment and repair to low quantity, specialty part production, which are staple characteristics in medical implant, energy, and aerospace industry sectors, among others. This expansion has led to the development of the Mazak VC-500A/5X AM HWD, a wire fed laser cladding unit equipped with a standard 5 axis CNC. This unit is capable of building near net geometry of complex medium to large parts within a profitable timeframe, due to its comparatively high rate of deposition to that of a powder fed hybrid system. In this study, deposition and machining capabilities of the VC-500A/5X AM HWD are assessed through the production of three different test geometries by different process plans. Production of these test geometries is supported by an open loop sensor package primarily for monitoring machine health, data collection, and machine operator aid. The viability of extended deposition followed by machining is evaluated against a more cyclical strategy of reoccurring deposition and machining operations. Lastly, common defects in as-built geometries are evaluated and addressed through revisions to original process plans and toolpaths, indicating the need for continued innovation in hybrid manufacturing specific CAM/CAD software, as well as closed loop machine monitoring and quality control.
DeWitte, Lisa N.↗