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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 451 records · Page 25
All sourcesNASA NTRSDOE OSTI
DOE OSTI2019

Component Testing Supporting SHINE Medical Technologies

SHINE is going to be implementing a tritium gas processing system to support their Mo-99 work. They have requested that the Hydrogen Process Group of SRNL does some required testing on the system components before startup. The lab plans on conducting both seismic and valve testing. Test Plan: - Testing 10 1C valves 750,000 cycles or until failure; - Testing intervals will be every couple thousand; - 1C valves will have metal stem tips instead of Polymer due to being in a tritium prone area; - Hope that the valves will still have enough force to create a sufficient seal with metal stem tips; - Goal is for a more cost and space efficient alternative to the 5C valves. Status: - Received half the parts, waiting on the other half due to long procurement times; - Waiting on the LabVIEW program which will perform the testing. Path Forward: - R and DE to change out the stem tips (July 2018); - Assemble Manifold (July 2018); - Perform Testing (August 2018); - Report (September 2018). Since SRNL does not own a shaker table, the test will be conducted at a facility like the NTS Facility in Huntsville, Alabama. Test Plans: - Leak Testing; - Use LabVIEW to monitor for leaks before, during and after seismic testing with an Electronic Pressure Transducer; - If leak is detected, sniff for location using Helium Leak Detector; - Connector Testing; - Use LabVIEW to test for electrical continuity before, during and after seismic testing; - If a connectors continuity is interrupted, further testing will be performed; - Each Pin in faulty connector will be testing to determine specific location of disruption. Path Forward: - Pick a Qualified Vender for testing (July 2018); - Procure the connector plugs (July 2018); - Send components and test plan to facility for testing (August 2018); - Perform Testing (August-September 2018); - Report Results (September 2018)

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2013

Controlling Low-Rate Signal Path Microdischarge for an Ultra-Low-Background Proportional Counter

ABSTRACT Pacific Northwest National Laboratory (PNNL) has developed an ultra-low-background proportional counter (ULBPC) made of high purity copper. These detectors are part of an ultra-low-background counting system (ULBCS) in the newly constructed shallow underground laboratory at PNNL (at a depth of ~30 meters water-equivalent). To control backgrounds, the current preamplifier electronics are located outside the ULBCS shielding. Thus the signal from the detector travels through ~1 meter of cable and is potentially susceptible to high voltage microdischarge and other sources of electronic noise. Based on initial successful tests, commercial cables and connectors were used for this critical signal path. Subsequent testing across different batches of commercial cables and connectors, however, showed unwanted (but still low) rates of microdischarge noise. To control this noise source, two approaches were pursued: first, to carefully validate cables, connectors, and other commercial components in this critical signal path, making modifications where necessary; second, to develop a custom low-noise, low-background preamplifier that can be integrated with the ULBPC and thus remove most commercial components from the critical signal path. This integrated preamplifier approach is based on the Amptek A250 low-noise charge-integrating preamplifier module. The initial microdischarge signals observed are presented and characterized according to the suspected source. Each of the approaches for mitigation is described, and the results from both are compared with each other and with the original performance seen with commercial cables and connectors.

low noise↗
DOE OSTI2020

Non-contact Current-Voltage (I-V) Tracer for Photovoltaics

This report presents a non-contact approach to simultaneously obtain current-voltage (I-V) curves of photovoltaic (PV) substrings and modules in a string without the need of disconnecting the individual modules from the string. There are two types of I-V curve tracers currently available in the marketplace, capacitor-based and electronic load-based. The primary requirement of these conventional I-V tracers is the disconnection of individual modules in the string so the individual modules contacted through the connectors of the individual modules. These contact-tracers have three major limitations in the utility scale power plants: First limitation – Weather and Accuracy: The mass-produced commercial contact-tracers cannot obtain the I-V curves of both string and its modules (as high as 30 modules), almost simultaneously (within about 5 minutes) at, practically, a single irradiance level, a single module temperature, a single spectrum and a single AOI (angle of incidence). This inability of the contact-tracers forces the testing personnel to wait for an extended or multiple sunny (>800 W/m 2 ) duration(s) of a cloudy day. This is a serious limitation as waiting for the sunny conditions or days is a huge practical challenge in almost all locations, except desert locations. Also, since the I-V curves are obtained at different prevailing weather conditions, it becomes critical to translate all the measured I-V curves of 30 modules in the string to a single test condition, for example STC (standard test conditions), so the underperforming modules can be identified. The accuracy of translation equations is heavily influenced by the irradiance level and temperature, spectral and AOI ranges; Second limitation - Safety: The second limitation is related to the high voltage electrical safety of the test personnel during disconnecting and reconnecting of individual modules or cable connectors from the string under daylight conditions and damaging of the original module connectors (especially the field aged connectors) during the disconnecting and reconnecting process; Third limitation – Labor: The third limitation is related to the enormous amount of time and hardship for the test personnel under prevailing (often harsh) protracted field conditions. This project was executed by Arizona State University in collaboration with its industry partner, PV Measurements Inc. (PVM). To mitigate all the three challenges of the state-of-the-art equipment indicated above, we utilized a non-contact I-V (NCIV) tracer approach. In this approach, we utilized an electrostatic voltmeter (ESV) and voltage sensor/probe combination to obtain I-V curves. The ESV units are extensively used in the high voltage industry but not in the PV industry. To obtain the simultaneous I-V curves of the substrings and modules within a string, we utilized multiple commercial ESV-Probe sets. In this approach, we utilized a non-contact voltage sensor (called, Probe) placed on the glass surface of the module (above the last cell of the module). This probe senses the module voltage (with respect to ground) through measured capacitance which is dictated by the surface charges (which in turn is dictated by the module voltage) and transmits the sensed voltage to the voltmeter (called, ESV or NCV, non-contact voltmeter). The current is sensed by a non-contact hall sensor. In a 30-module string, the 30th probe obtains the entire string I-V along with the string I-V obtained by the electronic load. so that the I-V curves of the substrings and modules can be obtained by NCIV without the need of disconnecting the individual modules in the string. The string I-V curves obtained by the electronic load and NCIV can be compared for the accuracy determination. One can use 30 ESV units and 30 Probes to obtain 30 I-V curves of a 30-module string or use just 5 ESV units and 30 Probes in conjunction with 5 six-channel switchboxes (called, 6:1 switchboxes). To reduce the equipment cost, we utilized the 6:1 switchbox approach so the number of ESV units is reduced from 30 to 5. The approaches, achievements and challenges of this project are detailed in this report.

14 SOLAR ENERGY↗
NASA NTRS1981

Fiber optics for aircraft engine/inlet control

NASA programs that focus on the use of fiber optics for aircraft engine/inlet control are reviewed. Fiber optics for aircraft control is attractive because of its inherent immunity to EMI and RFI noise. Optical signals can be safely transmitted through areas that contain flammable or explosive materials. The use of optics also makes remote sensing feasible by eliminating the need for electrical wires to be connected between sensors and computers. Using low-level optical signals to control actuators is also feasible when power is generated at the actuator. Each application of fiber optics for aircraft control has different requirements for both the optical cables and the optical connectors. Sensors that measure position and speed by using slotted plates can use lossy cables and bundle connectors if data transfer is in the parallel mode. If position and speed signals are multiplexed, cable and connector requirements change. Other sensors that depend on changes in transmission through materials require dependable characteristics of both the optical cables and the optical connectors. A variety of sensor types are reviewed, including rotary position encoders, tachometers, temperature sensors, and blade tip clearance sensors for compressors and turbines. Research on a gallium arsenide photoswitch for optically switched actuators that operate at 250 C is also described.

Baumbick, R. J.↗
NASA NTRS1986

Ejection Mechanism for Circuit Boards

Damage to connectors reduced and special tools not needed. Clockwise rotation of screw tightens wedges against mounting body and right heat sink. Counterclockwise rotation of screw drives bottom wedge downward and jacking ring upward, pulling pins away from mating connector. Screw in mechanism turned to produce jacking force that disengages board from mating connector. Force parallel to connector pins do not bend or brake. When disengaged, board protrudes from assembly and readily grasped by operator.

Houff, T. L.↗
NASA NTRS1987

Device for quick changeover between wind tunnel force and pressure testing

This device allows for expeditious and repeated changeovers between pressure and force testing and which uses a minimum internal volume of a wind tunnel test structure. A matrix configuration of holes is located on the outer surface of the structure. Pressure tubes lead through the internal cavity of the structure from test sites to this outer surface matrix configuration. A pressure tube connector with a corresponding matrix of holes is connected to the surface of the structure. Pressure tubes leading from remotely located transducers are joined to the connector, thus forming pressure passageways from the test sites to the transducers to allow for pressure testing. When force testing is required, the pressure tube connector is disconnected and a cover plate is connected. The cover plate seals the exposed internal pressure tubes. Also, the outer surface of the cover plate conforms to the exterior of the structure, providing the necessary smooth surface for force testing. If further pressure testing is required, the cover plate can be disconnected and the pressure tube connector reconnected.

Wood, Richard M.↗
NASA NTRS1992

Shrink-Fit Solderable Inserts Seal Hermetically

Shrink-fit stainless-steel insert in aluminum equipment housing allows electrical connectors to be replaced by soldering, without degrading hermeticity of housing or connector. Welding could destroy electrostatic-sensitive components and harm housing and internal cables. Steel insert avoids problems because connector soldered directly to it rather than welded to housing. Seals between flange and housing, and between connector and flange resistant to leaks, even after mechanical overloading and thermal shocking.

Croucher, William C.↗
NASA NTRS1995

Preload release mechanism

This invention relates to a preload release mechanism comprising a preload spring assembly adapted to apply a preload to a first connector member which is mounted on a support structure and adapted for connection with a second connector member on an object. The assembly comprises telescoped bushings and a preload spring. A tubular shaft extends through the spring assembly and openings in the first connector member and support structure, on which it is clamped. A plunger rod in the shaft is provided with a tip end and a recess in the rod near the other end thereof. A retainer precludes passage of the rod through the shaft in one direction and an end cap closes the bore of the shaft at the other end and provides a shoulder which extends radially of the shaft. A plunger return spring biases the plunger rod against the plunger retainer with the plunger tip protruding from the shaft and a spring assembly return spring engages at its ends the shoulder of the end cap and one end of the spring assembly. Detents received in lateral openings in the tubular shaft are held captive by the plunger rod and one end of the spring assembly to lock the spring assembly on the tubular shaft and apply a preload to the first connector member. Upon completion of the connection, detents and spring assembly are released by plunger contact with the object to be connected, thereby releasing the preload while the connection is maintained.

Generoli, Robert M.↗
NASA NTRS2009

Lunar Module Wiring Design Considerations and Failure Modes

This slide presentation reviews the considerations for the design of wiring for the Lunar Module. Included are a review of the choice of conductors and insulations, the wire splicing (i.e., crimping, and soldering), the wire connectors, and the fabrication of the wire harnesses. The problems in fabrication include the wires being the wrong length, the damage due to the sharp edges, the requried use of temproary protective covers and inadequate training. The problems in the wire harness installation include damge from sharp eges, work on adjacent harnesses, connector damage, and breaking wires. Engineering suggestions from the Apollo-era in reference to the conductors that are reviewed include: the use of plated conductors, and the use of alloys for stronger wiring. In refernce to insulation, the suggestions from Apollo era include the use of polymer tape-wrap wire insulation due to the light weight, however, other types of modern insulation might be more cost-effective. In reference to wire splices and terminal boards the suggestions from the Apollo Era include the use of crimp splices as superior to solder splices, joining multiple wire to a common point using modular plug-ins might be more reliable, but are heavier than crimp splicing. For connectors, the lessons from the Apollo era indicate that a rear environmental seal that does not require additional potting is preferred, and pins should be crimped or welded to the incoming wires and be removable from the rear of the connector.

Interbartolo, Michael↗
NASA NTRS2016

CryoCart Restoration and Vacuum Pipe Construction

Propulsion systems that utilize hypergolic propellants have been used to power space vehicles since the beginning of the space program. Liquid methane and oxygen propulsion systems have emerged as an alternative and have proven to be more environmentally friendly. The incorporation of liquid methane/liquid oxygen (LOX) into the propulsion system has demonstrated an increase in engine performance, as well as a reduction in the volume, size and complexity of the system. Consequently, reducing the total mass of the vehicle which is a crucial aspect that is considered when planning space missions to both the Moon and Mars [1]. Project Morpheus has made significant advancements in liquid oxygen/liquid methane propulsion system technologies by incorporating a LOX/methane propulsion system to a vertical test bed. The vehicle consisted of a 5,000 lb main engine and four 20 lb remote control system (RCS) engines that utilize liquid methane/LOX as its propellant [1]. The vehicle completed successful flight testing at Kennedy Space Center in 2014 which marked the completion of the Morpheus project. Subsequent projects utilizing Morpheus' vertical test bed have been developed to make further advancements. One of the subsequent projects consisted of the addition of a smaller 2,000 lb main engine and a cold helium heat exchanger which would make it possible for a pressurant tank systems to be send to Mars or the Moon by significantly decreasing the overall mass and volume of the pressurant tank. The hot fire tests of the integrated system with the smaller main engine and cold helium heat exchanger were successful at sea level, but further studies are being conducted to better understand how the vertical test bed will behave under thermal-vacuum conditions. For this reason, the integrated vehicle will be taken to Plum Brook to be tested in a chamber capable of simulating these conditions. To ensure that the vehicle will function properly under vacuum conditions, testing will be first completed at the component level. During this process, the igniter of the main engine and the RCS thrusters will be tested under a vacuum. To complete the testing of the components, the test setup first needed to be finalized. The CryoCart is being used to feed the propellants to the test article. The CryoCart is a movable test set-up that was developed in 2009 to provide a mobile platform for testing oxygen/methane systems with hot-fire capability up to 100 lbf. The CryoCart consists of three different systems: Oxygen, Methane, and liquid Nitrogen. The Oxygen and Methane systems are placed into two different carts while the liquid nitrogen system is mainly located in the methane cart. Over the years, the CryoCart has been utilized for different projects and has undergone deterioration. For this reason, a new phase has been developed to rebuild it to working conditions once again. During my internship, I was aiding in the construction and restoration of the CryoCart. In the initial stages of the process, I updated the fluid and electrical schematics for the oxygen, methane, and test article systems. The original CryoCart consisted of an electrical panel that utilized electromechanical relays and a terminal to drive the igniter power and signal, as well as the main fuel and oxygen valves. This electrical panel connected to the CryoCart through various wire harnesses that could be found exiting from the CryoCart. First, it was determined how these harnesses connected to the electromechanical relays so that they worked correctly. Once the electrical system was understood, an alternative for the electromechanical relays and the Molex connectors used throughout the system was sought since these components can often prove to be unreliable. Solid State relays and MIL connectors were purchased to serve as replacements. Upon arrival of the parts, crimping and wiring was completed to install the new solid state relays and MIL connectors. During the replacement of the relays and connectors, system checks of the electrical system were ran to ensure that the system was working correctly. While completing system checks, the pressure transducers that were not functioning properly were also replaced and any issue with the wiring or signal was addressed. Once the electrical components were replaced, the restoration of the fluid system began. Parts of the tubing in the CryoCart had to be rebuild and often consisted of sizing, cutting, bending, filing, and sanding the tubing to prepare it to be flared. Many components had to be proof-tested to bring their certifications up to date, and several components had to be replaced. Various flex hoses, valves, and fittings were send to the Clean Lab because they were new, dirty, or had gone through proof-testing. Once they arrived from the cleaning lab they had to be put back to the system and leak checks and functional tests were conducted. In the Nitrogen system, the copper tubing located in the Oxygen cart was rebuild and Aerogel insulation was added to this section. A new gaseous nitrogen system was added to the CryoCart to purge the vacuum tube which will serve as the test chamber. Once the CryoCart was completed, construction of parts of the vacuum tube began. A flange was manufactured with welded fittings to hold the line of the vacuum pump as well as some extra fittings which will serve as extra inlets used to introduce fluid lines to the vacuum tube. Stress analysis was ran in this flange to ensure that it would not fail under vacuum conditions. The fluid lines leading from the air side of the vacuum to the test article were also constructed and added to the mount that had already been manufactured. Three different sets of tubing were constructed to accommodate the seven different RCS thruster and the main engine igniter that are going to be tested. Full electrical system checks were completed to ensure that all the wire harnesses and valves were functioning. Upon the completion of the CryoCart and the vacuum tube, hot fire testing for the RCS thrusters and the main engine igniter are going to begin. During this time any issues encountered with the engines or igniter will be addressed to ensure that the components function under vacuum conditions. After successful completion of testing, the vertical test bed, Morpheus, will be rebuilt and prepared to be sent to Plum Brook. In Plum Brook, the vehicle will be tested in the thermal-vacuum chamber to demonstrate that integrated lox-methane propulsion system operation in space-like conditions. This internship has allowed me the opportunity to gain valuable hands on experience and to develop skills that will aid in my education as well as in the workforce, while at the same time helping me determine that I would like to further pursue a career in propulsion engineering.

Chaidez, Mariana↗
DOE OSTI2012

Electronic firing systems and methods for firing a device

An electronic firing system comprising a control system, a charging system, an electrical energy storage device, a shock tube firing circuit, a shock tube connector, a blasting cap firing circuit, and a blasting cap connector. The control system controls the charging system, which charges the electrical energy storage device. The control system also controls the shock tube firing circuit and the blasting cap firing circuit. When desired, the control system signals the shock tube firing circuit or blasting cap firing circuit to electrically connect the electrical energy storage device to the shock tube connector or the blasting cap connector respectively.

42 ENGINEERING↗
DOE OSTI2018

Electronic inverter assembly

A first driver portion comprises a set of first components mounted on or associated with a first circuit board. A second circuit board is spaced apart from the first circuit board. A second driver portion comprises a set of second components mounted on or associated with the second circuit board, where the first driver portion and the second driver portion collectively are adapted to provide input signals to the control terminal of each semiconductor switch of an inverter. A first edge connector is mounted on the first circuit board. A second edge connector is mounted on the second circuit board. An interface board has mating edges that mate with the first edge connector and the second edge connector.

42 ENGINEERING↗
DOE OSTI2018

Interconnect system with friction fit backshell

Various technologies described herein pertain to interconnect systems for electrical cables. An interconnect system can include a connector, an adapter ring, and a backshell. The connector includes a threaded distal coupling portion. The adapter ring includes a threaded proximal coupling portion and a non-threaded distal coupling portion. The backshell includes a proximal coupling portion and a port. The threaded proximal coupling portion of the adapter ring and the threaded distal coupling portion of the connector can be mechanically attached. Additionally, the proximal coupling portion of the backshell and the non-threaded distal coupling portion of the adapter ring can be mechanically attached. A wire bundle can enter the backshell through the port, pass through the adapter ring, and terminate at the connector. A shield that encloses the wire bundle can terminate at the backshell such that an end of the shield is positioned around an outer surface of the port.

42 ENGINEERING↗
DOE OSTI2018

Interconnect system with friction fit backshell

Various technologies described herein pertain to interconnect systems for electrical cables. An interconnect system can include a connector, an adapter ring, and a backshell. The connector includes a threaded distal coupling portion. The adapter ring includes a threaded proximal coupling portion and a non-threaded distal coupling portion. The backshell includes a proximal coupling portion and a port. The threaded proximal coupling portion of the adapter ring and the threaded distal coupling portion of the connector can be mechanically attached. Additionally, the proximal coupling portion of the backshell and the non-threaded distal coupling portion of the adapter ring can be mechanically attached. A wire bundle can enter the backshell through the port, pass through the adapter ring, and terminate at the connector. A shield that encloses the wire bundle can terminate at the backshell such that an end of the shield is positioned around an outer surface of the port.

42 ENGINEERING↗
DOE OSTI2019

Damping device for onshore and offshore wind turbines

A damping device for a wind turbine tower is disclosed having at least one upper mount extending from a tower structure, at least one lower mount extending from one of the tower structure or a tower foundation, at least one damping device extending only in a substantially vertical direction, the damping device having an upper connector coupled with the upper mount and a lower connector coupled with the lower mount, and at least one damper coupled between the upper connector and the lower connector.

17 WIND ENERGY↗
DOE OSTI2023

Gas sensor system

A gas sensing tube includes an outer surface, and an inner surface defining a passage. A sensor node is arranged along the sensing tube. The sensor node includes an inlet fluidically connected to the passage, an outlet fluidically connected to the passage, and an interior chamber arranged between the inlet and the outlet. A sensor cable extends along the sensing tube. The sensor cable includes a first conduit having a first connector coupled to the sensor node at the inlet and a second conduit having a second connector connected to the sensor node at the outlet. The sensor cable has a first conductor extending through the first conduit and being coupled to the first connector and a second conductor extending through the second conduit and being coupled to the second connector.

Challener, William Albert↗
DOE OSTI2023

System and method of making an enhanced cast iron crankshaft

A method and system for manufacturing a cast iron crankshaft for a vehicle are provided. The system comprises a molding unit arranged to form a negative sand cast mold of the cast iron crankshaft. The mold comprising at least one molded cavity having a pattern with dimensions of the cast iron crankshaft. The system further comprises a feeding mechanism comprising a riser having a connector through which molten metallic material flows to the cast mold. The feeding mechanism feeds the molten metallic material at a riser connection angle in the at least one mold cavity. The riser connection angle corresponds to a connector modulus. The connector modulus is 20% greater than a cast modulus. The riser geometry corresponds to a riser modulus. The riser modulus is 20% greater than the connector modulus. The system further comprises a furnace, a cooling area, a separation unit, a controller and a power source.

Wang, Liang↗
DOE OSTI2022

Development of Fixtures and Methods to Assess the Durability of Balance of Systems Components

The degradation of photovoltaic (PV) balance of systems (BoS) components is not well studied, but the consequences include offline modules, strings, and inverters; system shutdown; arc faults; and fires. A utility provider experienced a ~30% failure rate in their power transfer chain, originally attributed to branch connectors. Field-failed specimen assemblies were, therefore, examined, consisting of cable connector, branch connector, and discrete fuse components. In this study, unused field-vintage specimens are examined using a benchtop prototype fixture to identify the most influential environmental stressors on BoS components as well as the effect of external mechanical perturbation. The prototype fixture was used to develop a perturbation capability for future use in the combined-accelerated stress testing chamber. The benchtop experiments were also used to develop the in-situ data acquisition of specimen current, voltage, and temperature. A significant increase in operating temperature (~100 °C from ~40 °C) and a different failure mode (arcing at the metal pins rather than overheating of the fuse filament) were observed promptly once periodic mechanical perturbation was applied. The current at failure was decreased from 35 A (measured for static specimens, with failure occurring in the fuses) to 15 A (for tests with mechanical perturbation, with failure at the male/female metal pin connection). After initial examination using X-ray computed tomography, the external plastic was machined away from failed specimens to allow for failure analysis, including the extraction of the internal convolute springs for morphological examination (optical and electron microscopy). Chemical composition analysis included energy-dispersive X-ray spectroscopy, differential scanning calorimetry, and Fourier transform infrared spectroscopy.

14 SOLAR ENERGY↗