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At least 73 records · Page 4
All sourcesNASA NTRSDOE OSTI
NASA NTRS2003

Effect Of Low External Flow On Flame Spreading Over ETFE Insulated Wire Under Microgravity

Fire safety is one of the most important issues for manned space missions. A likely cause of fires in spacecraft is wire insulation combustion in electrical system. Regarding the wire insulation combustion it important to know the effect of low external flow on the combustion because of the presence of ventilation flow in spacecraft. Although, there are many researches on flame spreading over solid material at low external flows under microgravity, research dealing with wire insulation is very limited. An example of wire insulation combustion in microgravity is the Space Shuttle experiments carried out by Greenberg et al. However, the number of experiments was very limited. Therefore, the effect of low flow velocity is still not clear. The authors have reported results on flame spreading over ETFE (ethylene - tetrafluoroetylene) insulated wire in a quiescent atmosphere in microgravity by 10 seconds drop tower. The authors also performed experiments of polyethylene insulated nichrom wire combustion in low flow velocity under microgravity. The results suggested that flame spread rate had maximum value in low flow velocity condition. Another interesting issue is the effect of dilution gas, especially CO2, which is used for fire extinguisher in ISS. There are some researches working on dilution gas effect on flame spreading over solid material in quiescent atmosphere in microgravity. However the research with low external flow is limited and, of course, the research discussing a relation of the appearance of maximum wire flammability in low flow velocity region with different dilution gas cannot be found yet. The present paper, therefore, investigates the effect of opposed flow with different dilution gas on flame spreading over ETFE insulated wire and change in the presence of the maximum flammability depending on the dilution gas type is discussed within the limit of microgravity time given by ground-based facility.

Nishizawa, Katsuhiro↗
NASA NTRS2006

Thermal Model of a Current-Carrying Wire in a Vacuum

A computer program implements a thermal model of an insulated wire carrying electric current and surrounded by a vacuum. The model includes the effects of Joule heating, conduction of heat along the wire, and radiation of heat from the outer surface of the insulation on the wire. The model takes account of the temperature dependences of the thermal and electrical properties of the wire, the emissivity of the insulation, and the possibility that not only can temperature vary along the wire but, in addition, the ends of the wire can be thermally grounded at different temperatures. The resulting second-order differential equation for the steady-state temperature as a function of position along the wire is highly nonlinear. The wire is discretized along its length, and the equation is solved numerically by use of an iterative algorithm that utilizes a multidimensional version of the Newton-Raphson method.

Border, James↗
NASA NTRS2004

Improved Method of Locating Defects in Wiring Insulation

An improved method of locating small breaches in insulation on electrical wires combines aspects of the prior dielectric withstand voltage (DWV) and time-domain reflectometry (TDR) methods. The method was invented to satisfy a need for reliably and quickly locating insulation defects in spacecraft, aircraft, ships, and other complex systems that contain large amounts of wiring, much of it enclosed in structures that make it difficult to inspect. In the DWV method, one applies a predetermined potential (usually 1.5 kV DC) to the wiring and notes whether the voltage causes any arcing between the wiring and ground. The DWV method does not provide an indication of the location of the defect (unless, in an exceptional case, the arc happens to be visible). In addition, if there is no electrically conductive component at ground potential within about 0.010 in. (approximately equal to 0.254 mm) of the wire at the location of an insulation defect, then the DWV method does not provide an indication of the defect. Moreover, one does not have the option to raise the potential in an effort to increase the detectability of such a defect because doing so can harm previously undamaged insulation. In the TDR method as practiced heretofore, one applies a pulse of electricity having an amplitude of less than 25 V to a wire and measures the round-trip travel time for the reflection of the pulse from a defect. The distance along the wire from the point of application of the pulse to the defect is then calculated as the product of half the round-trip travel time and the characteristic speed of a propagation of an electromagnetic signal in the wire. While the TDR method as practiced heretofore can be used to locate a short or open circuit, it does not ordinarily enable one to locate a small breach in insulation because the pulse voltage is too low to cause arcing and thus too low to induce an impedance discontinuity large enough to generate a measurable reflection. The present improved method overcomes the weaknesses of both the prior DWV and the prior TDR method.

Greulich, Owen R.↗
NASA NTRSDate not supplied

Short Circuiting the Controller – Missteps in Maintenance and Inspection of Process and Wiring in STS-93

The primary objective of the Space Transportation System mission 93 (STS-93) was to deploy the Chandra X-Ray Observatory. Chandra, the world's most powerful X-Ray telescope, allowed scientists from around the world to study some of the most distant and dynamic objects in the universe. Stripped of nearly 7,000 pounds of its own gear to make room for the payload, the orbiter assigned to this mission was Space Shuttle Columbia. Prior to STS-93, Columbia had flown 25 flights and was NASA's oldest and heaviest orbiter. On July 23, 1999, after two prior launch scrubs, Eileen Collins and her crew of four launched from Kennedy Space Center. About five seconds after launch, Mission Control at Johnson Space Center detected a voltage drop on one of Columbia's electrical buses. As a result of this power fluctuation, a primary and back-up Main Engine controller dropped offline. Given design redundancy, the two remaining controllers supported all three engines. If there had been any other AC bus issues, one engine of the three on the Orbiter would have shut down. The redundant set of digital computer units in each engine controller saved Columbia and her crew from a very risky contingency abort. Post-flight inspection revealed soot on a screw head and a hole in an adjacent Kapton insulated wire. The single strand of polyimide wire was located nearly half-way down the payload bay. The Shuttle Independent Assessment Team (SIAT) reported that the wire had rubbed and chaffed against a burred screw head. The burr was later determined to be the result of overtightening of the screw by a technician during a maintenance refurbishment. Alone, the burr may not have been problematic, but later, during another ground processing event, possibly years after, someone inadvertently stepped on the wiring harness. With the pressure and motion of unintended contact, some of the Kapton insulation rubbed off against the burred screw head. The SIAT suspected the wire damage was pre-existing and was caused 4 or 5 years prior to the flight. Finally, the intense vibrations during the launch sequence allowed contact between the exposed conductor and exposed metal area on the burred screw head, resulting in the arcing and shorting of the wire. Due to the quick turnaround times of Space Shuttle Orbiters, wiring issues caused from multiple maintenance events were often overlooked. Additionally, failing to incorporate thorough and early inclusion of human systems integration (HSI) applications as a crucial part of the decision process can result in these types of misshaps. In order to reduce human error associated with integrated manufacturing, maintenance, refurbishment and flight preparations, wire inspection criteria should be refined and standardized, visual inspection processes should be quantified, and technicians should be certified by specially trained instructors. This case, among many others, unveils why human error management and development of safety metrics is a vital piece in the development of complex systems, and why it should be supported aggressively and implemented program wide.

Human Systems Integration↗
NASA NTRS1972

Development of explosively bonded TZM wire reinforced Columbian sheet composites

Methods of producing TZM molybdenum wire reinforced C129Y columbium alloy composites by explosive welding were studied. Layers of TZM molybdenum wire were wound on frames with alternate layers of C129Y columbium alloy foil between the wire layers. The frames held both the wire and foils in place for the explosive bonding process. A goal of 33 volume percent molybdenum wire was achieved for some of the composites. Variables included wire diameter, foil thickness, wire separation, standoff distance between foils and types and amounts of explosive. The program was divided into two phases: (1) development of basic welding parameters using 5 x 10-inch composites, and (2) scaleup to 10 x 20-inch composites.

Otto, H. E.↗
NASA NTRS1976

Impact tensile testing of wires

The test consists of fixing one end of a wire specimen and allowing a threaded falling weight to strike the other. Assuming the dynamic stress in the wire to be a function only of its strain, energy considerations show for negligible wire inertia effects that the governing dynamic stress-strain law can be determined directly from impact energy vs. wire elongation data. Theoretical calculations are presented which show negligible wire inertia effects for ratios of wire mass to striking mass of the order of .01 or less. The test method is applied to soft copper wires and the dynamic stress-strain curve so determined is found to be about 30 percent higher than the corresponding static curve.

Dawson, T. H.↗
NASA NTRS1978

Wire stripper

An insulation stripper is described which is especially useful for shielded wire, the stripper including a first pair of jaws with blades extending substantially perpendicular to the axis of the wire, and a second pair of jaws with blades extending substantially parallel to the axis of the wire. The first pair of jaws is pressed against the wire so the blades cut into the insulation, and the device is turned to form circumferential cuts in the insulation. Then the second pair of jaws is pressed against the wire so the blades cut into the insulation, and the wire is moved through the device to form longitudinal cuts that permit easy removal of the insulation. Each of the blades is located within the concave face of a V-block, to center the blades on the wire and to limit the depth of blade penetration.

Economu, M. A.↗
NASA NTRS1995

Hot-wire calibration in subsonic/transonic flow regimes

A different approach for calibrating hot-wires, which simplifies the calibration procedure and reduces the tunnel run-time by an order of magnitude was sought. In general, it is accepted that the directly measurable quantities in any flow are velocity, density, and total temperature. Very few facilities have the capability of varying the total temperature over an adequate range. However, if the overheat temperature parameter, a(sub w), is used to calibrate the hot-wire then the directly measurable quantity, voltage, will be a function of the flow variables and the overheat parameter i.e., E = f(u,p,a(sub w), T(sub w)) where a(sub w) will contain the needed total temperature information. In this report, various methods of evaluating sensitivities with different dependent and independent variables to calibrate a 3-Wire hot-wire probe using a constant temperature anemometer (CTA) in subsonic/transonic flow regimes is presented. The advantage of using a(sub w) as the independent variable instead of total temperature, t(sub o), or overheat temperature parameter, tau, is that while running a calibration test it is not necessary to know the recovery factor, the coefficients in a wire resistance to temperature relationship for a given probe. It was deduced that the method employing the relationship E = f (u,p,a(sub w)) should result in the most accurate calibration of hot wire probes. Any other method would require additional measurements. Also this method will allow calibration and determination of accurate temperature fluctuation information even in atmospheric wind tunnels where there is no ability to obtain any temperature sensitivity information at present. This technique greatly simplifies the calibration process for hot-wires, provides the required calibration information needed in obtaining temperature fluctuations, and reduces both the tunnel run-time and the test matrix required to calibrate hotwires. Some of the results using the above techniques are presented in an appendix.

Nagabushana, K. A.↗
NASA NTRS1995

NASA wiring for space applications program

An overview of the NASA Wiring for Space Applications Program and its relationship to NASA's space technology enterprise is given in viewgraph format. The mission of the space technology enterprise is to pioneer, with industry, the development and use of space technology to secure national economic competitiveness, promote industrial growth, and to support space missions. The objectives of the NASA Wiring for Space Applications Program is to improve the safety, performance, and reliability of wiring systems for space applications and to develop improved wiring technologies for NASA flight programs and commercial applications. Wiring system failures in space and commercial applications have shown the need for arc track resistant wiring constructions. A matrix of tests performed versus wiring constructions is presented. Preliminary data indicate the performance of the Tensolite and Filotex hybrid constructions are the best of the various candidates.

Schulze, Norman↗
NASA NTRS1999

Autonomous Command Operations of the WIRE Spacecraft

This paper presents operational innovations which will be introduced on NASA's Wide Field Infrared Explorer (WIRE) mission. These innovations include an end-to-end design architecture for an autonomous commanding capability for the uplink of command loads during unattended station contacts. The WIRE mission is the fifth and final mission of NASA's Goddard Space Flight Center Small Explorer (SMEX) series to be launched in March of 1999. Its primary mission is the targeting of deep space fields using an ultra-cooled infrared telescope. Due to its mission design WIRE command loads are large (approximately 40 Kbytes per 24 hours) and must be performed daily. To reduce the cost of mission operations support that would be required in order to uplink command loads, the WIRE Flight Operations Team has implemented all autonomous command loading capability. This capability allows completely unattended operations over a typical two-day weekend period. The key factors driving design and implementation of this capability were: 1) integration with already existing ground system autonomous capabilities and systems, 2) the desire to evolve autonomous operations capabilities based upon previous SMEX operations experience - specifically the TRACE mission, 3) integration with ground station operations - both autonomous and man-tended, 4) low cost and quick implementation, and 5) end-to-end system robustness. A trade-off study was performed to examine these factors in light of the low-cost, higher-risk SMEX mission philosophy. The study concluded that a STOL (Spacecraft Test and Operations Language) based script, highly integrated with other scripts used to perform autonomous operations, was best suited given the budget and goals of the mission. Each of these factors is discussed in addition to use of the TRACE mission as a testbed for autonomous commanding prior to implementation on WIRE. The capabilities implemented on the WIRE mission are an example of a low-cost, robust, and efficient method for autonomous command loading when implemented with other autonomous features of the ground system. They call be used as a design and implementation template by other missions interested in evolving toward autonomous and lower cost operations. Additionally, the WIRE spacecraft will be used as an operational testbed upon completion of its nominal mission later in 1999. One idea being studied is advanced on-board modeling. Advanced on-board modeling techniques will be used to more efficiently display the spacecraft state. This health and safety information could be used by engineers on the ground or could be used by tile spacecraft for its own assessments. Additionally, this same state information could also be input into the event-driven scheduling system, as the scheduling system will need to assess the spacecraft state before undertaking a new activity. Advanced modeling techniques are being evaluated for a number of NASA missions including The Next Generation Space Telescope (NGST), which is scheduled to launch in 2007.

Walyus, Keith↗
NASA NTRS2003

Aging Wire Insulation Assessment by Phase Spectrum Examination of Ultrasonic Guided Waves

Wire integrity has become an area of concern to the aerospace community including DoD, NASA, FAA, and Industry. Over time and changing environmental conditions, wire insulation can become brittle and crack. The cracks expose the wire conductor and can be a source of equipment failure, short circuits, smoke, and fire. The technique of using the ultrasonic phase spectrum to extract material properties of the insulation is being examined. Ultrasonic guided waves will propagate in both the wire conductor and insulation. Assuming the condition of the conductor remains constant then the stiffness of the insulator can be determined by measuring the ultrasonic guided wave velocity. In the phase spectrum method the guided wave velocity is obtained by transforming the time base waveform to the frequency domain and taking the phase difference between two waveforms. The result can then be correlated with a database, derived by numerical model calculations, to extract material properties of the wire insulator. Initial laboratory tests were performed on a simple model consisting of a solid cylinder and then a solid cylinder with a polymer coating. For each sample the flexural mode waveform was identified. That waveform was then transformed to the frequency domain and a phase spectrum was calculated from a pair of waveforms. Experimental results on the simple model compared well to numerical calculations. Further tests were conducted on aircraft or mil-spec wire samples, to see if changes in wire insulation stiffness can be extracted using the phase spectrum technique.

Anastasi, Robert F.↗
NASA NTRS2004

Non-Destructive Evaluation of Wire Insulation and Coatings

The present invention uses the generation and detection of acoustic guided waves to evaluate the condition of the insulation on electrical wiring. Low order axisymmetric and flexural acoustic modes are generated in the insulated wire and travel partially in the center conductor and partially in the outer insulation. The stiffness of the insulation and the insulation's condition affect the overall wave speed and amplitude of the guided wave. Analysis of the received signal provides information about the age or useful life of the wire insulation. In accordance with the present invention, signal transmission occurs at one location on the electrical wire to be evaluated, and detection occurs at one or more locations along the electrical wire. Additional receivers can be used to improve measurement accuracy. Either the transmission transducer or one or more receiver transducers may be angled at other than 90 degrees to the wire. Generation of the guided waves can be accomplished by imparting a pressure pulse on the wire. Alternative embodiments include generation via a laser, such as a Q-switched laser or a laser diode.

Eric I Madaras↗
NASA NTRS2007

Wire Crimp Termination Verification Using Ultrasonic Inspection

The development of a new ultrasonic measurement technique to quantitatively assess wire crimp terminations is discussed. The amplitude change of a compressional ultrasonic wave propagating through the junction of a crimp termination and wire is shown to correlate with the results of a destructive pull test, which is a standard for assessing crimp wire junction quality. Various crimp junction pathologies such as undercrimping, missing wire strands, incomplete wire insertion, partial insulation removal, and incorrect wire gauge are ultrasonically tested, and their results are correlated with pull tests. Results show that the nondestructive ultrasonic measurement technique consistently (as evidenced with destructive testing) predicts good crimps when ultrasonic transmission is above a certain threshold amplitude level. A physics-based model, solved by finite element analysis, describes the compressional ultrasonic wave propagation through the junction during the crimping process. This model is in agreement within 6% of the ultrasonic measurements. A prototype instrument for applying this technique while wire crimps are installed is also presented. The instrument is based on a two-jaw type crimp tool suitable for butt-splice type connections. Finally, an approach for application to multipin indenter type crimps will be discussed.

Perey, Daniel F.↗
NASA NTRS2007

Fabrication of a Thermally Isolated and Pre-amplified Transistor Module with Polyimide Micro-wires for Cryogenic Detectors

For use in cryogenic applications such as bolometer and x-ray microcalorimeter arrays, pre-amplifying Junction Field Effect Transistors (JFETs) are often required for the readout electronics. The optimum operating temperature of the JFETs is 130 Kelvin while the cryogenic detectors operate in the milli-Kelvin range. Thus, the JFETs must be heated up but thermally isolated from the surrounding cryogenic instruments. In the past, the thermal isolation was accomplished by suspending the JFETs with low conductance wires such as manganium or stainless steel on a Kevlar support platform [I]. This also achieved electrical connections. However, this assembly required manual soldering work, which could raise a reliability issue for the cryogenic applications. In order to eliminate the manual work, polyimide micro-wires were developed [2]. The wires must be of sufficient length to decrease the heat load and in tension to prevent microphonic noise from vibration of the wires: the polyimide wires were patterned into llS"shaped curves over a thin metal wires such as aluminum, titanium, or niobium. The bilayer of the films were then suspended by etching silicon substrate thus to make freestanding air bridges (enough explanation?). In this paper, we present a method to fabricate micromachined JFET mechanical modules suspended by polyimide Pyraline micro-wires and heated up with built-in aluminum micro-heaters.

Oh, L. H.↗
NASA NTRS2007

Wire Crimp Connectors Verification using Ultrasonic Inspection

The development of a new ultrasonic measurement technique to quantitatively assess wire crimp connections is discussed. The amplitude change of a compressional ultrasonic wave propagating through the junction of a crimp connector and wire is shown to correlate with the results of a destructive pull test, which previously has been used to assess crimp wire junction quality. Various crimp junction pathologies (missing wire strands, incorrect wire gauge, incomplete wire insertion in connector) are ultrasonically tested, and their results are correlated with pull tests. Results show that the ultrasonic measurement technique consistently (as evidenced with pull-testing data) predicts good crimps when ultrasonic transmission is above a certain threshold amplitude level. A physics-based model, solved by finite element analysis, describes the compressional ultrasonic wave propagation through the junction during the crimping process. This model is in agreement within 6% of the ultrasonic measurements. A prototype instrument for applying the technique while wire crimps are installed is also presented.

Cramer, K. Elliott↗
NASA NTRS2006

Ultrasonics Equipped Crimp Tool: A New Technology for Aircraft Wiring Safety

We report on the development of a new measurement technique to quantitatively assess the condition of wire crimp connections. This ultrasonic (UT) method transmits high frequency sound waves through the joint under inspection. The wire-crimp region filters and scatters the ultrasonic energy as it passes through the crimp and wire. The resulting output (both time and frequency domains) provides a quantitative measure of the joint quality that is independent and unaffected by current. Crimps of poor mechanical and electrical quality will result in low temporal output and will distort the spectrum into unique and predictable patterns, depending on crimp "quality". This inexpensive, real-time measurement system can provide certification of crimps as they are made and recertification of existing wire crimps currently in service. The measurements for re-certification do not require that the wire be disconnected from its circuit. No other technology exists to measure in-situ the condition of wire joints (no electrical currents through the crimp are used in this analytical technique). We discuss the signals obtained from this instrument, and correlate these signals with destructive wire pull tests.

Yost, William T.↗
NASA NTRS2013

Use of beam deflection to control an electron beam wire deposition process

A method for controlling an electron beam process wherein a wire is melted and deposited on a substrate as a molten pool comprises generating the electron beam with a complex raster pattern, and directing the beam onto an outer surface of the wire to thereby control a location of the wire with respect to the molten pool. Directing the beam selectively heats the outer surface of the wire and maintains the position of the wire with respect to the molten pool. An apparatus for controlling an electron beam process includes a beam gun adapted for generating the electron beam, and a controller adapted for providing the electron beam with a complex raster pattern and for directing the electron beam onto an outer surface of the wire to control a location of the wire with respect to the molten pool.

Taminger, Karen M.↗
NASA NTRS2007

Next Generation Wiring

Wiring is a major operational component on aerospace hardware that accounts for substantial weight and volumetric space. Over time wire insulation can age and fail, often leading to catastrophic events such as system failure or fire. The next generation of wiring must be reliable and sustainable over long periods of time. These features will be achieved by the development of a wire insulation capable of autonomous self-healing that mitigates failure before it reaches a catastrophic level. In order to develop a self-healing insulation material, three steps must occur. First, methods of bonding similar materials must be developed that are capable of being initiated autonomously. This process will lead to the development of a manual repair system for polyimide wire insulation. Second, ways to initiate these bonding methods that lead to materials that are similar to the primary insulation must be developed. Finally, steps one and two must be integrated to produce a material that has no residues from the process that degrades the insulating properties of the final repaired insulation. The self-healing technology, teamed with the ability to identify and locate damage, will greatly improve reliability and safety of electrical wiring of critical systems. This paper will address these topics, discuss the results of preliminary testing, and remaining development issues related to self-healing wire insulation.

Medelius, Petro↗