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NASA NTRS1997

Microfabricated Ice-Detection Sensor

Knowledge of ice conditions on important aircraft lift and control surfaces is critical for safe operation. These conditions can be determined with conventional ice-detection sensors, but these sensors are often expensive, require elaborate installation procedures, and interrupt the airflow. A micromachined, silicon-based, flush-mounted sensor which generates no internal heat has been designed, batch fabricated, packaged, and tested. The sensor is capable of distinguishing between an ice-covered and a clean surface. It employs a bulk micromachined wafer with a 7 micrometer-thick, boron-doped, silicon diaphragm which serves as one plate of a parallel-plate capacitor. This is bonded to a second silicon wafer which contains the fixed electrodes, one to drive the diaphragm by application of a voltage, the other to measure the deflection by a change in capacitance. The diaphragm sizes ranged from 1x1 mm to 3x3 mm, and the gap between parallel-plate capacitors is 2 micrometers. A 200 V d.c. was applied to the driving electrode which caused the capacitance to increase approximately 0.6pf, from a nominal capacitance of 0.6pf, when the surface was ice free. After the sensor was cooled below the freezing point of water, the same voltage range was applied to the drive electrode. The capacitance increased by the same amount. Then a drop of water was placed over the diaphragm and allowed to freeze. This created an approximately 2mm-thick ice layer. The applied 200V d.c. produced no change in capacitance, confirming that the diaphragm was locked to the ice layer. Since the sensor uses capacitive actuation, it uses very little power and is an ideal candidate for inclusion in a wireless sensing system.

DeAnna, Russell G.↗

NASA NTRS1998

Experimental Performance of a Micromachined Heat Flux Sensor

Steady-state and frequency response calibration of a microfabricated heat-flux sensor have been completed. This sensor is batch fabricated using standard, micromachining techniques, allowing both miniaturization and the ability to create arrays of sensors and their corresponding interconnects. Both high-frequency and spatial response is desired, so the sensors are both thin and of small cross-sectional area. Thin-film, temperature-sensitive resistors are used as the active gauge elements. Two sensor configurations are investigated: (1) a Wheatstone-bridge using four resistors; and (2) a simple, two-resistor design. In each design, one resistor (or pair) is covered by a thin layer (5000 A) thermal barrier; the other resistor (or pair) is covered by a thick (5 microns) thermal barrier. The active area of a single resistor is 360 microns by 360 microns; the total gauge area is 1.5 mm square. The resistors are made of 2000 A-thick metal; and the entire gauge is fabricated on a 25 microns-thick flexible, polyimide substrate. Heat flux through the surface changes the temperature of the resistors and produces a corresponding change in resistance. Sensors were calibrated using two radiation heat sources: (1) a furnace for steady-state, and (2) a light and chopper for frequency response.

TEMPERATURE SENSITIVE ELEMENTS↗

NASA NTRS1998

Microfabricated Chemical Sensors for Safety and Emission Control Applications

Chemical sensor technology is being developed for leak detection, emission monitoring, and fire safety applications. The development of these sensors is based on progress in two types of technology: 1) Micromachining and microfabrication (MicroElectroMechanical Systems (MEMS)-based) technology to fabricate miniaturized sensors. 2) The development of high temperature semiconductors, especially silicon carbide. Using these technologies, sensors to measure hydrogen, hydrocarbons, nitrogen oxides, carbon monoxide, oxygen, and carbon dioxide are being developed. A description is given of each sensor type and its present stage of development. It is concluded that microfabricated sensor technology has significant potential for use in a range of aerospace applications.

Hunter, G. W.↗

NASA NTRS1999

Improved Earth Sensor Performance Using a Sequentially Correlated Noise Model

Spacecraft attitude estimation by means of an extended Kalman filter requires a reasonably true model of the inherent noise of each sensor. For some sensors, the largest uncorrected noise comes not from the sensor itself, but from errors in the model for the predicted observations. This is certainly the case for Earth horizon sensors. The Earth horizon as seen from low Earth orbit is nearly a circle whose radius depends primarily on altitude. A straightforward latitude-dependent correction is added to this to account for the oblateness of the Earth. There also are both seasonal and stochastic variations in the horizon height. The seasonal variations can be predicted to some limited degree based on models de(ived from historical data. The stochastic component characteristically shows variations that are correlated both in time and space but which are unpredictable over long time spans. This work investigates whether Earth horizon sensor performance can be improved by solving for its systematic error as an augmentation of an attitude Kalman filter. It is found that using only Earth and Sun sensors, the augmented state is not fully observable. Even when magnetometer data is included, only the pitch axis component of the error can be improved; the roll component is unobservable.

Sedlak, Joseph↗

NASA NTRS1996

The Clouds and the Earth's Radiant Energy System (CERES) Sensors and Preflight Calibration Plans

The Clouds and the Earth's Radiant Energy System (CERES) spacecraft sensors are designed to measure broadband earth-reflected solar shortwave (0.3-5 microns) and earth-emitted longwave (5- > 100 microns) radiances at the top of the atmosphere as part of the Mission to Planet Earth program. The scanning thermistor bolometer sensors respond to radiances in the broadband shortwave (0.3-5 microns) and total-wave (0.3- > 100 microns) spectral regions, as well as to radiances in the narrowband water vapor window (8-12 microns) region. 'ne sensors are designed to operate for a minimum of 5 years aboard the NASA Tropical Rainfall Measuring Mission and Earth Observing System AM-1 spacecraft platforms that are scheduled for launches in 1997 and 1998, respectively. The flight sensors and the in-flight calibration systems will be calibrated in a vacuum ground facility using reference radiance sources, tied to the international temperature scale of 1990. The calibrations will be used to derive sensor gains, offsets, spectral responses, and point spread functions within and outside of the field of view. The shortwave, total-wave, and window ground calibration accuracy requirements (1 sigma) are +/-0.8, +/-0.6, and +/-0.3 W /sq m/sr, respectively, while the corresponding measurement precisions are +/-O.5% and +/-1.0% for the broadband longwave and shortwave radiances, respectively. The CERES sensors, in-flight calibration systems, and ground calibration instrumentation are described along with outlines of the preflight and in-flight calibration approaches.

Lee, Robert B., III↗

NASA NTRS1999

Chemical Sensors Based on IR Spectroscopy and Surface-Modified Waveguides

Sol-gel processing techniques have been used to apply thin porous films to the surfaces of planar infrared (IR) waveguides to produce widely useful chemical sensors. The thin- film coating serves to diminish the concentration of water and increase the concentration of the analyte in the region probed by the evanescent IR wave. These porous films are composed of silica, and therefore, conventional silica surface modification techniques can be used to give the surface a specific functional character. The sol-gel film was surface-modified to make the film highly hydrophobic. These sensors were shown to be capable of detecting non-polar organic analytes, such as benzonitrile, in aqueous solution with detection limits in the ppb range. Further, these porous sol-gel structures allow the analytes to diffuse into and out of the films rapidly, thus reaching equilibrium in less than ten seconds. These sensors are unique because of the fact that their operation is based on the measurement of an IR absorption spectrum. Thus, these sensors are able to identify the analytes as well as measure concentration with high sensitivity. These developments have been documented in previous reports and publications. Recently, we have also targeted detection of the polar organic molecules acetone and isopropanol in aqueous solution. Polar organics are widely used in industrial and chemical processes, hence it is of interest to monitor their presence in effluents or decontamination process flows. Although large improvements in detection limits were expected with non-polar organic molecules in aqueous solutions using very hydrophobic porous sol-gel films on silicon attenuated total reflectance (Si ATR) waveguides, it was not as clear what the detection enhancements might be for polar organic molecules. This report describes the use of modified sol-gel-coated Si ATR sensors for trace detection and quantitation of small polar organic molecules in aqueous solutions. The detection of both acetone and isopropanol molecules in aqueous solution has been previously reported for chalcogenide fiber optic sensors. The sol-gel film was produced using a mixture of ethyltriethoxysilane and tetraethoxysilane and the surface modification was carried out using trimethylchlorosilane. We have demonstrated that this film concentrates the target polar analytes from aqueous solution in the region probed by the evanescent wave to improve detection limits by as much as a factor of 450.

Lopez, Gabriel P.↗

NASA NTRS1999

Improved Earth Sensor Performance Using a Sequentially Correlated Noise Model

Spacecraft attitude estimation by means of an extended Kalman filter requires a reasonably true model of the inherent noise of each sensor. For some sensors, the largest uncorrected noise comes not from the sensor itself, but from errors in the model for the predicted observations. This is certainly the case for Earth horizon sensors. The Earth horizon as seen from low Earth orbit is nearly a circle whose radius depends primarily on altitude. A straightforward latitude-dependent correction is added to this to account for the oblateness of the Earth. There also are both seasonal and stochastic variations in the horizon height. The seasonal variations can be predicted to some limited degree based on models derived from historical data. The stochastic component characteristically shows variations that are correlated both in time and space but which are unpredictable over long time spans. This work investigates whether Earth horizon sensor performance can be improved by solving for its systematic error as an augmentation of an attitude Kalman filter. It is found that using only Earth and Sun sensors, the augmented state is not fully observable. Even when magnetometer data is included, only the pitch axis component of the error can be improved; the roll component is unobservable.

Sedlak, J.↗

NASA NTRS1999

The Chilled-Mirror Humidity Sensor: Improved Radiosonde Measurements

Chilled-mirror humidity sensor technology recently was adapted for use with the VIZ radiosonde. The principle of the chilled-mirror operation is to lower its temperature until dew forms on the mirror, at that point the dew point temperature is noted and the mirror is then heated to evaporate the moisture. The cycle is repeated. Research conducted from NASA's Wallops Flight Facility has provided comparisons between the chilled-mirror sensor and the carbon hygristor of VIZ, and the capacitive sensors of AIR Inc. and Vaisala Co. We believe the chilled-mirror sensor is accurate and would serve as a reference standard for evaluating operational radiosonde relative humidity sensors. Thus, differences seen in the comparisons are beginning to furnish insight into developing better humidity sensors. We discuss these comparison results as well as reproducibility results from a dual chilled-mirror measurement.

Schmidlin, F. J.↗

NASA NTRS1999

Cryogenic High Pressure Sensor Module

A pressure sensor is provided for cryogenic, high pressure applications. A highly doped silicon piezoresistive pressure sensor is bonded to a silicon substrate in an absolute pressure sensing configuration. The absolute pressure sensor is bonded to an aluminum nitride substrate. Aluminum nitride has appropriate coefficient of thermal expansion for use with highly doped silicon at cryogenic temperatures. A group of sensors, either two sensors on two substrates or four sensors on a single substrate are packaged in a pressure vessel.

Chapman, John J.↗

NASA NTRS1999

Gas Sensor Evaluations in Polymer Combustion Product Atmospheres

Toxic gases produced by the combustion or thermo-oxidative degradation of materials such as wire insulation, foam, plastics, or electronic circuit boards in space shuttle or space station crew cabins may pose a significant hazard to the flight crew. Toxic gas sensors are routinely evaluated in pure gas standard mixtures, but the possible interferences from polymer combustion products are not routinely evaluated. The NASA White Sands Test Facility (WSTF) has developed a test system that provides atmospheres containing predetermined quantities of target gases combined with the coincidental combustion products of common spacecraft materials. The target gases are quantitated in real time by infrared (IR) spectroscopy and verified by grab samples. The sensor responses are recorded in real time and are compared to the IR and validation analyses. Target gases such as carbon monoxide, hydrogen cyanide, hydrogen chloride, and hydrogen fluoride can be generated by the combustion of poly(vinyl chloride), polyimide-fluoropolymer wire insulation, polyurethane foam, or electronic circuit board materials. The kinetics and product identifications for the combustion of the various materials were determined by thermogravimetric-IR spectroscopic studies. These data were then scaled to provide the required levels of target gases in the sensor evaluation system. Multisensor toxic gas monitors from two manufacturers were evaluated using this system. In general, the sensor responses satisfactorily tracked the real-time concentrations of toxic gases in a dynamic mixture. Interferences from a number of organic combustion products including acetaldehyde and bisphenol-A were minimal. Hydrogen bromide in the products of circuit board combustion registered as hydrogen chloride. The use of actual polymer combustion atmospheres for the evaluation of sensors can provide additional confidence in the reliability of the sensor response.

Delgado, Rafael H.↗

NASA NTRS1999

Uncertainty Analysis of Inertial Model Attitude Sensor Calibration and Application with a Recommended New Calibration Method

Statistical tools, previously developed for nonlinear least-squares estimation of multivariate sensor calibration parameters and the associated calibration uncertainty analysis, have been applied to single- and multiple-axis inertial model attitude sensors used in wind tunnel testing to measure angle of attack and roll angle. The analysis provides confidence and prediction intervals of calibrated sensor measurement uncertainty as functions of applied input pitch and roll angles. A comparative performance study of various experimental designs for inertial sensor calibration is presented along with corroborating experimental data. The importance of replicated calibrations over extended time periods has been emphasized; replication provides independent estimates of calibration precision and bias uncertainties, statistical tests for calibration or modeling bias uncertainty, and statistical tests for sensor parameter drift over time. A set of recommendations for a new standardized model attitude sensor calibration method and usage procedures is included. The statistical information provided by these procedures is necessary for the uncertainty analysis of aerospace test results now required by users of industrial wind tunnel test facilities.

Tripp, John S.↗

NASA NTRS1999

Recent Developments in Chemically Reactive Sensors for Propellants

Propellant system leaks can pose a significant hazard in aerospace operations. For example, a leak in the hydrazine supply system of the shuttle auxiliary power unit (APU) has resulted in hydrazine ignition and fire in the aft compartment of the shuttle. Sensors indicating the location of a leak could provide valuable information required for operational decisions. WSTF has developed a small, single-use sensor for detection of propellant leaks. The sensor is composed of a thermistor bead coated with a substance which is chemically reactive with the propellant. The reactive thermistor is one of a pair of closely located thermistors, the other being a reference. On exposure to the propellant, the reactive coating responds exothermically to it and increases the temperature of the coated-thermistor by several degrees. The temperature rise is sensed by a resistive bridge circuit, and an alarm is registered by data acquisition software. The concept is general and has been applied to sensors for hydrazine, monomethylhydrazine, unsym-dimethylhydrazine, ammonia, hydrogen peroxide, ethanol, and dinitrogen tetroxide. Responses of these sensors to humidity, propellant concentration, distance from the liquid leak, and ambient pressure levels arc presented. A multi-use sensor has also been developed for hydrazine based on its catalytic reactivity with noble metals.

Davis, Dennis D.↗

NASA NTRS1999

An Inexpensive Radiosonde Chilled Mirror Sensor: An Old Technology With New Impact

The availability of an inexpensive chilled mirror dewpoint sensor has made improved atmospheric relative humidity measurements accessible. Comparisons between the chilled mirror sensor and routine radiosonde sensors have provided new information on the limitation and reliability of the routine measurements. The chilled mirror has observed detailed moisture profiles at cirrus cloud levels when cirrus was not visible, a feature that routine sensors fail to observe. Comparison measurements between the chilled mirror, the carbon resistive (hygristor) and, the capacitive sensors will be discussed. Measurements from three locations (Wallops Island; Andros Island, Bahamas; and Camborne, UK) will be highlighted. It is conceivable that the chilled mirror sensor, when its capability is fully understood, may be sufficiently reliable to serve as a reference.

Schmidlin, F. J.↗

NASA NTRS2000

Optical Sensors Based on Single on Arm Thin Film Waveguide Interferometer

Single-arm dual-mode optical waveguide interferometer utilizes interference between two modes of different order. Sensing effect results from the change in propagation conditions of the modes caused by the environment. The waveguide is made as an open asymmetric structure containing a dye-doped polymer film onto a quartz substrate. It is more sensitive to the change of environment than its conventional polarimetric analog using orthogonal modes (TE and TM) of the same order. The sensor still preserves the option of operating in polarimetric regime using a variety of mode combinations such as TE(sub 0)/TM(sub 0) (conventional) TE(sub 0)/TM(sub 1), TE(sub 1)/TM(sub 0), or TE(sub 1)/TM(sub 1) but can also work in nonpolarimetric regime using combinations TE(sub 0)/TE(sub 1) or TM(sub 0)/TM(sub 1). Utilization of different mode combinations simultaneously makes the device more versatile. Application of the sensor to gas sensing is based on doping polymer film with an organic indicator dye targeting a particular gaseous reagent. Change of the optical absorption spectrum of the dye caused by the gaseous pollutant results in change of the reactive index of the dye-doped polymer film that can be detected by the sensor. As indicator dyes we utilize Bromocresol Purple doped into polymer poly(methyl) methacrylate that is sensitive to small concentrations of ammonia. The indicator dye demonstrated an irreversible increase in optical absorption near the peak at 350 nm being exposed to 5% ammonia in pure nitrogen at 600 Torr. The dye also showed reversible growth of the absorption peak near 600 nm after exposure to a vapor of standard medical ammonia spirit (65% alcohol). We have built a breadboard prototype of the sensor with He-Ne laser as a light source and with a single mode fiber input and a multimode fiber output. The prototype showed a sensitivity to temperature change of the order of 2 C per 2pi phase shift. The sensitivity of the sensor to the presence of dTy ammonia is not less than 300 ppm per 2pi phase shift. The proposed sensor can be used as a robust stand-alone instrument for continuous environment pollution monitoring.

Sarkisov, S. S.↗

NASA NTRS2000

Shape Measurement of Large Aerospace Structures Using Sensitivity Electrical TDR Distributed Strain Sensor

Electrical time domain reflectometry (ETDR) sensing technique can be best described as "closed-loop radar," where the information is derived from the reflections of a voltage pulse sent through a transmission medium. The ETDR sensing technique is a well-developed method and has been widely used to locate and evaluate discontinuities in long coaxial power transmission cables. The ETDR technique provides a true distributed sensing capability which can not only sense the distributed loading condition of the structure but also can pin-point the location of disturbance, such as the locations of stress concentration and structural damages. Proof-of-concept experiments have been conducted using photoelastic specimens with embedded commercial coaxial cables, i.e., RG85/U and RG174, to demonstrate the stress/strain sensing capability of ETDR sensors for structural health monitoring application. Although the test results showed that the ETDR sensor signals capture specimen deformation pattern both in bending and tension and indicate the location and type of crack damages of the photoelastic specimen; yet, the low signal-to-noise ratio of the sensor signal smears the details of the strain measurement that the ETDR signals can convey. A high-sensitivity ETDR coaxial strain sensor prototype newly developed at Clark Atlanta University will be presented. The construction of the prototype sensing cable as well as its electrical properties relevant to distributed strain sensing application will be shown in details. Test results of the sensitivity and tension responses of the ETDR signal of the prototype sensor will be presented and compared with those of commercial coaxial cables. Promising potentials of the ETDR distributed strain sensing method for shape measurement application of large aerospace structures will also be demonstrated using long slender beam with surface-bonded ETDR distributed strain sensor.

Lin, Mark W.↗

NASA NTRS2001

Cryogenic, Absolute, High Pressure Sensor

John J Chapman↗

NASA NTRS2001

Position Sensor with Integrated Signal-Conditioning Electronics on a Printed Wiring Board

A position sensor, such as a rotary position sensor, includes the signal-conditioning electronics in the housing. The signal-conditioning electronics are disposed on a printed wiring board, which is assembled with another printed wiring board including the sensor windings to provide a sub-assembly. A mu-metal shield is interposed between the printed wiring boards to prevent magnetic interference. The sub-assembly is disposed in the sensor housing adjacent to an inductor board which turns on a shaft. The inductor board emanates an internally or externally generated excitation signal that induces a signal in the sensor windings. The induced signal represents the rotary position of the inductor board relative to the sensor winding board.

Alhorn, Dean C.↗

NASA NTRS2001

Optical Sensors Based on Single Arm Thin Film Waveguide Interferometer

Single-arm double-mode double-order optical waveguide interferometer utilizes interference between two propagating modes of different orders. Sensing effect results from the change in propagation conditions of the modes caused by the environment. The waveguide is made as an open asymmetric slab structure containing a dye-doped polymer film onto a fused quartz substrate. It is more sensitive to the change of environment than its conventional polarimetric analog using orthogonal modes (TE and TM) of the same order. The sensor still preserves the option of operating in polarimetric regime using a variety of mode combinations such as TE(sub 0)/TM(sub 0) (conventional), TE(sub 0)/TM(sub 1), TE(sub 1)/TM(sub 0), or TE(sub 1)/TM(sub 1) but can also work in nonpolarimetric regime using combinations TE(sub 0)/TM(sub 1) or TE(sub 0)/TM(sub 1). Utilization of different mode combinations simultaneously makes the device more versatile. Application of the sensor to gas sensing is based on doping polymer film with an organic indicator dye sensitive to a particular gas. Change of optical absorption spectrum of the dye caused by the gaseous pollutant results change of the reactive index of the dye-doped polymer film that can be detected by the sensor. As an indicator dyes, we utilize Bromocresol Purple doped into polymer poly(methyl) methacrylate, which shows a reversible growth of the absorption peak neat 600 nm after exposure to wet ammonia. We have built a breadboard prototype of the sensor with He-Ne laser as a light source and with a single mode fiber input and a multimode fiber output. The prototype showed sensitivity to temperature change of the order of 2 C per one full oscillation of the signal. The sensitivity of the sensor to the presence of wet ammonia is 200 ppm per one full oscillation of the signal. The further improvements include switching to a longer wavelength laser source (750-nm semiconductor laser), substitution of poly(methyl) methacrylate with hydrophilic high-temperature polyimide, and increase the doping rate of indicator dye. All these improvements are expected to bring sensitivity to 10 ppm of ammonia per one full oscillation of signal independent on the humidity of ambient air. The proposed sensor can be used as a robust and inexpensive stand-alone instrument for continuous environment pollution monitoring.

Sarkisov, S. S.↗