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Optical Sensors for Use in Propulsion Control Systems

This final technical report describes the results of a cooperative effort which was originally established between John Carroll University and the Instrumentation and Control Technology Division at NASA Lewis Research Center on November, 1982, and then continued with the Engine Sensor Technology Branch at NASA Lewis until March, 1995. All work at John Carroll University was directed by the principal investigator of this grant, Klaus Fritsch, Ph.D. For the first two years of this grant this effort was supervised at NASA by Mr. Robert J. Baumbick and for the remainder of the grant by Dr. Glenn M. Beheim. All research was carried out in close cooperation with Dr. Beheim. Electrically passive optical sensors for measurands such as pressure, temperature, position, and rotational speed are required for aircraft engine control in fly-by-light digital aircraft control systems. Fiberoptic data links and optical multiplexing techniques should be used for combining and processing the outputs from several sensors, sharing as many optical end electronic parts as possible. The overall objective of this grant was to explore techniques for designing and constructing such electrically passive optical sensors for measuring physical parameters in jet aircraft engines and for use in aircraft control systems. We have concentrated our efforts on pressure, temperature, and position sensors employing techniques which are relatively immune to transmissivity variations of the fiber links and to variations in intensity of the light source. Infrared light-emitting diodes are employed because of their longevity and immunity to vibration. We have also studied a number of multiplexing techniques. On the following pages I will give thumbnail sketches of the projects carried out under this grant and provide references to publications and John Carroll M.S. theses which resulted directly from this work and which describe these projects in greater detail.

Fritsch, Klaus↗

Directional Radio-Frequency Identification Tag Reader

A directional radio-frequency identification (RFID) tag reader has been designed to facilitate finding a specific object among many objects in a crowded room. The device could be an adjunct to an electronic inventory system that tracks RFID-tagged objects as they move through reader-equipped doorways. Whereas commercial RFID-tag readers do not measure directions to tagged objects, the device is equipped with a phased-array antenna and a received signal-strength indicator (RSSI) circuit for measuring direction. At the beginning of operation, it is set to address only the RFID tag of interest. It then continuously transmits a signal to interrogate that tag while varying the radiation pattern of the antenna. It identifies the direction to the tag as the radiation pattern direction of peak strength of the signal returned by the tag. An approximate distance to the tag is calculated from the peak signal strength. The direction and distance can be displayed on a screen. A prototype containing a Yagi antenna was found to be capable of detecting a 915.5-MHz tag at a distance of approximately equal to 15 ft (approximately equal to 4.6 m).

Medelius, Pedro J.↗

Cleaning Carbon Nanotubes by Use of Mild Oxygen Plasmas

Experiments have shown that it is feasible to use oxygen radicals (specifically, monatomic oxygen) from mild oxygen plasmas to remove organic contaminants and chemical fabrication residues from the surfaces of carbon nanotubes (CNTs) and metal/CNT interfaces. A capability for such cleaning is essential to the manufacture of reproducible CNT-based electronic devices. The use of oxygen radicals to clean surfaces of other materials is fairly well established. However, previously, cleaning of CNTs and of graphite by use of oxygen plasmas had not been attempted because both of these forms of carbon were known to be vulnerable to destruction by oxygen plasmas. The key to success of the present technique is, apparently, to ensure that the plasma is mild . that is to say, that the kinetic and internal energies of the oxygen radicals in the plasma are as low as possible. The plasma oxygen-radical source used in the experiments was a commercial one marketed for use in removing hydrocarbons and other organic contaminants from vacuum systems and from electron microscopes and other objects placed inside vacuum systems. In use, the source is installed in a vacuum system and air is leaked into the system at such a rate as to maintain a background pressure of .0.56 torr (.75 Pa). In the source, oxygen from the air is decomposed into monatomic oxygen by radio-frequency excitation of a resonance of the O2 molecule (N2 is not affected). Hence, what is produced is a mild (non-energetic) oxygen plasma. The oxygen radicals are transported along with the air molecules in the flow created by the vacuum pump. In the experiments, exposure to the oxygen plasma in this system was shown to remove organic contaminants and chemical fabrication residues from several specimens. Many high-magnification scanning electron microscope (SEM) images of CNTs were taken before and after exposure to the oxygen plasma. As in the example shown in the figure, none of these images showed evidence of degradation of CNT structures.

Petkov, Mihail↗

Power Hibernation for Low-Cost Solar Powered Lunar Missions

Because the surface of the Moon drops to cryogenic temperatures, no solar-powered lunar spacecraft have reliably operated beyond a single lunar day. Passive thermal control cannot keep a spacecraft sufficiently warm for the 354-hour lunar night, and active thermal control requires a dramatic increase in battery mass at the expense of payload mass. Extreme conditions seen on the lunar surface suggest a radioisotope solution is ideal, but mass, cost, and schedule are inconsistent with low-cost frequent flight intent of the commercial lunar payload services (CLPS) program. To solve the issue of lunar night survivability without radioisotope sources of power and heat, a lunar power hibernation approach is being developed at the Glenn Research Center, which exploits the ability of common 18650 Lithium-ion cells to passively survive cryogenic freeze-thaw cycles and recover without apparent performance degradation. A key aspect of this hibernation approach is the use of cryogenically operable electronics that safely manage the restoration of the battery thermal environment at lunar dawn. A spacecraft utilizing this strategy will operate into the lunar night on batteries until the state of charge or spacecraft temperature reaches a predetermined threshold. At this point, systems are shut down and the battery is isolated from the main bus to prevent charge or discharge during the freezing and thawing transitions. The system remains passive until lunar dawn, where temperatures can reach as low as 50 K. All electronics must be tolerant to these conditions. When the solar arrays are finally illuminated at lunar dawn, the main bus power electronics will initiate a “cold start” and begin regulating array power. The main bus electronics must be designed to operate at cryogenic temperatures. Array power is used to warm the battery and passive electronics back to operational temperatures. Once batteries are returned to normal temperatures, diagnostics and precharging is performed, as needed, and the battery is reconnected. The overall spacecraft system reboots and returns to nominal operations until lunar night returns. To assure that we can develop batteries suited for many hibernation freeze/thaw cycles, STMD Space Technology Research Grant Program (STRG) has selected two principal investigators that will thoroughly characterize of the Li-ion cell through the freeze-thaw process, investigate degradation mechanisms, and identify potential diagnostic techniques. STMD STRG is also funding an investigation of Gallium-Nitride semiconductors for cryogenic power applications. This work includes physics-informed modeling that considers cryogenic conductivity, carrier mobility, and quantum effects that govern semiconductor performance at cryogenic temperatures. These models can enable engineers to develop accurate cryogenic simulation models that assist in the design of power controls stable over the entire lunar surface temperature range. Meanwhile, Glenn is performing cryogenic testing of batteries and electronics, establishing design guidelines for power applications in extreme cold lunar environment, and potentially developing a hibernation technology demonstrator. The hibernation approach will enable low-cost lunar robotic missions to extend their operating lifetime to many months while minimizing development costs and impact on payload capacity. The need for cryogenically operable electronics is restricted to only main bus power and battery controls, as the majority of systems simply need to passively tolerate cryogenic temperatures. This allows developers to continue to exploit the cost savings of legacy and COTS hardware with minimum modification. For these reasons, lunar power hibernation is a viable near-term solution for lunar night survivability for solar powered commercial landers.

Space power↗

Qualification of a Pulsed, Millinewton Class Metal Plasma Thruster for Broad Mission Applications

In the field of low power (<100W) electric propulsion, all thruster options demand significant trade-offs between operating parameters, reliability and scalable cost. With many systems on the market there are concerns with reliability, the need for extra considerations such as electron neutralizers for pure ion plumes, and the cost or craft compatibility of propellants. The Metal Plasma Thruster (MPT) is a new type of electric propulsion technology intended for low power applications. The system imparts momentum using inert, solid metal pucks as a propellant by using pulsed power to convert the metal into high velocity (~17km/s for Mo) jets of quasi-neutral plasma. The MPT technology does not require gas or liquid propellants, neutralizers, standby heaters, high voltage electronics, high electric or magnetic fields to operate. This comparatively simple pulsed operation is amenable to closed loop control, which provides for fine thrust control and S/C directed impulse on demand. Furthermore, the technology can use any metal as propellant, opening up unique opportunities for In-Situ Resource Utilization (ISRU) as well as customizability of performance for meeting specific mission needs. This paper describes implementation and direct measurement of this closed loop control mode as well as impulse measurement of multiple metals consistent with the aim of ISRU at NASA Glenn Research Center (GRC).

Electric Propulsion↗

Qualification of a Pulsed, Millinewton Class Metal Plasma Thruster for Broad Mission Applications

In the field of low power (<100W) electric propulsion, all thruster options demand significant trade-offs between operating parameters, reliability and scalable cost. With many systems on the market there are concerns with reliability, the need for extra considerations such as electron neutralizers for pure ion plumes, and the cost or craft compatibility of propellants. The Metal Plasma Thruster (MPT) is a new type of electric propulsion technology intended for low power applications. The system imparts momentum using inert, solid metal pucks as a propellant by using pulsed power to convert the metal into high velocity (~17km/s for Mo) jets of quasi-neutral plasma. The MPT technology does not require gas or liquid propellants, neutralizers, standby heaters, high voltage electronics, high electric or magnetic fields to operate. This comparatively simple pulsed operation is amenable to closed loop control, which provides for fine thrust control and S/C directed impulse on demand. Furthermore, the technology can use any metal as propellant, opening up unique opportunities for In-Situ Resource Utilization (ISRU) as well as customizability of performance for meeting specific mission needs. This paper describes implementation and direct measurement of this closed loop control mode as well as impulse measurement of multiple metals consistent with the aim of ISRU at NASA Glenn Research Center (GRC).

Electric Propulsion↗

Avionics/crew station integration

The U.S. Navy has been encouraging advanced development concepts aimed at increasing the aircraft instrumentation performance for multi-platform applications of 1990's weapons systems. The three areas covered by the Navy's research and development effort are: System Integration, Technology, and Human Factors. The System Integration objectives are to produce a system architecture easily adaptable to many platforms. Technology objectives are to determine the state of the art for displays, electronics, and controls. The Human Factors objectives are to determine the proper human-machine interfaces so that the ultimate crew station will be capable of providing the pilot with the proper display and controls performance to satisfy the diverse requirements of a fighter, attack, ASW, fixed-wing, rotary-wing, and V/STOL platforms in both a one-man crew or two-man crew matrix. All data/control interface among units of this crew station and other platform subsystems will be via digital data buses and video multiplex buses. No individual discrete signal, data, or control lines will be needed. This paper discusses the six interfaces necessary to ensure the optimum development of this crew station, the predicted platform mission improvements, and the requisite life-cycle cost considerations. This concept will serve as a basis for planning the integration of the necessary hardware and software features in current and future weapons systems.

Mulley, W. G.↗

LDEF archival system plan

The Long Duration Exposure Facility (LDEF) Science Office is developing a comprehensive archival system to enable access to LDEF data, analysis, publications, and hardware for further research and design applications. The archival system will be a space environmental effects resource designed to encompass other data relevant to the space environment in addition to that which has resulted from LDEF. Elements of the archival system will include electronically stored data, hardcopies, photographs, hardware, and samples. Currently LDEF data and analytical results are being recorded by principal investigators and special investigation groups in many forms and for both inhouse uses and outside distribution. It is intended that the LDEF archival system will include access to some of these independent sources of information as part of the complete archives. This paper will discuss the LDEF archival system, including the procedures for acquiring information and hardware.

Wilson, Brenda K.↗

Pt/HTCC Alumina based Electronic Packaging System and Integration Processes for High Temperature Harsh Environment Applications

Electronic devices capable of operation at 500°C are required for long term Venus surface missions, as well as for in situ monitoring and control of next generation aeronautical engines. High temperature sensors and electronics can also find many applications in military, and energy and automobile industries. Various silicon carbide (SiC) sensors and electronic devices have been developed for operation at 500 °C, and a compatible packaging system is needed for long term test and deployment of these high temperature devices. High temperature co-fired ceramics (HTCC) alumina with platinum (Pt) conductor was proposed for high temperature electronic packaging. A prototype Pt/HTCC alumina packaging system including chip-level package and circuit board has been briefly reported previously for long-term electrical testing of SiC integrated circuits at 500 °C, and brief testing at much higher temperatures. HTCC alumina is an excellent dielectric material with acceptable dielectric constant and low dielectric loss over wide temperature and frequency ranges. Pt is chemically noble and can be co-fired with HTCC alumina in air ambient producing a viable electronic packaging material system for high temperature applications. This paper presents a more detailed description of this packaging system including prototype low power packages and circuit boards based on HTCC alumina and Pt metallization for 500°C and other harsh environment applications. The key technical considerations for chip-level packaging and circuit board assembly, including materials and processes for 500 °C durable wire-bonding and SiC die attach, and integration of multi-chip circuit boards, are presented. Experimental test results of this packaging approach applied to SiC integrated circuits at 500 °C and 700°C are discussed as well.

High temperature↗

Pt/HTCC Alumina based Electronic Packaging System and Integration Processes for High Temperature Harsh Environment Applications

Electronic devices capable of operation at 500°C are required for long term Venus surface missions, as well as for in situ monitoring and control of next generation aeronautical engines. High temperature sensors and electronics can also find many applications in military, and energy and automobile industries. Various silicon carbide (SiC) sensors and electronic devices have been developed for operation at 500 °C, and a compatible packaging system is needed for long term test and deployment of these high temperature devices. High temperature co-fired ceramics (HTCC) alumina with platinum (Pt) conductor was proposed for high temperature electronic packaging. A prototype Pt/HTCC alumina packaging system including chip-level package and circuit board has been briefly reported previously for long-term electrical testing of SiC integrated circuits at 500 °C, and brief testing at much higher temperatures. HTCC alumina is an excellent dielectric material with acceptable dielectric constant and low dielectric loss over wide temperature and frequency ranges. Pt is chemically noble and can be co-fired with HTCC alumina in air ambient producing a viable electronic packaging material system for high temperature applications. This paper presents a more detailed description of this packaging system including prototype low power packages and circuit boards based on HTCC alumina and Pt metallization for 500°C and other harsh environment applications. The key technical considerations for chip-level packaging and circuit board assembly, including materials and processes for 500 °C durable wire-bonding and SiC die attach, and integration of multi-chip circuit boards, are presented. Experimental test results of this packaging approach applied to SiC integrated circuits at 500 °C and 700°C are discussed as well.

electronic packaging↗

Up Periscope! Designing a New Perceptual Metric for Imaging System Performance

Modern electronic imaging systems include optics, sensors, sampling, noise, processing, compression, transmission and display elements, and are viewed by the human eye. Many of these elements cannot be assessed by traditional imaging system metrics such as the MTF. More complex metrics such as NVTherm do address these elements, but do so largely through parametric adjustment of an MTF-like metric. The parameters are adjusted through subjective testing of human observers identifying specific targets in a set of standard images. We have designed a new metric that is based on a model of human visual pattern classification. In contrast to previous metrics, ours simulates the human observer identifying the standard targets. One application of this metric is to quantify performance of modern electronic periscope systems on submarines.

imaging↗

Random Vibration Testing of Advanced Wet Tantalum Capacitors

Advanced wet tantalum capacitors allow for improved performance of power supply systems along with substantial reduction of size and weight of the systems that is especially beneficial for space electronics. Due to launch-related stresses, acceptance testing of all space systems includes random vibration test (RVT). However, many types of advanced wet tantalum capacitors cannot pass consistently RVT at conditions specified in MIL-PRF-39006, which impedes their use in space projects. This requires a closer look at the existing requirements, modes and mechanisms of failures, specifics of test conditions, and acceptance criteria. In this work, different lots of advanced wet tantalum capacitors from four manufacturers have been tested at step stress random vibration conditions while their currents were monitored before, during, and after the testing. It has been shown that the robustness of the parts and their reliability are mostly due to effective self-healing processes and limited current spiking or minor scintillations caused by RVT do not increase the risk of failures during operation. A simple model for scintillations events has been used to simulate current spiking during RVT and optimize test conditions. The significance of scintillations and possible effects of gas generation have been discussed and test acceptance criteria for limited current spiking have been suggested.

cracking↗

Random Vibration Testing of Advanced Wet Tantalum Capacitors

Advanced wet tantalum capacitors allow for improved performance of power supply systems along with substantial reduction of size and weight of the systems that is especially beneficial for space electronics. Due to launch-related stresses, acceptance testing of all space systems includes random vibration test (RVT). However, many types of advanced wet tantalum capacitors cannot pass consistently RVT at conditions specified in MIL-PRF-39006, which impedes their use in space projects. This requires a closer look at the existing requirements, modes and mechanisms of failures, specifics of test conditions, and acceptance criteria. In this work, different lots of advanced wet tantalum capacitors from four manufacturers have been tested at step stress random vibration conditions while their currents were monitored before, during, and after the testing. It has been shown that the robustness of the parts and their reliability are mostly due to effective self-healing processes and limited current spiking or minor scintillations caused by RVT do not increase the risk of failures during operation. A simple model for scintillations events has been used to simulate current spiking during RVT and optimize test conditions. The significance of scintillations and possible effects of gas generation have been discussed and test acceptance criteria for limited current spiking have been suggested.

wet tantalum capacitors↗

Random Vibration Testing of Advanced Wet Tantalum Capacitors

Advanced wet tantalum capacitors allow for improved performance of power supply systems along with substantial reduction of size and weight of the systems that is especially beneficial for space electronics. Due to launch-related stresses, acceptance testing of all space systems includes random vibration test (RVT). However, many types of advanced wet tantalum capacitors cannot pass consistently RVT at conditions specified in MIL-PRF-39006, which impedes their use in space projects. This requires a closer look at the existing requirements, modes and mechanisms of failures, specifics of test conditions, and acceptance criteria. In this work, different lots of advanced wet tantalum capacitors from four manufacturers have been tested at step stress random vibration conditions while their currents were monitored before, during, and after the testing. It has been shown that the robustness of the parts and their reliability are mostly due to effective self-healing processes and limited current spiking or minor scintillations caused by RVT do not increase the risk of failures during operation. A simple model for scintillations events has been used to simulate current spiking during RVT and optimize test conditions. The significance of scintillations and possible effects of gas generation have been discussed and test acceptance criteria for limited current spiking have been suggested.

cracking↗

Corrosion Failure in Electronic Devices for Aerospace Application

Corrosion of complex electronic systems is a growing and expensive concern. New materials and technology are constantly being introduced to increase performance of devices. There are many factors that can induce a corrosive environment during the various stages of manufacturing, processing, transport, and storage of these devices. The scope of this paper was to identify potential causes for the corrosion failure of optocoupler batches being used in launch applications. Optical microscope with surface profile measurements, scanning electron microscopy (SEM), energy-dispersive X-ray spectrometry (EDS), and X-ray photoelectron spectroscopy (XPS) were used to identify and analyze the source of these failure. These studies revealed that the loss of adhesion between the electrolytic plated gold and nickel layers is the critical area that traps impurity ions into the chip allowing for blisters to form along the pins of the optocoupler.

Corrosion↗

Could Zinc Whiskers Be Impacting Your Electronic Systems? Raise Your Awareness

During the past several decades electrical short circuits induced by "Zinc Whiskers" have been cited as the root cause of failure for various electronic systems (e.g., apnea monitors, telecom switches). These tiny filaments of zinc that may grow from some zinc-coated items (especially those coated by electroplating processes) have the potential to induce electrical shorts in exposed circuitry. Through this article, the authors describe a particular failure scenario attributed to zinc whiskers that has affected many facilities (including some NASA facilities) that utilized zinc-coated raised "access" floor tiles and support structures. Zinc whiskers that may be growing beneath your raised floor have the potential to wreak havoc on electronic systems operating above the floor.

Sampson, Michael↗

Energy Efficient Engine: Control system component performance report

An Energy Efficient Engine (E3) program was established to develop technology for improving the energy efficiency of future commercial transport aircraft engines. As part of this program, General Electric designed and tested a new engine. The design, fabrication, bench and engine testing of the Full Authority Digital Electronic Control (FADEC) system used for controlling the E3 Demonstrator Engine is described. The system design was based on many of the proven concepts and component designs used on the General Electric family of engines. One significant difference is the use of the FADEC in place of hydromechanical computation currently used.

Beitler, R. S.↗

The Telestation: A product for distributed data gathering and operations

Advances in computer, navigation and wireless telecommunication technologies are enabling better electronic devices at reduced costs. Individually, these devices have been applied to increase the performance of many common systems, such as desktop computers, surveying equipment, and modems. However, we believe the convergence of these three technologies will create a product that simultaneously lowers life cycle costs while increasing operational effectiveness. Space Systems/Loral (SS/L) is developing portions of this product, known as the Telestation, for both terrestrial and orbital applications. The Telestation consists of an advanced microprocessor for command and data handling; a GPS receiver for position, time, and attitude information; and a Globalstar Transceiver for two-way digital communications. The Telestation provides the user with real-time command and control of globally distributed hardware elements. This capability can be applied terrestrially for gathering information (e.g., science, environmental, etc.) in remote or inhospitable locations, or where logistical support is inadequate. An in-orbit version can be used for spacecraft or payload operations, allowing principal investigators instant access to their payloads during all phases of a mission. This paper describes some cost effectiveness metrics of the Telestation, its development status, and its utility in both terrestrial and orbital applications.

Cleave, Robert R.↗