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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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Compact resistance-welding pinch gun lets one operator do jobs formerly needing two workers. Light in weight and produces repeatable, high-quality weld joints. Welding-electrode head rotates for easy positioning. Lever at top of handle activates spring to pinch electrodes together at preset welding force. Button at bottom of handle activates welding current. Cables supply electrical power.
Composite and honeycomb panels are commonly used for spacecraft structural components. The impact test results and analysis of six different composite and honeycomb combinations for use on the advanced X-ray astrophysics facility (AXAF) are reported. The AXAF consists of an X-ray telescope and the associated detecting devices attached to an octagonal spacecraft with an internal propulsion system. The spacecraft's structural panels and optical bench are made of two different graphite fiber reinforced polyimides or composite panels bonded to either side of an aluminum honeycomb. The instrument is required to have at least a 0.92 probability of no failure of any of the critical elements due to meteoroids and debris. In relation to the no-failure probability determination in its low earth orbit environment, hypervelocity impact testing was performed to determine the ballistic limit range and the extent of damage due to impact. The test results for a power and signal cable bundle located behind a panel are presented. Tests planned for a multilayer insulation (MLI) blanket and four types of cable bundles are discussed.
On the fourth day of STS-112, its crew (Jeffrey Ashby, Commander; Pamela Melroy, Pilot; David Wolf, Mission Specialist; Piers Sellers, Mission Specialist; Sandra Magnus, Mission Specialist; Fyodor Yurchikhin, Mission Specialist) onboard Atlantis and the Expedition 5 crew (Valery Korzun, Commander; Peggy Whitson, Flight Engineer; Sergei Treschev, Flight Engineer) onboard the International Space Station (ISS) are seen preparing for the installation of the S1 truss structure. Inside the Destiny Laboratory Module, Korzun and other crewmembers are seen as they busily prepare for the work of the day. Sellers dons an oxygen mask and uses an exercise machine in order to purge the nitrogen from his bloodstream, in preparation for an extravehicular activity (EVA). Whitson uses the ISS's Canadarm 2 robotic arm to grapple the S1 truss and remove it from Atlantis' payload bay, with the assistance of Magnus. Using the robotic arm, Whitson slowly maneuvers the 15 ton truss structure into alignment with its attachment point on the starboard side of the S0 truss structure, where the carefully orchestrated mating procedures take place. There is video footage of the entire truss being rotated and positioned by the arm, and ammonia tank assembly on the structure is visible, with Earth in the background. Following the completion of the second stage capture, the robotic arm is ungrappled from truss. Sellers and Wolf are shown exiting the the Quest airlock hatch to begin their EVA. They are shown performing a variety of tasks on the now attached S1 truss structure, including work on the Crew Equipment Translation Cart (CETA), the S-band Antenna Assembly, and umbilical cables that provide power and remote operation capability to cameras. During their EVA, they are shown using a foot platform on the robotic arm. Significant portions of their activities are shown from the vantage of helmet mounted video cameras. The video closes with a final shot of the ISS and its new S1 truss.
Highly insulating materials often acquire significant charges when subjected to fluxes of electrons, ions, or photons. This charge can significantly modify the materials properties of the materials and have profound effects on the functionality of the materials in a variety of applications. These include charging of spacecraft materials due to interactions with the severe space environment, enhanced contamination due to charging in Lunar of Martian environments, high power arching of cables and sources, modification of tethers and ion thrusters for propulsion, and scanning electron microscopy, to name but a few examples. This paper describes new techniques and measurements of the electron emission properties and resistivity of highly insulating materials. Electron yields are a measure of the number of electrons emitted from a material per incident particle (electron, ion or photon). Electron yields depend on incident species, energy and angle, and on the material. They determine the net charge acquired by a material subject to a give incident flu. New pulsed-beam techniques will be described that allow accurate measurement of the yields for uncharged insulators and measurements of how the yields are modified as charge builds up in the insulator. A key parameter in modeling charge dissipation is the resistivity of insulating materials. This determines how charge will accumulate and redistribute across an insulator, as well as the time scale for charge transport and dissipation. Comparison of new long term constant-voltage methods and charge storage methods for measuring resistivity of highly insulating materials will be compared to more commonly used, but less accurate methods.
Sensors are a critical element to any monitoring, control, and evaluation processes such as those needed to support ground based testing for rocket engine test. Sensor applications involve tens to thousands of sensors; their reliable performance is critical to achieving overall system goals. Many figures of merit are used to describe and evaluate sensor characteristics; for example, sensitivity and linearity. In addition, sensor selection must satisfy many trade-offs among system engineering (SE) requirements to best integrate sensors into complex systems [1]. These SE trades include the familiar constraints of power, signal conditioning, cabling, reliability, and mass, and now include considerations such as spectrum allocation and interference for wireless sensors. Our group at NASA s John C. Stennis Space Center (SSC) works in the broad area of integrated systems health management (ISHM). Core ISHM technologies include smart and intelligent sensors, anomaly detection, root cause analysis, prognosis, and interfaces to operators and other system elements [2]. Sensor technologies are the base fabric that feed data and health information to higher layers. Cost-effective operation of the complement of test stands benefits from technologies and methodologies that contribute to reductions in labor costs, improvements in efficiency, reductions in turn-around times, improved reliability, and other measures. ISHM is an active area of development at SSC because it offers the potential to achieve many of those operational goals [3-5].
The scope of this testing includes the Surface Acoustic Wave Sensor System delivered to KSC: two interrogator (transceiver) systems, four temperature sensors, with wooden mounting blocks, two antennas, two power supplies, network cables, and analysis software. Also included are a number of additional temperature sensors and newly-developed hydrogen sensors
This presentation provides an overview of common mode conducted emissions (CMCE) measurements on power and signal cables. The presentation focuses on how such measurements directly apply to electromagnetic compatibility at the system level and provides a discussion of different techniques for performing them correctly and accurately.
A mission plan for an integrated radio and optical communications payload, based on the Mars Reconnaissance Orbiter, is presented with emphasis on the derivation of precision pointing requirements. The Canfield joint, a parallel robotic linkage capable of hemispherical pointing, is discussed as a platform for optical communication and other deep space instrumentation. The capabilities of a prototype are compared to those of currently available gimbals qualified for deep space, and the advantages of the Canfield joint, including size, weight and power (SWaP) savings, cable handling, and mechanical redundancy, are discussed. Validation procedures and results for the space hardware prototype are presented. This work was undertaken through the Integrated Radio and Optical Communication (iROC) project at NASA Glenn Research Center.
The Poker Flat 49.92-MHz MST radar uses 64 phase-controlled transmitters in individual shelters distributed throughout the antenna array. Phase control is accomplished by sampling the transmitted pulse at the directional coupler of each transmitter and sending the sample pulse back to a phase-control unit. This method requires phase matching 64 long (256 meter) coaxial cables (RG-213) to within several electrical degrees. Tests with a time domain reflectometer showed that attenuation of high frequency components in the long RG-213 cable rounded the leading edge of the reflected pulse so that the cables could only be measured to within 50 cm (about 45 deg at 49.92 MHz). Another measurement technique using a vector voltmeter to compare forward and reflected phase required a directional coupler with unattainable directivity. Several other techniques were also found lacking, primarily because of loss in the long RG-213 cables. At this point it was realized that what was needed was a simple version of the phase-coherent clear-air radar, i.e., a cable radar. The design and operation of this cable are described.
An optical navigation system is being flown as the backup system to the primary Deep Space Network telemetry for navigation and guidance purposes on Orion. This is required to ensure Orion can recover from a loss of communication, which would simultaneously cause a loss of DSN telemetry. Images taken of the Moon and Earth are used to give range and position information to the navigation computer for trajectory calculations and maneuver execution. To get telemetry data from these images, the size and location of the moon need to be calculated with high accuracy and precision. The reentry envelope for the Orion EM-1 mission requires the centroid and radius of the moon images to be determined within 1/3 of a pixel 3 sigma. In order to ensure this accuracy and precision can be attained, I was tasked with building precise dot grid images for camera calibration as well as building a hardware in the loop test stand for flight software and hardware proofing. To calibrate the Op-Nav camera a dot grid is imaged with the camera, the error between the image dot location and the actual dot location can be used to build a distortion map of the camera and lens system so that images can be fixed to display truth locations. To build the dot grid images I used the Electro Optics Lab optical bench Bright Object Simulator System, and gimbal. The gimbal was slewed to a series of elevations and azimuths. An image of the collimated single point light source was then taken at each position. After a series of 99 images were taken at different locations the single light spots were extracted from each image and added to a composite image containing all 99 points. During the development of these grids it was noticed that an intermittent error in the artificial "star" locations occurred. Prior to the summer this error was attributed to the gimbal having glitches in it's pointing direction and was going to be replaced, however after further examining the issue I determined it to be a software issue. I have since narrowed the likely source of the error down to a Software Development Kit released by the camera supplier PixeLink. I have since developed a workaround in order to build star grids for calibration until the software bug can be isolated and fixed. I was also tasked with building a Hardware in the Loop test stand in order to test the full Op-Nav system. A 4k screen displays simulated Lunar and Terrestrial images from a possible Orion trajectory. These images are then projected through a collimator and then captured with an Op-Nav camera controlled by an Intel NUC computer running flight software. The flight software then analyzes the images to determine attitude and position, this data is then reconstructed into a trajectory and matched to the simulated trajectory in order to determine the accuracy of the attitude and position estimates. In order for the system to work it needs to be precisely and accurately aligned. I developed an alignment procedure that allows the screen, collimator and camera to be squared, centered and collinear with each other within a micron spatially and 5 arcseconds in rotation. I also designed a rigid mount for the screen that was machined on site in Building 10 by another intern. While I was working in the EOL we received a $500k Orion startracker for alignment procedure testing. Due to my prior experience in electronics development, as an ancillary duty, I was tasked with building the cables required to operate and power the startracker. If any errors are made building these cables the startracker would be destroyed, I was honored that the director of the lab entrusted such a critical component with me. This internship has cemented my view on public space exploration. I always preferred public sector to privatization because, as a scientist, the most interesting aspects of space for me are not necessarily the most profitable. I was concerned that the public sector was faltering however, and that in order to improve human space exploration I would be forced into private sector. I now know that, at least at JSC, human spaceflight is still progressing, and exciting work is still being done. I am now actively seeking employment at JSC after I complete my Ph.D and have met with my branch chiefs and mentor to discuss transitioning to a grad Co-op position.
Sustainable electrified aircraft propulsion (EAP) is likely to lead to an increase in the electrical wiring contained within a single aircraft. Since the electrical resistance and mass of copper (Cu) conductors are associated with power losses, it is desirable to design high-conductivity lightweight conductor materials, thus reducing the mass of components like motor windings, low-voltage signal cables, and transmission cables for data and power to improve the overall energy efficiency. This paper describes a unique framework for manufacturing metalized carbon nanotube (CNT) composite conductors, measuring their electrical conductivity and strength, and modeling the overall conductivity and current sharing within such composites. Tensile testing was conducted on the processed composite conductor cables with the use of acoustic emission and electrical resistivity to determine stress-dependent-failure mechanisms while monitoring the electrical conductivity. The average of measured electrical conductivities of annealed Cu/CNT samples from batch 5 was greater than theoretical predictions by 9.8 percent and was also greater than the conductivity of pure annealed Cu by 4.8 percent and had comparable ultimate tensile strengths. Additionally, those Cu/CNT samples provide a 13.5% weight saving over current state of the art copper wires. Theories explaining improved intrinsic conductivity are discussed.
As part of NASA's New Millennium Program, the Space Technology 5 mission will validate a variety of technologies for nano-satellite and constellation mission applications. Included are: a miniaturized and low power X-band transponder, a constellation communication and navigation transceiver, a cold gas micro-thruster, two different variable emittance (thermal) controllers, flex cables for solar array power collection, autonomous groundbased constellation management tools, and a new CMOS ultra low-power, radiation-tolerant, +0.5 volt logic technology. The ST-5 focus is on small and low-power. A single-processor, multi-function flight computer will implement direct digital and analog interfaces to all of the other spacecraft subsystems and components. There will not be a distributed data system that uses a standardized serial bus such as MIL-STD-1553 or MIL-STD-1773. The flight software running on the single processor will be responsible for all real-time processing associated with: guidance, navigation and control, command and data handling (C&DH) including uplink/downlink, power switching and battery charge management, science data analysis and storage, intra-constellation communications, and housekeeping data collection and logging. As a nanosatellite trail-blazer for future constellations of up to 100 separate space vehicles, ST-5 will demonstrate a compact (single board), low power (5.5 watts) solution to the data acquisition, control, communications, processing and storage requirements that have traditionally required an entire network of separate circuit boards and/or avionics boxes. In addition to the New Millennium technologies, other major spacecraft subsystems include the power system electronics, a lithium-ion battery, triple-junction solar cell arrays, a science-grade magnetometer, a miniature spinning sun sensor, and a propulsion system.
Power transmitted along fiber-optic cables. Transmitted as infrared light along fiber-optic cable, converted to electricity to supply small electronic circuit. Power source and circuit remains electrically isolated from each other for safety or reduces electromagnetic interference. Array of diodes made by standard integrated-circuit techniques and packaged for mounting at end of fiber-optic cable.
The power and communications module is a printed circuit board (PCB) that has the capability of providing power to an embedded processor and converting Ethernet packets into serial data to transfer to the processor. The purpose of the new design is to address the shortcomings of previous designs, including limited bandwidth and program memory, lack of control over packet processing, and lack of support for timing synchronization. The new design of the module creates a robust serial-to-Ethernet conversion that is powered using the existing Ethernet cable. This innovation has a small form factor that allows it to power processors and transducers with minimal space requirements.
Various approaches to the problem of generating, maintaining and distributing a coherent, reference phase signal over a large area are suggested, mathematically modeled and analyzed with respect to their ability to minimize: phase build-up, beam diffusion and beam steering phase jitter, cable length, and maximize power transfer efficiency. In addition, phase control configurations are suggested which alleviate the need for layout symmetry.
Power systems for undersea observatories are required to deliver high power with good reliability. For the proposed NEPTUNE observatory, the authors have developed a power scheme that combines ideas from terrestial power systems and switching power supplies with experience from undersea cable systems.
Concept for distribution of 60-Hz ac power in large building devoted to assembly and testing of equipment improves safety, reduces number of outlets and lengthy cables, and readily accommodates frequent changes in operations and configuration. Power from floor recess fed via unobtrusive cable to portable power management center. A cart containing variety of outlets and circuit breakers, wheeled to convenient location near equipment to be assembled or tested. Power distribution system presents larger range of operational configurations than fixed location. Meets tighter standards to feed computers and delicate instruments. Industrial-grade power suitable for power tools and other hardware. Three-phase and single-phase outlets available from each.
As part of the 2023 strategic analysis cycle to explore the trade space, the NASA Mars Architecture Team wanted to explore what it takes to produce in situ on Mars many hundreds of tons of propellants for a large all-chemical transportation system. The conceptual operations and design of the LO 2 /LCH 4 in situ resource utilization (ISRU) water acquisition, propellant production and liquification system was assigned to the NASA Compass concurrent engineering team with support from various NASA ISRU, cryogenic fluid management, and surface power experts. The conceptual point design examined one case producing 300 t of LO 2 /LCH 4 from the Mars atmosphere and delivered water in 20 months and storing the liquified propellants in a to-be-reused lander. Several of these large single-stage, all-chemical class large vertical landers would deliver the required ISRU equipment. The required 150 t of water stock for the ISRU system was traded between three options: delivered, pumped from subsurface ice deposits or extracted from surface soils. The large propellant production systems consist of atmospheric CO 2 collection scroll pumps, a combined solid oxide electrolysis and methanation system to convert the CO 2 and water into gaseous O 2 and CH 4 , and various dryers, scrubbers, and separators to remove the excess water, CO 2 and H 2 . The liquefaction system consisted of 90 K cryocoolers to provide cold Ne to the launch vehicle tanks to liquify these CH 4 and O 2 gases and store them as rocket propellants. The systems are deployed using a 6 t (payload) capable chassis derived from conceptual pressurized rover designs. In total, the propellant production and liquefaction systems required three propellant production pallets, two liquefaction pallets, two water tankers, and six 40 kW-fission surface power systems (FSPS) with cabling. All this equipment was found to notionally fit inside two- 75 metric ton payload capacity Mars ascent and landing vehicles (MALV). For the case where 150 t of water delivered from Earth, four cargo MALVs are required for the full system. The same is true when the 150 t of water is extracted through surface mining. For the borehole system, only 3 cargo MALVs are necessary. A comparison of approaches in terms of number of landers, number and type of elements, power and time is made.