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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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Contactless Coupling For Power And Data

Experimental flat-plate coupling transmits digital data signals and electrical power across small gap between two modules. Split transformer and optoelectronic components transmit electrical power and digital signals across small gap. Coupling concept useful substitute for electrical connectors in equipment assembled by robots, remote manipulators, or humans working in protective clothing or otherwise restricted in dexterity. Offers higher reliability due to one overall alignment mechanism as opposed to multiple pin/socket alignment requirements.

Moody, John C.↗

Microwave Comb Generator

Stable reference tones aid testing and calibration of microwave receivers. Signal generator puts out stable tones in frequency range of 2 to 10 GHz at all multiples of reference input frequency, at any frequency up to 1 MHz. Called "comb generator" because spectral plot resembles comb. DC reverse-bias current switched on and off at 1 MHz to generate sharp pulses in step-recovery diode. Microwave components mounted on back of special connector containing built-in attenuator. Used in testing microwave and spread-spectrum wide-band receivers.

Sigman, E. H.↗

Spline screw multiple rotations mechanism

A system for coupling two bodies together and for transmitting torque from one body to another with mechanical timing and sequencing is reported. The mechanical timing and sequencing is handled so that the following criteria are met: (1) the bodies are handled in a safe manner and nothing floats loose in space, (2) electrical connectors are engaged as long as possible so that the internal processes can be monitored throughout by sensors, and (3) electrical and mechanical power and signals are coupled. The first body has a splined driver for providing the input torque. The second body has a threaded drive member capable of rotation and limited translation. The embedded drive member will mate with and fasten to the splined driver. The second body has an embedded bevel gear member capable of rotation and limited translation. This bevel gear member is coaxial with the threaded drive member. A compression spring provides a preload on the rotating threaded member, and a thrust bearing is used for limiting the translation of the bevel gear member so that when the bevel gear member reaches the upward limit of its translation the two bodies are fully coupled and the bevel gear member then rotates due to the input torque transmitted from the splined driver through the threaded drive member to the bevel gear member. An output bevel gear with an attached output drive shaft is embedded in the second body and meshes with the threaded rotating bevel gear member to transmit the input torque to the output drive shaft.

Vranish, John M.↗

Photon Counting Using Edge-Detection Algorithm

New applications such as high-datarate, photon-starved, free-space optical communications require photon counting at flux rates into gigaphoton-per-second regimes coupled with subnanosecond timing accuracy. Current single-photon detectors that are capable of handling such operating conditions are designed in an array format and produce output pulses that span multiple sample times. In order to discern one pulse from another and not to overcount the number of incoming photons, a detection algorithm must be applied to the sampled detector output pulses. As flux rates increase, the ability to implement such a detection algorithm becomes difficult within a digital processor that may reside within a field-programmable gate array (FPGA). Systems have been developed and implemented to both characterize gigahertz bandwidth single-photon detectors, as well as process photon count signals at rates into gigaphotons per second in order to implement communications links at SCPPM (serial concatenated pulse position modulation) encoded data rates exceeding 100 megabits per second with efficiencies greater than two bits per detected photon. A hardware edge-detection algorithm and corresponding signal combining and deserialization hardware were developed to meet these requirements at sample rates up to 10 GHz. The photon discriminator deserializer hardware board accepts four inputs, which allows for the ability to take inputs from a quadphoton counting detector, to support requirements for optical tracking with a reduced number of hardware components. The four inputs are hardware leading-edge detected independently. After leading-edge detection, the resultant samples are ORed together prior to deserialization. The deserialization is performed to reduce the rate at which data is passed to a digital signal processor, perhaps residing within an FPGA. The hardware implements four separate analog inputs that are connected through RF connectors. Each analog input is fed to a high-speed 1-bit comparator, which digitizes the input referenced to an adjustable threshold value. This results in four independent serial sample streams of binary 1s and 0s, which are ORed together at rates up to 10 GHz. This single serial stream is then deserialized by a factor of 16 to create 16 signal lines at a rate of 622.5 MHz or lower for input to a high-speed digital processor assembly. The new design and corresponding hardware can be employed with a quad-photon counting detector capable of handling photon rates on the order of multi-gigaphotons per second, whereas prior art was only capable of handling a single input at 1/4 the flux rate. Additionally, the hardware edge-detection algorithm has provided the ability to process 3-10 higher photon flux rates than previously possible by removing the limitation that photoncounting detector output pulses on multiple channels being ORed not overlap. Now, only the leading edges of the pulses are required to not overlap. This new photon counting digitizer hardware architecture supports a universal front end for an optical communications receiver operating at data rates from kilobits to over one gigabit per second to meet increased mission data volume requirements.

Gin, Jonathan W.↗

Spacewire on Earth orbiting scatterometers

The need for a high speed, reliable and easy to implement communication link has led to the development of a space flight oriented version of IEEE 1355 called SpaceWire. SpaceWire is based on high-speed (200 Mbps) serial point-to-point links using Low Voltage Differential Signaling (LVDS). SpaceWIre has provisions for routing messages between a large network of processors, using wormhole routing for low overhead and latency. {additionally, there are available space qualified hybrids, which provide the Link layer to the user's bus}. A test bed of multiple digital signal processor breadboards, demonstrating the ability to meet signal processing requirements for an orbiting scatterometer has been implemented using three Astrium MCM-DSPs, each breadboard consists of a Multi Chip Module (MCM) that combines a space qualified Digital Signal Processor and peripherals, including IEEE-1355 links. With the addition of appropriate physical layer interfaces and software on the DSP, the SpaceWire link is used to communicate between processors on the test bed, e.g. sending timing references, commands, status, and science data among the processors. Results are presented on development issues surrounding the use of SpaceWire in this environment, from physical layer implementation (cables, connectors, LVDS drivers) to diagnostic tools, driver firmware, and development methodology. The tools, methods, and hardware, software challenges and preliminary performance are investigated and discussed.

serial↗

Design of object-oriented distributed simulation classes

Distributed simulation of aircraft engines as part of a computer aided design package is being developed by NASA Lewis Research Center for the aircraft industry. The project is called NPSS, an acronym for 'Numerical Propulsion Simulation System'. NPSS is a flexible object-oriented simulation of aircraft engines requiring high computing speed. It is desirable to run the simulation on a distributed computer system with multiple processors executing portions of the simulation in parallel. The purpose of this research was to investigate object-oriented structures such that individual objects could be distributed. The set of classes used in the simulation must be designed to facilitate parallel computation. Since the portions of the simulation carried out in parallel are not independent of one another, there is the need for communication among the parallel executing processors which in turn implies need for their synchronization. Communication and synchronization can lead to decreased throughput as parallel processors wait for data or synchronization signals from other processors. As a result of this research, the following have been accomplished. The design and implementation of a set of simulation classes which result in a distributed simulation control program have been completed. The design is based upon MIT 'Actor' model of a concurrent object and uses 'connectors' to structure dynamic connections between simulation components. Connectors may be dynamically created according to the distribution of objects among machines at execution time without any programming changes. Measurements of the basic performance have been carried out with the result that communication overhead of the distributed design is swamped by the computation time of modules unless modules have very short execution times per iteration or time step. An analytical performance model based upon queuing network theory has been designed and implemented. Its application to realistic configurations has not been carried out.

Schoeffler, James D.↗

Design of Object-Oriented Distributed Simulation Classes

Distributed simulation of aircraft engines as part of a computer aided design package being developed by NASA Lewis Research Center for the aircraft industry. The project is called NPSS, an acronym for "Numerical Propulsion Simulation System". NPSS is a flexible object-oriented simulation of aircraft engines requiring high computing speed. It is desirable to run the simulation on a distributed computer system with multiple processors executing portions of the simulation in parallel. The purpose of this research was to investigate object-oriented structures such that individual objects could be distributed. The set of classes used in the simulation must be designed to facilitate parallel computation. Since the portions of the simulation carried out in parallel are not independent of one another, there is the need for communication among the parallel executing processors which in turn implies need for their synchronization. Communication and synchronization can lead to decreased throughput as parallel processors wait for data or synchronization signals from other processors. As a result of this research, the following have been accomplished. The design and implementation of a set of simulation classes which result in a distributed simulation control program have been completed. The design is based upon MIT "Actor" model of a concurrent object and uses "connectors" to structure dynamic connections between simulation components. Connectors may be dynamically created according to the distribution of objects among machines at execution time without any programming changes. Measurements of the basic performance have been carried out with the result that communication overhead of the distributed design is swamped by the computation time of modules unless modules have very short execution times per iteration or time step. An analytical performance model based upon queuing network theory has been designed and implemented. Its application to realistic configurations has not been carried out.

Schoeffler, James D.↗

Alternative Setup for Long-Duration Low-Duty-Cycle 600°C Ambient Testing of SiC Integrated Circuits

A scalable, compact oven testbed system for simultaneously evaluating a multitude of high temperature integrated circuits (ICs) for prolonged operating times of up to 600 °C has been prototyped. The new testbed system enables long-duration high temperature testing in sufficient statistical quantities consistent with standard aerospace electronics engineering standards. This setup is comprised of multiple compact ovens housing chips or packages mounted to ceramic circuit boards. Each oven is a compact 15.2 cm length by 15.2 cm width by 12.7 cm depth with a maximum 400 Watts of heating power. The custom-made silicon oxide ceramic heating block inside each oven is based on a 3D printed design adapted for the easy insertion of the IC device under test (DUT). This innovative design provides the quick insertion of ICs with or without a ceramic package into a 600 °C environment by utilizing a movable 11.43 cm long ceramic substrate with electrical traces extending from the oven hot zone to external standard plastic-based board connectors. Another key oven design feature is the minimization of the DUT exposure to electromagnetic interference (EMI) by utilizing a filtered DC power source to reduce heating element noise. Additionally, the ovens can be configured in a parallel arrangement allowing global data monitoring over a single industrial RS422 serial port. This feature is important for scaling up to test multiple ICs semi-simultaneously. A USB serial port is provided to independently control the operating parameters of each oven such as the oven target temperature and oven ramp rate. The oven temperature can reach up to 600 °C with a confirmed +/- 4 °C maximum deviation across the test zone region. The ramp rate can be programmed from 1 °C/minute up to 10 °C/minute. Furthermore, a programmable switchboard is used to interface with the DUT. This switchboard comprises a National Instruments Peripheral Component Interconnect eXtension for Instrumentation (NI PXI) system and a breakout board to send and receive power, analog or digital test signals. By using this unique oven testbed system, a variety of ICs can now be tested in parallel using the same test components configured for a diverse set of requirements.

DC Powered Oven↗

Cable Tester Box

Cables are very important electrical devices that carry power and signals across multiple instruments. Any fault in a cable can easily result in a catastrophic outcome. Therefore, verifying that all cables are built to spec is a very important part of Electrical Integration Procedures. Currently, there are two methods used in lab for verifying cable connectivity. (1) Using a Break-Out Box and an ohmmeter this method is time-consuming but effective for custom cables and (2) Commercial Automated Cable Tester Boxes this method is fast, but to test custom cables often requires pre-programmed configuration files, and cables used on spacecraft are often uniquely designed for specific purposes. The idea is to develop a semi-automatic continuity tester that reduces human effort in cable testing, speeds up the electrical integration process, and ensures system safety. The JPL-Cable Tester Box is developed to check every single possible electrical connection in a cable in parallel. This system indicates connectivity through LED (light emitting diode) circuits. Users can choose to test any pin/shell (test node) with a single push of a button, and any other nodes that are shorted to the test node, even if they are in the same connector, will light up with the test node. The JPL-Cable Tester Boxes offers the following advantages: 1. Easy to use: The architecture is simple enough that it only takes 5 minutes for anyone to learn how operate the Cable Tester Box. No pre-programming and calibration are required, since this box only checks continuity. 2. Fast: The cable tester box checks all the possible electrical connections in parallel at a push of a button. If a cable normally takes half an hour to test, using the Cable Tester Box will improve the speed to as little as 60 seconds to complete. 3. Versatile: Multiple cable tester boxes can be used together. As long as all the boxes share the same electrical potential, any number of connectors can be tested together.

Lee, Jason H.↗

The Wizard Staff: A Mobile Tool Supporting Human Exploration on The Lunar Surface

The Wizard Staff is a rechargeable, battery powered mobile tool with multiple uses for lunar surface exploration. It supports human activity as a surface survey tool, provides external illumination to enhance safety, delivers networking, communications, and navigation features to remote sites, and assists crew rescue with an emergency beacon and rigid splint structure. As a survey tool, it assists crewed geologic field site exploration with external lights, cameras, and LiDAR to illuminate, map, and record the sample collection process. As a relay station, it provides a surface intranet communications and navigation node for extended exploration far from the lander or habitation module. A separately developed Search-and-Rescue (SAR) handheld device can broadcast a signal to the Gandalf Staff containing crew position and biometric data. The staff then formats the message and sends it orbiting satellite(s) for emergency response via the LunaNET on a dedicated frequency similar to terrestrial applications using an Emergency Position-Indicating Radiobeacon (EPIRB). The staff is designed with an upper and lower segment. Components in the upper segment are the LiDAR, external lighting arrays, cameras, communications equipment, intelligence devices, and user interface for crew operations. The lower segment is a set of FeLiPO4 battery cells packed into the 2” diameter carbon fiber tube. When the battery pack is discharged, a spring connector (designed for the dusty lunar environment) easily disconnects the two segments for replacement with another fully charged battery pack. The lower segment can be used for Incapacitated Crew Rescue (ICR) as a rigid splint. As a stand-alone science platform, the Wizard Staff provides infrastructure for instruments and sensors to record the lunar environment over long periods of time. After a crew installs the components on the lunar surface, the platform delivers data to the lunar lander or base station for analysis. The stand-alone mode requires an auxiliary power source (e.g. solar array) and energy storage system (e.g. battery), so it could also be used as an electrical recharging station. A working prototype of Wizard Staff has been developed with collaboration between NASA (JSC, MSFC, and GSFC), Texas Space Technology Applications and Research (T STAR), and Texas A&M University (TAMU) using $300k of innovation funding in FY’21 and FY’22. The functional staff weights 36# on Earth (6# on the Moon), stands 2.1m tall and delivers external lighting with an array of 40 LED bulbs generating 1460 Lux at 2m range (near field), or 2 Lux at 50m (far field).

Gandalf Staff↗

SiC Multi-Chip Power Modules as Power-System Building Blocks

The term "SiC MCPMs" (wherein "MCPM" signifies "multi-chip power module") denotes electronic power-supply modules containing multiple silicon carbide power devices and silicon-on-insulator (SOI) control integrated-circuit chips. SiC MCPMs are being developed as building blocks of advanced expandable, reconfigurable, fault-tolerant power-supply systems. Exploiting the ability of SiC semiconductor devices to operate at temperatures, breakdown voltages, and current densities significantly greater than those of conventional Si devices, the designs of SiC MCPMs and of systems comprising multiple SiC MCPMs are expected to afford a greater degree of miniaturization through stacking of modules with reduced requirements for heat sinking. Moreover, the higher-temperature capabilities of SiC MCPMs could enable operation in environments hotter than Si-based power systems can withstand. The stacked SiC MCPMs in a given system can be electrically connected in series, parallel, or a series/parallel combination to increase the overall power-handling capability of the system. In addition to power connections, the modules have communication connections. The SOI controllers in the modules communicate with each other as nodes of a decentralized control network, in which no single controller exerts overall command of the system. Control functions effected via the network include synchronization of switching of power devices and rapid reconfiguration of power connections to enable the power system to continue to supply power to a load in the event of failure of one of the modules. In addition to serving as building blocks of reliable power-supply systems, SiC MCPMs could be augmented with external control circuitry to make them perform additional power-handling functions as needed for specific applications: typical functions could include regulating voltages, storing energy, and driving motors. Because identical SiC MCPM building blocks could be utilized in a variety of ways, the cost and difficulty of designing new, highly reliable power systems would be reduced considerably. Several prototype DC-to-DC power-converter modules containing SiC power-switching devices were designed and built to demonstrate the feasibility of the SiC MCPM concept. In anticipation of a future need for operation at high temperature, the circuitry in the modules includes high-temperature inductors and capacitors. These modules were designed to be stacked to construct a system of four modules electrically connected in series and/or parallel. The packaging of the modules is designed to satisfy requirements for series and parallel interconnection among modules, high power density, high thermal efficiency, small size, and light weight. Each module includes four output power connectors two for serial and two for parallel output power connections among the modules. Each module also includes two signal connectors, electrically isolated from the power connectors, that afford four zones for signal interconnections among the SOI controllers. Finally, each module includes two input power connectors, through which it receives power from an in-line power bus. This design feature is included in anticipation of a custom-designed power bus incorporating sockets compatible with snap-on type connectors to enable rapid replacement of failed modules.

Lostetter, Alexander↗