Engineering topics
Publications and source records attributed to Scott, W. R..
Components passed stringent qualification tests tabulated and described. Destructive and nondestructive qualification testing confirmed parts capable of withstanding spacecraft environments without excessive degradation and have stable characteristics during operating lives. Testing assessed effects of electrical, environmental, and mechanical stresses in various levels and time durations.
Deep-discharge reconditioning (DDR) can be of great benefit to battery performance, especially in geosynchronous orbit, if performed properly and regularly, and can be essential to operation of batteries at the high depths of discharge (DOD) required to minimize weight. The procedure should be tailored to fit the nature of the degradation occuring during regular cycling. DDR is not without its drawbacks, however, and these differ depending on the normal DOD to be sustained and/or whether the discharge is done at the battery or the cell level. Battery-level discharge carries the minimum weight penalty but raises questions of the effects of low-rate cell reversal that as yet have no firm answers. Cell level discharge avoids cell reversal but carries significant penalties of weight and complexity. Thus no universal procedure or method of implementation of deep-discharge reconditioning is now available and thus the various approaches must be evaluated for each application.
The JPL Preferred Parts List was prepared to provide a basis for selection of electronic parts for JPL spacecraft programs. Supporting tests for the listed parts were designed to comply with specific spacecraft environmental requirements. The list tabulates the electronic, magnetic, and electromechanical parts applicable to all JPL electronic equipment wherein reliability is a major concern. The parts listed are revelant to equipment supplied by subcontractors as well as fabricated at the laboratory.
The plate stocks of nickel cadmium batteries were disassembled to locate shorts. Through testing, the cause of the shorts was discovered to be a growth of cadmium coming through the separator.
The data collected from the results of battery reconditioning accumulated from three different spacecraft programs are summarized. The basic design characteristics of the programs are also presented.
The design, procurement, testing, and application of aerospace quality, hermetically sealed nickel-cadmium cells and batteries are presented. Cell technology, cell and battery development, and spacecraft applications are emphasized. Long term performance is discussed in terms of the effect of initial design, process, and application variables. Design guidelines and practices are given.
Ordinary Rayleigh-Schroudinger perturbation theory with Moller-Plesset (RSMP) partitioning is used to calculate second- and third-order correlation corrections to the CHF polarizability and dipole moment of the water molecule by a finite-field procedure. Pade approximants are found to be useful in accelerating the convergence of the property perturbation expansions. Field-induced polarization functions suitable for polarizability calculations are determined. The average polarizability calculated, neglecting vibrational averaging, with Dunning's (9s5p/4s-4s2p/2s) contracted GTO basis set augmented by field-induced lslp2d/lp polarization functions is within 3 per cent of the experimental result. Correlation corrections to the dipole moment and polarizability of the water molecule calculated by the finite-field RSMP and single + double excitation CI(SDCI) methods for the same basis set are found to be in close agreement. The RSMP approach has the advantages of being size-consistent and of being capable of greater efficiency than the SCDI method. Comparative calculations carried out using Epstein-Nesbet partitioning show that through third order RSEN correlation perturbation expansions for the dipole moment and polarizability are less rapidly convergent than RSMP expansions. However, reasonable accord with RSMP results can be achieved by using Pade approximants to accelerate the convergence of RSEN energy perturbation expansions. The convergence of RSMP property correlation expansions based on the zeroth-order uncoupled-Hartree-Fock (UCHF) and coupled-Hartree-Fock (CHF) approximations are compared through third order. Whereas the CHF + RSMP expansions are for practical purposes fully converged, the UCHF + RSMP expansions are not adequately converged.
Workshop sessions and papers were devoted to various aspects of microprocessor and large scale integrated circuit technology. Presentations were made on advanced LSI developments for high reliability military and NASA applications. Microprocessor testing techniques were discussed, and test data were presented. High reliability procurement specifications were also discussed.
The long-term effects of storing batteries over a period of years prior to their use in a synchronous orbit application are discussed. A previous experiment is discussed where life testing was performed on cells after having stored the battery for a period of three years with the cell shorted and at a temperature on the order of 5-10 C. The test consisted of performing a sequence of 10 simulated eclipse seasons (equivalent in cycling of five years in synchronous orbit). Results of this test indicated very little degradation and change in the physical and chemical conditions of the cell. The program was extended for an additional year (battery was stored for four years) under the same conditions and testing. The results of the four year storage (one exception) indicate that no further change occurred that is significant from the three year test.
Nylon separator degradation was examined as a function of temperature. Electrochemically active uncharged excess negative (overcharge protection)was measured by charging a cell venting it until it became fully charged, and continuing to overcharge the vent gas. The gas was analyzed as a function of time. The amount of hydrogen evolved was examined, and the cell voltage was observed as the oxygen and/or hydrogen evolved from the cell.
Methods for testing nickel-cadmium cells for internal shorts and charge retention were studied. Included were (a) open circuit voltage decay after a brief charge, (b) open circuit voltage recovery after shorting, and (c) open circuit voltage decay and capacity loss after a full charge. The investigation included consideration of the effects of prior history, of conditioning cells prior to testing, and of various test method variables on the results of the tests. Sensitivity of the tests was calibrated in terms of equivalent external resistance. The results were correlated. It was shown that a large number of variables may affect the results of these tests. It is concluded that the voltage decay after a brief charge and the voltage recovery methods are more sensitive than the charged stand method, and can detect an internal short equivalent to a resistance of about (10,000/C)ohms where "C' is the numerical value of the capacity of the cell in ampere hours.
Ten classes of parts covered in report: capacitors, crystals, diodes, fuses, inductors, microcircuits, relays, fixed resistors, transformers, and transistors. Each class is contained in separate section and includes discussion of inherent failure modes, screening rationale, general screening requirements, derating criteria, and stress-analysis data.
The relative merits of coining and not coining of sintered nickel oxide and cadmium plates was investigated. Sample plate materials from most commercial cell suppliers were obtained and characterized for properties that may correlate with the tendency toward physical disintegration during handling and over long periods of time in the cell. Special test methods were developed to obtain comparative data in a short time. A wide range of physical properties and coining thickness was observed, resulting in a range of responses. The stronger materials resisted loss of sinter better than weaker materials whether or not coined. Coining improved handling and resistance to electrochemical cycling of weaker materials. The mechanism of break-down of positive plate edges under cycling appears to be the same as that of thickening and blistering. Brittle, nonadherent sinter, resulting from certain impregnation processes, is the most vulnerable to degradation. It is concluded that the latter type of materials should be coined, but coining of strong materials is optional.
The relative merits of coining and not coining of sintered nickel-oxide and cadmium plates was investigated. A survey of the industry including cell manufactures and users was made and results summarized. Sample plate materials from most commercial cell suppliers were obtained and characterized for properties that may correlate with the tendency toward physical disintegration during handling and over long periods of time in the cell. Special test methods were developed to obtain comparative data in a short time. A wide range of physical properties and coining thicknesses was observed, resulting in a range of responses. The stronger, less brittle materials resisted loss of sinter better than weaker materials whether or not coined. Coining improved handling and resistance to electrochemical cycling in all materials tested. An apparent exception was found to be due to improper coining of a tapered edge.
Manufacturing methods, cost estimates, advantages, and limitations of various types of hermetic seals for secondary alkaline spacecraft cells
No abstract available