Digital Wire Analyzer of Mechanical Tension, Electrical Continuity, and Isolation
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42 ENGINEERING↗
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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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In-Situ Wire Damage Detection System
An in-situ system for detecting damage in an electrically conductive wire. The system includes a substrate at least partially covered by a layer of electrically conductive material forming a continuous or non-continuous electrically conductive layer connected to an electrical signal generator adapted to delivering electrical signals to the electrically conductive layer. Data is received and processed to identify damage to the substrate or electrically conductive layer. The electrically conductive material may include metalized carbon fibers, a thin metal coating, a conductive polymer, carbon nanotubes, metal nanoparticles or a combination thereof.
Williams, Martha K.↗
Conductivity of a Copper-Carbon Covetic Composite
NASA is currently engaged in the development of highly electrically conductive wire for space and aviation power and propulsion applications. Higher levels of electrical conductivity and lower densities compared to copper and aluminum are needed to improve the efficiency of commercial aviation and space flight. Carbon, in various forms, is being considered as a component in composites to increase conductivity and decrease density in Cu and Al. One form of carbon that is currently receiving much interest is known as covectic. The technology currently known as covetics was first introduced by Shugart and Scherer whose patents claimed "Carbon can be incorporated into any of these metals by melting the metal, mixing the carbon into the molten metal and, while mixing, applying a current of sufficient amperage to the molten mixture such that the carbon becomes incorporated into the metal, thereby forming a single phase metal-carbon material." It is reported that in this process a conversion reaction occurs with the carbon forming covalent bonds with the host metal, and that covetic processing enables higher carbon solubility and improvements in properties. Although there is a growing body of work supporting covetic materials, it is still a very new and somewhat controversial field. Composition, density, and electrical conductivity measurements of a covetically processed alloy ingot of Cu and C, with a nominal composition of Cu-0.4wt.% C, were made. A pure Cu ingot was similarly processed for comparison. Sections of these ingots were worked into wire and tested. Only small amounts of C could be detected in the Cu-0.4wt.% C ingot, and trace amounts (0.006 wt.%) in the wire. All wires had densities very close to the full density of pure Cu, indicating a high level of Cu purity and low void fraction. Finally, the electrical conductivity of the Cu-0.4wt.% C wires were 9% lower than the samples similarly processed but without C additions. The wires made without C additions had conductivities approximately equal to pure Cu. The low conductivity of the Cu-0.4wt.% C material is believed to be due to: (1) a structure of interfaces in the wire created by collapsed voids lined with elemental C, (2) impurities, such as Fe in the Cu, which came from the added C, and (3) a small volume fraction of voids.
Degroh, Henry C.↗
Electrohydrodynamic Pool Boiling in Reduced Gravity
This research is concerned with studying the effects of applied electric fields on pool boiling in a reduced-gravity environment. Experiments are conducted at the NASA Lewis 2.2 sec Drop tower using a drop rig constructed at UC Davis. In the experiments, a platinum wire is heated while immersed in saturated liquid refrigerants (FC-72 and FC-87), or water, causing vapor formation at the wire surface. Electric fields are applied between the wire surface and an outer screen electrode that surrounds the wire. Preliminary normal-gravity experiments with water have demonstrated that applied electric fields generated by the rig electronics can influence boiling characteristics. Reduced-gravity experiments will be performed in the summer of 1996. The experiments will provide fundamental data on electric field strengths required to disrupt film boiling (for various wire heat generation input rates) in reduced gravity for a cylindrical geometry. The experiments should also shed light on the roles of characteristic bubble generation times and charge relaxation times in determining the effects of electric fields on pool boiling. Normal-gravity comparison experiments will also be performed.
Shaw, Benjamin D.↗
Third NASA Workshop on Wiring for Space Applications
This workshop addressed key technology issues in the field of electrical power wiring for space applications, and transferred information and technology related to space wiring for use in government and commercial applications. Speakers from space agencies, U.S. Federal labs, industry, and academia presented program overviews and discussed topics on arc tracking phenomena, advancements in insulation materials and constructions, and new wiring system topologies.
Hammoud, Ahmad↗
Pot-ability Assessment of Litz Wires for High Power Density Electric Motor
An alternative process technique, namely vacuum-assisted axial injection potting (VaAIP), has been developed to pot the Litz wires in the stator winding of high power density electric motors for the future electrified aircrafts. Initial trials of the process showed significant improvement in potting quality with less voids, thus potential improvement in thermal management of the motors. As an initial effort of pot-ability assessment, microstructures, 2-D and 3-D, of the Litz wires including dimensions and distribution of conductor filament, coating, and open spaces; packing patterns; shape/configuration changes of each bundles or the overall cross-sections per degree of twist were determined and quantified successfully. The microstructure analyses were performed not only for effective potting process development but also for more realistic electro-thermal modeling solutions. This paper will present results of the microstructure analyses, potentials of the VaAIP process from the trials, and future plans for scale-up and implementation of the process into a full-scale prototype stator winding.
Electrified aircraft↗
Using Electrostriction to Manipulate Ullage in Microgravity
A report proposes to use electrostriction to manipulate the ullage in a tank containing a dielectric liquid in a microgravitational environment. In the original intended application, the liquid would be a spacecraft propellant and the goal would be to force the ullage (comprising bubbles of noncondensible gas) to coalesce at one end of the tank, to enable use of one of the established means of (1) measuring the position of the gas/liquid interface and (2) inferring the quantity of liquid from the measurement. Electrically insulated wires would be installed in the tank, shaped and positioned so that application of a suitably high potential (e.g., 1 kV) between adjacent wires in successive pairs would give rise to a sufficient electric field gradient along the tank. The resulting electrostriction in the liquid would give rise to a pressure gradient that would force the ullage toward the low-electric-field-magnitude end of the tank. The feasibility of this proposal was demonstrated in an experiment in a tank containing liquid helium aboard an airplane flying a low-gravity arc. The ullage-segregating electrostrictive effect is expected to be considerably greater in other liquids.
Chui, Talso↗
Gratings Fabricated on Flat Surfaces and Reproduced on Non-Flat Substrates
A method has been developed for fabricating gratings on flat substrates, and then reproducing the groove pattern on a curved (concave or convex) substrate and a corresponding grating device. First, surface relief diffraction grating grooves are formed on flat substrates. For example, they may be fabricated using photolithography and reactive ion etching, maskless lithography, holography, or mechanical ruling. Then, an imprint of the grating is made on a deformable substrate, such as plastic, polymer, or other materials using thermoforming, hot or cold embossing, or other methods. Interim stamps using electroforming, or other methods, may be produced for the imprinting process or if the same polarity of the grating image is required. The imprinted, deformable substrate is then attached to a curved, rigid substrate using epoxy or other suitable adhesives. The imprinted surface is facing away from the curved rigid substrate. As an alternative fabrication method, after grating is imprinted on the deformable substrate as described above, the grating may be coated with thin conformal conductive layer (for example, using vacuum deposition of gold). Then the membrane may be mounted over an opening in a pressured vessel in a manner of a membrane on a drum, grating side out. The pressure inside of the vessel may be changed with respect to the ambient pressure to produce concave or convex membrane surface. The shape of the opening may control the type of the surface curvature (for example, a circular opening would create spherical surface, oval opening would create toroidal surface, etc.). After that, well-known electroforming methods may be used to create a replica of the grating on the concave or convex membrane. For example, the pressure vessel assembly may be submerged into an electro-forming solution and negative electric potential applied to the metal coated membrane using an insulated wire. Positive electric potential may be then applied to a nickel or other metal plate submerged into the same solution. Metal ions would transfer from the plate through the solution into the membrane, producing high fidelity metal replica of the grating on the membrane. In one variation, an adhesive may be deposited on the deformable substrate, and then cured without touching the rigid, curved substrate. Edges of the deformable substrate may be attached to the rigid substrate to ensure uniform deformation of the deformable substrate. The assembly may be performed in vacuum, and then taken out to atmospheric pressure conditions to ensure that no air is trapped between the deformable and rigid substrates. Alternatively, a rigid surface with complementary curvature to the rigid substrate may be used to ensure uniform adhesion of the deformable substrate to the rigid substrate. Liquid may be applied to the surface of the deformable substrate to uniformly distribute pressure across its surface during the curing or hardening of the adhesive, or the film may be pressed into the surface using a deformable object or surface. After the attachment is complete, the grooves may be coated with reflective or dielectric layers to improve diffraction efficiency.
Content, David↗
Depositing High-T(sub c) Superconductors On Normal-Conductor Wires
Experiments have demonstrated feasibility of depositing thin layers of high-T(sub c) superconductor on normally electrically conductive wires. Superconductivity evident at and below critical temperature (T{sub c}) of 71 K. OMCVD, organometallic vapor deposition, apparatus coats Ag wire with layer high-T(sub c) superconductor. Superconductive phase of this material formed subsequently by annealing under controlled conditions.
Kirlin, Peter S.↗
Voltages and currents induced on wiring
Aircraft lightning strikes were investigated in regard to their effects on voltages and currents in aircraft wiring. An electrical conductor's response to magnetic fields and electric fields was examined as part of the voltage and current calculations. The wiring system of the space shuttle was briefly considered as an example.
Franklin A Fisher↗
Verification of Small Hole Theory for Application to Wire Chaffing Resulting in Shield Faults
Our work is focused upon developing methods for wire chafe fault detection through the use of reflectometry to assess shield integrity. When shielded electrical aircraft wiring first begins to chafe typically the resulting evidence is small hole(s) in the shielding. We are focused upon developing algorithms and the signal processing necessary to first detect these small holes prior to incurring damage to the inner conductors. Our approach has been to develop a first principles physics model combined with probabilistic inference, and to verify this model with laboratory experiments as well as through simulation. Previously we have presented the electromagnetic small-hole theory and how it might be applied to coaxial cable. In this presentation, we present our efforts to verify this theoretical approach with high-fidelity electromagnetic simulations (COMSOL). Laboratory observations are used to parameterize the computationally efficient theoretical model with probabilistic inference resulting in quantification of hole size and location. Our efforts in characterizing faults in coaxial cable are subsequently leading to fault detection in shielded twisted pair as well as analysis of intermittent faulty connectors using similar techniques.
Schuet, Stefan R.↗
Evaluation of high temperature superconductive thermal bridges for space borne cryogenic detectors
Infrared sensor satellites are used to monitor the conditions in the earth's upper atmosphere. In these systems, the electronic links connecting the cryogenically cooled infrared detectors to the significantly warmer amplification electronics act as thermal bridges and, consequently, the mission lifetimes of the satellites are limited due to cryogenic evaporation. High-temperature superconductor (HTS) materials have been proposed by researchers at the National Aeronautics and Space Administration Langley's Research Center (NASA-LaRC) as an alternative to the currently used manganin wires for electrical connection. The potential for using HTS films as thermal bridges has provided the motivation for the design and the analysis of a spaceflight experiment to evaluate the performance of this superconductive technology in the space environment. The initial efforts were focused on the preliminary design of the experimental system which allows for the quantitative comparison of superconductive leads with manganin leads, and on the thermal conduction modeling of the proposed system. Most of the HTS materials were indicated to be potential replacements for the manganin wires. In the continuation of this multi-year research, the objectives of this study were to evaluate the sources of heat transfer on the thermal bridges that have been neglected in the preliminary conductive model and then to develop a methodology for the estimation of the thermal conductivities of the HTS thermal bridges in space. The Joule heating created by the electrical current through the manganin wires was incorporated as a volumetric heat source into the manganin conductive model. The radiative heat source on the HTS thermal bridges was determined by performing a separate radiant interchange analysis within a high-T(sub c) superconductor housing area. Both heat sources indicated no significant contribution on the cryogenic heat load, which validates the results obtained in the preliminary conduction model. A methodology was presented for the estimation of the thermal conductivities of the individual HTS thermal bridge materials and the effective thermal conductivities of the composite HTS thermal bridges as functions of temperature. This methodology included a sensitivity analysis and the demonstration of the estimation procedure using simulated data with added random errors. The thermal conductivities could not be estimated as functions of temperature; thus the effective thermal conductivities of the HTS thermal bridges were analyzed as constants.
Scott, Elaine P.↗
Mapping flowfields with a heated wire and an infrared imaging system
IR imaging system measurements of longitudinal temperature variations created in wakes, jet flows, etc. by an electrically heated wire can furnish indications of air velocity distributions through Nusselt number correlations. These correlations can either account for, or minimize and neglect, wire conduction and radiation effects under steady state conditions. The IR imaging system whose experimental use is presently evaluated employs an InSb detector sensitive to 3.5-5.6-micron IR emissions.
Gartenberg, Ehud↗
Easily-wired toggle switch
Crimp-type connectors reduce assembly and disassembly time. With design, no switch preparation is necessary and socket contracts are crimped to wires inserted in module attached to back of toggle switch engaging pins inside module to make electrical connections. Wires are easily removed with standard detachment tool. Design can accommodate wires of any gage and as many terminals can be placed on switch as wire gage and switch dimensions will allow.
Dean, W. T.↗
Empirical method for frequency compensation of the hot-wire anemometer
Explore the source record for details and available documents.
INSTRUMENTS - ANEMOMETERS↗
Space Shuttle Columbia Aging Wiring Failure Analysis
A Space Shuttle Columbia main engine controller 14 AWG wire short circuited during the launch of STS-93. Post-flight examination divulged that the wire had electrically arced against the head of a nearby bolt. More extensive inspection revealed additional damage to the subject wire, and to other wires as well from the mid-body of Columbia. The shorted wire was to have been constructed from nickel-plated copper conductors surrounded by the polyimide insulation Kapton, top-coated with an aromatic polyimide resin. The wires were analyzed via scanning electron microscope (SEM), energy dispersive X-Ray spectroscopy (EDX), and electron spectroscopy for chemical analysis (ESCA); differential scanning calorimetry (DSC) and thermal gravimetric analysis (TGA) were performed on the polyimide. Exemplar testing under laboratory conditions was performed to replicate the mechanical damage characteristics evident on the failed wires. The exemplar testing included a step test, where, as the name implies, a person stepped on a simulated wire bundle that rested upon a bolt head. Likewise, a shear test that forced a bolt head and a torque tip against a wire was performed to attempt to damage the insulation and conductor. Additionally, a vibration test was performed to determine if a wire bundle would abrade when vibrated against the head of a bolt. Also, an abrasion test was undertaken to determine if the polyimide of the wire could be damaged by rubbing against convolex helical tubing. Finally, an impact test was performed to ascertain if the use of the tubing would protect the wire from the strike of a foreign object.
McDaniels, Steven J.↗
Assessment of the Electrical Substation-Grid Testbed with Inside/Outside Devices and Distributed Ledger Technology
The electrical substation-grid testbed was created to integrate the GOOSE and/or DNP (Distributed Network Protocol) messages with time synchronized sources and Distributed Ledger Technology (DLT). The objective was to study the impact of faults and cyber-events at an electrical substation with inside (protective relays) and outside (power meters) substation devices. The electrical substation-grid testbed was based on the design of a 34.5/ 12.47 kV electrical substation (sectionalized bus configuration) with two power transformers, connected to radial power lines and load feeders. The electrical substation-grid testbed was installed at 252 lab space (Advanced Power System Protection), Grid Research Integration and Deployment Center (GRID-C), Oak Ridge National Laboratory. This testbed was created for Task 5, DarkNet project. The electrical substation-grid testbed was created to simulate fault and/or cyber events that could potentially result in damage to the electrical infrastructure. In addition, tests were run that are usually not allowed to be performed in an operational electrical power grid, because these test scenarios could trip breakers and/or generate fault situations that could potentially damage equipment. The number of tests performed in the electrical substation-grid testbed were executed in a better way than in a real electrical substation and/or power grid, because multiple tests could be run in a short period of time, and complex permits, and safety/ schedule restrictions like in a real electrical substation environment were not needed. The electrical substation-grid testbed was created using real measurement, communication, and protection devices that are used by electrical utilities, to have same conditions that we could observe in a real power grid or electrical substation. The electrical substation-grid testbed was based on using a real time simulator and expansion box with amplifiers that were wired to electrical substation-grid devices. This hardware-in-the-loop (HIL) was provided by protective relays, power meters, ethernet switches, remote terminal units, synchronized timing network clock, DLT devices, workstations, and servers. This report includes the design, installation, and assessment of the electrical substation-grid testbed that was similar to an operational electrical substation, integrating the power system protection, communication, and control systems. The results for the electrical substation-grid testbed were based on:• verifying the analog signals for protective relays and power meters, • observing the synchronized time source frame at devices, • authenticating the GOOSE (IEC 61850) and DNP messages from power meters and protective relays, and • verifying the trip conditions of protective relays at fault tests with the power system fault event detection, using DLT devices. For future work, the electrical substation-grid testbed with protective relays and power meters, using DLT and synchronized time source from DarkNet, will be used to study the impact of cyber-events at inside and outside substation devices. Advanced algorithms for detecting cyber-events produced by non-desired protective relay settings will be studied, to improve the detection and reliability of protection, control, and communication systems at power grids.
24 POWER TRANSMISSION AND DISTRIBUTION↗
Space Station Freedom secondary power wiring requirements
Secondary power is produced by DDCU's (direct current to direct current converter units) and routed to and through secondary power distribution assemblies (SPDA's) to loads or tertiary distribution assemblies. This presentation outlines requirements of Space Station Freedom (SSF) EEE (electrical, electronic, and electromechanical) parts wire and the approved electrical wire and cable. The SSF PDRD (Program Definition and Requirements Document) language problems and resolution are reviewed. The cable routing to and from the SPDA's is presented as diagrams and the wire recommendations and characteristics are given.
Sawyer, C. R.↗