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NASA NTRS2017

Transparent Conductive Ink for Additive Manufacturing

NASA analyzes, tests, packages, and fabricates electrical, electronic, and electromechanical (EEE) parts. Nanotechnology is listed in NASA's Technology Roadmap as a key area to invest for further development.1 This research project focused on using nanotechnology to improve electroluminescent lighting in terms of additive manufacturing and to increase energy efficiency. Specifically, this project's goal was to produce a conductive but transparent printable ink that can be sprayed on any surface for use as one of the electrodes in electroluminescent device design. This innovative work is known as thick film dielectric electroluminescent (TDEL) technology. TDEL devices are used for "backlighting, illumination, and identification due to their tunable color output, scalability, and efficiency" (I.K. Small, T.D. Rolin, and A.D. Shields, "3D Printed Electroluminescent Light Panels," NASA Fiscal Year 2017 Center Innovation Fund Proposal, unpublished data, 2017). These devices use a 'front-to-back' printing method, where the substrate is the transparent layer, and the dielectric and phosphor are layered on top. This project is a first step in the process of creating a 3D printable 'back-to-front' electroluminescent device. Back-to-front 3D-printed devices are beneficial because they can be printed onto different substrates and embedded in different surfaces, and the substrate is not required to be transparent, all because the light is emitted from the top surface through the transparent conductor. Advances in this area will help further development of printing TDEL devices on an array of different surfaces. Figure 1 demonstrates the layering of the two electrodes that are aligned in a parallel plate capacitor structure (I.K. Small, T.D. Rolin, and A.D. Shields, "3D Printed Electroluminescent Light Panels," NASA Fiscal Year 2017 Center Innovation Fund Proposal, unpublished data, 2017). Voltage is applied across the device, and the subsequent electron excitation results in light emission at the top layer.

Patlan, X. J.↗

NASA NTRS1990

Reliability and quality EEE parts issues

NASA policy and procedures are established which govern the selection, testing, and application of electrical, electronic, and electromechanical (EEE) parts. Recent advances in the state-of-the-art of electronic parts and associated technologies can significantly impact the electronic designs and reliability of NASA space transportation avionics. Significant issues that result from these advances are examined, including: recent advances in microelectronics technology (as applied to or considered for use in NASA projects); electron packaging technology advances (concurrent with, and as a result of, the development of the advanced microelectronic devices); availability of parts used in space avionics; and standardization and integration of parts activities between projects, centers, and contractors.

Barney, Dan↗

NASA NTRS1991

Kate's Model Verification Tools

Kennedy Space Center's Knowledge-based Autonomous Test Engineer (KATE) is capable of monitoring electromechanical systems, diagnosing their errors, and even repairing them when they crash. A survey of KATE's developer/modelers revealed that they were already using a sophisticated set of productivity enhancing tools. They did request five more, however, and those make up the body of the information presented here: (1) a transfer function code fitter; (2) a FORTRAN-Lisp translator; (3) three existing structural consistency checkers to aid in syntax checking their modeled device frames; (4) an automated procedure for calibrating knowledge base admittances to protect KATE's hardware mockups from inadvertent hand valve twiddling; and (5) three alternatives for the 'pseudo object', a programming patch that currently apprises KATE's modeling devices of their operational environments.

Morgan, Steve↗

NASA NTRS2015

Solid State Ultracapacitor

NASA analyzes, tests, packages, and fabricates electrical, electronic, and electromechanical (EEE) parts used in space vehicles. One area that NASA wishes to advance is energy storage and delivery. Currently, space vehicles use rechargeable batteries that utilize silver zinc or lithium ion electrochemical processes. These current state-of-the-art rechargeable batteries cannot be rapidly charged, contain harmful chemicals, and suffer from early wear-out mechanisms. A solid state ultracapacitor is an EEE part that offers significant advantages over current electrochemical and electrolytic devices. The objective of this research is to develop an internal barrier layer ultracapacitor (IBLC) using novel dielectric materials as a battery replacement with a focus on these advantages: longer life, lower mass-toweight ratio, rapid charging, on-demand pulse power, improved on-pad standby time without maintenance, and environmental friendliness. The approach is unique in two areas. A deposition technique is used that has been shown to produce a more uniformly coated nanoparticle than sol-gel, which has resulted in colossal permittivities. These particles are then distributed in an ink formulation developed at NASA Marshall Space Flight Center (MSFC) and deposited utilizing a 3D aerosol jet technique. This additive manufacturing technique controls layer thickness, resulting in extremely large capacitance and energy density.

Rolin, Terry D.↗

NASA NTRS2001

Simulation of MEMS for the Next Generation Space Telescope

The NASA Goddard Space Flight Center (GSFC) is developing optical micro-electromechanical system (MEMS) components for potential application in Next Generation Space Telescope (NGST) science instruments. In this work, we present an overview of the electro-mechanical simulation of three MEMS components for NGST, which include a reflective micro-mirror array and transmissive microshutter array for aperture control for a near infrared (NIR) multi-object spectrometer and a large aperture MEMS Fabry-Perot tunable filter for a NIR wide field camera. In all cases the device must operate at cryogenic temperatures with low power consumption and low, complementary metal oxide semiconductor (CMOS) compatible, voltages. The goal of our simulation efforts is to adequately predict both the performance and the reliability of the devices during ground handling, launch, and operation to prevent failures late in the development process and during flight. This goal requires detailed modeling and validation of complex electro-thermal-mechanical interactions and very large non-linear deformations, often involving surface contact. Various parameters such as spatial dimensions and device response are often difficult to measure reliably at these small scales. In addition, these devices are fabricated from a wide variety of materials including surface micro-machined aluminum, reactive ion etched (RIE) silicon nitride, and deep reactive ion etched (DRIE) bulk single crystal silicon. The above broad set of conditions combine to be a formidable challenge for space flight qualification analysis. These simulations represent NASA/GSFC's first attempts at implementing a comprehensive strategy to address complex MEMS structures.

Mott, Brent↗

NASA NTRS2001

Science Autonomy in Robotic Exploration

Historical mission operations have involved: (1) return of scientific data; (2) evaluation of these data by scientists; (3) recommendations for future mission activity by scientists; (4) commands for these transmitted to the craft; and (5) the activity being undertaken. This cycle is repeated throughout the mission with command opportunities once or twice per day. For a rover, this historical cycle is not amenable to rapid long range traverses or rapid response to any novel or unexpected situations. In addition to real-time response issues, imaging and/or spectroscopic devices can produce tremendous data volumes during a traverse. However, such data volumes can rapidly exceed on-board memory capabilities prior to the ability to transmit it to Earth. Additionally, the necessary communication band-widths are restrictive enough so that only a small portion of these data can actually be returned to Earth. Such scenarios suggest enabling some science decisions to be made on-board the robots. These decisions involve automating various aspects of scientific discovery instead of the electromechanical control, health, and navigation issues associated with robotic operations. The robot retains access to the full data fidelity obtained by its scientific sensors, and is in the best position to implement actions based upon these data. Such an approach would eventually enable the robot to alter observations and assure only the highest quality data is obtained for analysis. Additionally, the robot can begin to understand what is scientifically interesting and implement alternative observing sequences, because the observed data deviate from expectations based upon current theories/models of planetary processes. Such interesting data and/or conclusions can then be prioritized and selectively transmitted to Earth; reducing memory and communications demands. Results of Ames' current work in this area will be presented.

Roush, Ted L.↗

NASA NTRS2001

Robotic Exploration: The Role of Science Autonomy

Historical mission operations have involved: (1) return of scientific data; (2) evaluation of these data by scientists; (3) recommendations for future mission activity by scientists; (4) commands for these transmitted to the craft; and (5) the activity being, undertaken. This cycle is repeated throughout the mission with command opportunities once or twice per day. For a rover, this historical cycle is not amenable to rapid long range traverses or rapid response to any novel or unexpected situations. In addition to real-time response issues, imaging and/or spectroscopic devices can produce tremendous data volumes during a traverse. However, such data volumes can rapidly exceed on-board memory capabilities prior to the ability to transmit it to Earth. Additionally, the necessary communication band-widths are restrictive enough so that only a small portion of these data can actually be returned to Earth. Such scenarios suggest enabling some science decisions to be made on-board the robots. These decisions involve automating various aspects of scientific discovery instead of the electromechanical control, health, and navigation issues associated with robotic operations. The robot retains access to the full data fidelity obtained by its scientific sensors, and is in the best position to implement actions based upon these data. Such an approach would eventually enable the robot to alter observations and assure only the highest quality data is obtained for analysis. Additionally, the robot can begin to understand what is scientifically interesting and implement alternative observing sequences, because the observed data deviate from expectations based upon current theories/models of planetary processes. Such interesting data and/or conclusions can then be prioritized and selectively transmitted to Earth; reducing memory and communications demands. Results of Ames' current work in this area will be presented.

Roush, Ted L.↗

NASA NTRS2012

Systematic Destruction of Electronic Parts for Aid in Electronic Failure Analysis

NASA analyzes electrical, electronic, and electromechanical (EEE) parts used in space vehicles to understand failure modes of these components. Operational amplifiers and transistors are two examples of EEE parts critical to NASA missions that can fail due to electrical overstress (EOS). EOS is the result of voltage or current over time conditions that exceeds a component s specification limit. The objective of this study was to provide known voltage pulses over well-defined time intervals to determine the type and extent of damage imparted to the device. The amount of current was not controlled but measured so that pulse energy was determined. The damage was ascertained electrically using curve trace plots and optically using various metallographic techniques. The resulting data can be used to build a database of physical evidence to compare to damaged components removed from flight avionics. The comparison will provide the avionics failure analyst necessary information about voltage and times that caused flight or test failures when no other electrical data is available.

Decker, S. E.↗

NASA NTRS1993

An emergency response mobile robot for operations in combustible atmospheres

A mobile, self-powered, self-contained, and remote-controlled robot is presented. The robot is capable of safely operating in a combustible atmosphere and providing information about the atmosphere to the operator. The robot includes non-sparking and non-arcing electro-mechanical and electronic components designed to prevent the robot from igniting the combustible atmosphere. The robot also includes positively pressurized enclosures that house the electromechanical and electronic components of the robot and prevent intrusion of the combustible atmosphere into the enclosures. The enclosures are interconnected such that a pressurized gas injected into any one of the enclosures is routed to all the other enclosures through the interconnections. It is preferred that one or more sealed internal channels through structures intervening between the enclosures be employed. Pressure transducers for detecting if the pressure within the enclosures falls below a predetermined level are included. The robot also has a sensing device for determining the types of combustible substances in the surrounding atmosphere, as well as the concentrations of each type of substance relative to a pre-determined lower explosive limit (LEL). In addition, the sensing device can determine the percent level of oxygen present in the surrounding atmosphere.

Stone, Henry W.↗

NASA NTRS1995

Emergency response mobile robot for operations in combustible atmospheres

Stone, Henry W.↗

NASA NTRS2011

Development of a Piezoelectric Rotary Hammer Drill

The Piezoelectric Rotary Hammer Drill is designed to core through rock using a combination of rotation and high frequency hammering powered by a single piezoelectric actuator. It is designed as a low axial preload, low mass, and low power device for sample acquisition on future missions to extraterrestrial bodies. The purpose of this internship is to develop and test a prototype of the Piezoelectric Rotary Hammer Drill in order to verify the use of a horn with helical or angled cuts as a hammering and torque inducing mechanism. Through an iterative design process using models in ANSYS Finite Element software and a Mason's Equivalent Circuit model in MATLAB, a horn design was chosen for fabrication based on the predicted horn tip motion, electromechanical coupling, and neutral plane location. The design was then machined and a test bed assembled. The completed prototype has proven that a single piezoelectric actuator can be used to produce both rotation and hammering in a drill string through the use of a torque inducing horn. Final data results include bit rotation produced versus input power, and best drilling rate achieved with the prototype.

sampling↗

NASA NTRS1998

On-board Science Understanding: NASA Ames' Efforts

In the near future NASA intends to explore various regions of our solar system using robotic devices such as rovers, spacecraft, airplanes, and/or balloons. Such platforms will likely carry imaging devices, and a variety of analytical instruments intended to evaluate the chemical and mineralogical nature of the environment(s) that they encounter. Historically, mission operations have involved: (1) return of scientific data from the craft; (2) evaluation of the data by space scientists; (3) recommendations of the scientists regarding future mission activity; (4) commands for achieving these activities being transmitted to the craft; and (5) the activity being undertaken. This cycle is then repeated for the duration of the mission with command opportunities once or perhaps twice per day. In a rapidly changing environment, such as might be encountered by a rover traversing hundreds of meters a day or a spacecraft encountering an asteroid, this historical cycle is not amenable to rapid long range traverses, discovery of novelty, or rapid response to any unexpected situations. In addition to real-time response issues, the nature of imaging and/or spectroscopic devices are such that tremendous data volumes can be acquired, for example during a traverse. However, such data volumes can rapidly exceed on-board memory capabilities prior to the ability to transmit it to Earth. Additionally, the necessary communication band-widths are restrictive enough so that only a small portion of these data can actually be returned to Earth. Such scenarios clearly require the enabling of some crucial decisions to be made on-board by these robotic explorers. These decisions transcend the electromechanical control, health, and navigation issues associated with robotic operations. Instead they focus upon a long term goal of automating scientific discovery based upon data returned by sensors of the robot craft. Such an approach would eventually enable it to understand what is interesting because the data deviates from expectations generated by current theories/models of planetary processes that could have resulted in the observed data. Such interesting data and/or conclusions can then be selectively transmitted to Earth thus reducing memory and communications demands.

Roush, Ted L.↗

NASA NTRS2007

Development of a Tunable Electromechanical Acoustic Liner for Engine Nacelles

This report describes the development of a tunable electromechanical Helmholtz resonator (EMHR) for engine nacelles using smart materials technology. This effort addresses both near-term and long-term goals for tunable electromechanical acoustic liner technology for the Quiet Aircraft Technology (QAT) Program. Analytical models, i.e. lumped element model (LEM) and transfer matrix (TM) representation of the EMHR, have been developed to predict the acoustic behavior of the EMHR. The models have been implemented in a MATLAB program and used to compare with measurement results. Moreover, the prediction performance of models is further improved with the aid of parameter extraction of the piezoelectric backplate. The EMHR has been experimentally investigated using standard two-microphone method (TMM). The measurement results validated both the LEM and TM models of the EMHR. Good agreement between predicted and measured impedance is obtained. Short- and open circuit loads define the limits of the tuning range using resistive and capacitive loads. There is approximately a 9% tuning limit under these conditions for the non-optimized resonator configuration studied. Inductive shunt loads result in a 3 degree-of-freedom DOF) system and an enhanced tuning range of over 20% that is not restricted by the short- and open-circuit limits. Damping coefficient ' measurements for piezoelectric backplates in a vacuum chamber are also performed and indicate that the damping is dominated by the structural damping losses, such as compliant boundaries, and other intrinsic loss mechanisms. Based on models of the EMHR, a Pareto optimization design of the EMHR has been performed for the EMHR with non-inductive loads. The EMHR with non-inductive loads is a 2DOF system with two resonant fiequencies. The tuning ranges of the two resonant frequencies of the EMHR with non-inductive loads cannot be optimized simultaneously; a trade-off (i.e., a Pareto solution) must be reached. The Pareto solution provides the information for a designer that shows how design trade-offs can be used to satisfy specific design requirements. The optimization design of the EMHR with inductive loads aims at optimal tuning of these three resonant fiequencies. The results indicate that it is possible to keep the acoustic reactance of the resonator close to a constant over a given frequency range. An effort to mimic the second layer of the NASA 2DOF liner using a piezoelectric composite diaphragm has been made. The optimal acoustic reactance of the second layer of the NASA 2DOF liner is achieved using a thin PVDF composite diaphragm, but matching the acoustic resistance requires further investigation. Acoustic energy harvesting is achieved by connecting the EMHR to an energy reclamation circuit that converts the ac voltage signal across the piezoceramic to a conditioned dc signal. Energy harvesting experiment yields 16 m W continuous power for an incident SPL of 153 dB. Such a level is sufficient to power a variety of low power electronic devices. Finally, technology transfer has been achieved by converting the original NASA ZKTL FORTRAN code to a MATLAB code while incorporating the models of the EMHR. Initial studies indicate that the EMHR is a promising technology that may enable lowpower, light weight, tunable engine nacelle liners. This technology, however, is very immature, and additional developments are required. Recommendations for future work include testing of sample EMHR liner designs in NASA Langley s normal incidence dual-waveguide and the grazing-incidence flow facility to evaluating both the impedance characteristics as well as the energy reclamation abilities. Additional design work is required for more complex tuning circuits with greater performance. Poor electromechanical coupling limited the electromechanical tuning capabilities of the proof of concept EMHR. Different materials than those studies and perhaps novel composite material systems may dramatically improvehe electromechanical coupling. Such improvements are essential to improved mimicking of existing double layer liners.

Liu, Fei↗

NASA NTRS1993

Design of power electronics for TVC EMA systems

The Composite Development Division of the Propulsion Laboratory at Marshall Space Flight Center (MSFC) is currently developing a class of electromechanical actuators (EMA's) for use in space transportation applications such as thrust vector control (TVC) and propellant control valves (PCV). These high power servomechanisms will require rugged, reliable, and compact power electronic modules capable of modulating several hundred amperes of current at up to 270 volts. MSFC has selected the brushless dc motor for implementation in EMA's. This report presents the results of an investigation into the applicability of two new technologies, MOS-controlled thyristors (MCT's) and pulse density modulation (PDM), to the control of brushless dc motors in EMA systems. MCT's are new power semiconductor devices, which combine the high voltage and current capabilities of conventional thyristors and the low gate drive requirements of metal oxide semiconductor field effect transistors (MOSFET's). The commanded signals in a PDM system are synthesized using a series of sinusoidal pulses instead of a series of square pulses as in a pulse width modulation (PWM) system. A resonant dc link inverter is employed to generate the sinusoidal pulses in the PDM system. This inverter permits zero-voltage switching of all semiconductors which reduces switching losses and switching stresses. The objectives of this project are to develop and validate an analytical model of the MCT device when used in high power motor control applications and to design, fabricate, and test a prototype electronic circuit employing both MCT and PDM technology for controlling a brushless dc motor.

Nelms, R. Mark↗

NASA NTRS2016

Initial Work Toward a Robotically Assisted EVA Glove

The Space Suit RoboGlove is a device designed to provide additional grasp strength or endurance for an EVA crew member since gloved hand performance is a fraction of what the unencumbered human hand can achieve. There have been past efforts to approach this problem by employing novel materials and construction techniques to the glove design, as well as integrating powered assistance devices. This application of the NASA/GM RoboGlove technology uses a unique approach to integrate the robotic actuators and sensors into a Phase VI EVA glove. This design provides grasp augmentation to the glove user while active, but can also function as a normal glove when disabled. Care was taken to avoid adding excessive bulk to the glove or affecting tactility by choosing low-profile sensors and extrinsically locating the actuators. Conduits are used to guide robotic tendons from linear actuators, across the wrist, and to the fingers. The second generation of the SSRG includes updated electronics, sensors, and actuators to improve performance. The following discusses the electromechanical design, softgoods integration, and control system of the SSRG. It also presents test results from the first integration of a powered mobility element onto a space suit, the NASA Mark III. Early results show that sensor integration did not impact tactile feedback in the glove and the actuators show potential for reduction in grasp fatigue over time.

Rogers, J.↗

NASA NTRS1999

Electro-Statically Stricted Polymers (ESSP)

Miniature, lightweight, miser actuators that operate similar to biological muscles can be used to develop robotic devices with unmatched capabilities and impact many technology areas. Electroactive polymers (EAP) offer the potential to producing such actuators and their main attractive feature is their ability to induce relatively large bending or longitudinal strain. EAP actuators can change the paradigm about the complexity of robots, where robotic components such as motors, gears, bearings, and others can be eliminated with simple drive mechanisms. Generally, these materials produce a relatively low force and the applications that can be considered at the current state of the art are relatively limited. While improved material are being developed there is a need for methods to develop longitudinal actuators that can contract similar to muscles. In this study, the authors began investigating the electromechanical behavior of polymers in reaction to a complex configuration of electric fields. A computer model was used to simulate the electromechanical response. Efforts were made to develop both the material basis as well as the electromechanical modeling of the actuator.

Liu, C.↗

NASA NTRS2013

Analysis of the Impedance Resonance of Piezoelectric Multi-Fiber Composite Stacks

Multi-Fiber CompositesTM (MFC's) produced by Smart Materials Corp behave essentially like thin planar stacks where each piezoelectric layer is composed of a multitude of fibers. We investigate the suitability of using previously published inversion techniques for the impedance resonances of monolithic co-fired piezoelectric stacks to the MFCTM to determine the complex material constants from the impedance data. The impedance equations examined in this paper are those based on the derivation. The utility of resonance techniques to invert the impedance data to determine the small signal complex material constants are presented for a series of MFC's. The technique was applied to actuators with different geometries and the real coefficients were determined to be similar within changes of the boundary conditions due to change of geometry. The scatter in the imaginary coefficient was found to be larger. The technique was also applied to the same actuator type but manufactured in different batches with some design changes in the non active portion of the actuator and differences in the dielectric and the electromechanical coupling between the two batches were easily measureable. It is interesting to note that strain predicted by small signal impedance analysis is much lower than high field stains. Since the model is based on material properties rather than circuit constants, it could be used for the direct evaluation of specific aging or degradation mechanisms in the actuator as well as batch sorting and adjustment of manufacturing processes.

Multi-fiber composites↗

NASA NTRS1994

Design of passive piezoelectric damping for space structures

Passive damping of structural dynamics using piezoceramic electromechanical energy conversion and passive electrical networks is a relatively recent concept with little implementation experience base. This report describes an implementation case study, starting from conceptual design and technique selection, through detailed component design and testing to simulation on the structure to be damped. About 0.5kg. of piezoelectric material was employed to damp the ASTREX testbed, a 500kg structure. Emphasis was placed upon designing the damping to enable high bandwidth robust feedback control. Resistive piezoelectric shunting provided the necessary broadband damping. The piezoelectric element was incorporated into a mechanically-tuned vibration absorber in order to concentrate damping into the 30 to 40 Hz frequency modes at the rolloff region of the proposed compensator. A prototype of a steel flex-tensional motion amplification device was built and tested. The effective stiffness and damping of the flex-tensional device was experimentally verified. When six of these effective springs are placed in an orthogonal configuration, strain energy is absorbed from all six degrees of freedom of a 90kg. mass. A NASTRAN finite element model of the testbed was modified to include the six-spring damping system. An analytical model was developed for the spring in order to see how the flex-tensional device and piezoelectric dimensions effect the critical stress and strain energy distribution throughout the component. Simulation of the testbed demonstrated the damping levels achievable in the completed system.

Hagood, Nesbitt W., IV↗