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Study of a High Voltage Ion Engine Power Supply
A complete laboratory breadboard version of a ion engine power converter was built and tested. This prototype operated on a line voltage of 80-120 Vdc, and provided output ratings of 1100 V at 1.8 kW, and 250 V at 20 mA. The high-voltage (HV) output voltage rating was revised from the original value of 1350 V at the beginning of the project. The LV output was designed to hold up during a 1-A surge current lasting up to 1 second. The prototype power converter included a internal housekeeping power supply which also operated from the line input. The power consumed in housekeeping was included in the overall energy budget presented for the ion engine converter. HV and LV output voltage setpoints were commanded through potentiometers. The HV converter itself reached its highest power efficiency of slightly over 93% at low line and maximum output. This would dip below 90% at high line. The no-load (rated output voltages, zero load current) power consumption of the entire system was less than 13 W. A careful loss breakdown shows that converter losses are predominately Metal-Oxide-Semiconductor Field Effect Transistor (MOSFET) conduction losses and HV rectifier snubbing losses, with the rectifier snubbing losses becoming predominant at high line. This suggests that further improvements in power efficiency could best be obtained by either developing a rectifier that was adequately protected against voltage overshoot with less snubbing, or by developing a pre-regulator to reduced the range of line voltage on the converter. The transient testing showed the converter to be fully protected against load faults, including a direct short-circuit from the HV output to the LV output terminals. Two currents sensors were used: one to directly detect any core ratcheting on the output transformer and re-initiate a soft start, and the other to directly detect a load fault and quickly shut down the converter for load protection. The finished converter has been extensively fault tested without failure. The finished converter has been packaged suitable for use as a laboratory prototype for further testing. The finished converter is readily transportable. An article on design issues for high voltage converters for ion engines is included as an attachement.
A Multiple Model Based Approach for Deep Space Power System Fault Diagnosis
Improving protection and health management capabilities onboard the electrical power system (EPS) for spacecraft is essential for ensuring safe and reliable conditions for deep space human exploration. Electrical protection and control technologies on the National Aeronautics and Space Administration's (NASA's) current human space platform relies heavily on ground support to monitor and diagnose power systems and failures. As communication bandwidth diminishes for deep space applications, a transformation in system monitoring and control becomes necessary to maintain high reliability of electric power service. This paper presents a novel approach for on-line power system security monitoring for autonomous deep space spacecraft.
Functional requirements for an intelligent RPC
An intelligent remote power controller (RPC) based on microcomputer technology can implement advanced functions for the accurate and secure detection of all types of faults on a spaceborne electrical distribution system. The intelligent RPC will implement conventional protection functions such as overcurrent, under-voltage, and ground fault protection. Advanced functions for the detection of soft faults, which cannot presently be detected, can also be implemented. Adaptive overcurrent protection changes overcurrent settings based on connected load. Incipient and high-impedance fault detection provides early detection of arcing conditions to prevent fires, and to clear and reconfigure circuits before soft faults progress to a hard-fault condition. Power electronics techniques can be used to implement fault current limiting to prevent voltage dips during hard faults. It is concluded that these techniques will enhance the overall safety and reliability of the distribution system.
Fault detection and isolation
Erroneous measurements in multisensor navigation systems must be detected and isolated. A recursive estimator can find fast growing errors; a least squares batch estimator can find slow growing errors. This process is called fault detection. A protection radius can be calculated as a function of time for a given location. This protection radius can be used to guarantee the integrity of the navigation data. Fault isolation can be accomplished using either a snapshot method or by examining the history of the fault detection statistics.
Electrical short circuit and current overload tests on aircraft wiring
The findings of electrical short circuit and current overload tests performed on commercial aircraft wiring are presented. A series of bench-scale tests were conducted to evaluate circuit breaker response to overcurrent and to determine if the wire showed any visible signs of thermal degradation due to overcurrent. Three types of wire used in commercial aircraft were evaluated: MIL-W-22759/34 (150 C rated), MIL-W-81381/12 (200 C rated), and BMS 1360 (260 C rated). A second series of tests evaluated circuit breaker response to short circuits and ticking faults. These tests were also meant to determine if the three test wires behaved differently under these conditions and if a short circuit or ticking fault could start a fire. It is concluded that circuit breakers provided reliable overcurrent protection. Circuit breakers may not protect wire from ticking faults but can protect wire from direct shorts. These tests indicated that the appearance of a wire subjected to a current that totally degrades the insulation looks identical to a wire subjected to a fire; however the 'fire exposed' conductor was more brittle than the conductor degraded by overcurrent. Preliminary testing indicates that direct short circuits are not likely to start a fire. Preliminary testing indicated that direct short circuits do not erode insulation and conductor to the extent that ticking faults did. Circuit breakers may not safeguard against the ignition of flammable materials by ticking faults. The flammability of materials near ticking faults is far more important than the rating of the wire insulation material.
Fault tolerance in space-based digital signal processing and switching systems: Protecting up-link processing resources, demultiplexer, demodulator, and decoder
Fault tolerance features in the first three major subsystems appearing in the next generation of communications satellites are described. These satellites will contain extensive but efficient high-speed processing and switching capabilities to support the low signal strengths associated with very small aperture terminals. The terminals' numerous data channels are combined through frequency division multiplexing (FDM) on the up-links and are protected individually by forward error-correcting (FEC) binary convolutional codes. The front-end processing resources, demultiplexer, demodulators, and FEC decoders extract all data channels which are then switched individually, multiplexed, and remodulated before retransmission to earth terminals through narrow beam spot antennas. Algorithm based fault tolerance (ABFT) techniques, which relate real number parity values with data flows and operations, are used to protect the data processing operations. The additional checking features utilize resources that can be substituted for normal processing elements when resource reconfiguration is required to replace a failed unit.
Self-healing fuse development
The mercury-filled self-healing fuses developed for this program afford very good protection from circuit faults with rapid reclosure. Fuse performance and design parameters have been characterized. Life tests indicate a capability of 500 fuse operations. Fuse ratings are 150 v at 5, 15, 25 and 50 circuit A. A series of sample fuses using alumina and beryllia insulation have been furnished to NASA for circuit evaluation.
Rectenna array measurement results
The measured performance characteristics of a rectenna array are reviewed and compared to the performance of a single element. It is shown that the performance may be extrapolated from the individual element to that of the collection of elements. Techniques for current and voltage combining are demonstrated. The array performance as a function of various operating parameters is characterized and techniques for overvoltage protection and automatic fault clearing in the array are demonstrated. A method for detecting failed elements also exists. Instrumentation for deriving performance effectiveness is described. Measured harmonic radiation patterns and fundamental frequency scattered patterns for a low level illumination rectenna array are presented.
Rectenna array measurement results
The measured performance characteristics of a rectenna array are reviewed and compared to the performance of a single element. It is shown that the performance may be extrapolated from the individual element to that of the collection of elements. Techniques for current and voltage combining were demonstrated. The array performance as a function of various operating parameters is characterized and techniques for overvoltage protection and automatic fault clearing in the array demonstrated. A method for detecting failed elements also exists. Instrumentation for deriving performance effectiveness is described. Measured harmonic radiation patterns and fundamental frequency scattered patterns for a low level illumination rectenna array are presented.
Automated Power-Distribution System
Automated power-distribution system monitors and controls electrical power to modules in network. Handles both 208-V, 20-kHz single-phase alternating current and 120- to 150-V direct current. Power distributed to load modules from power-distribution control units (PDCU's) via subsystem distributors. Ring busses carry power to PDCU's from power source. Needs minimal attention. Detects faults and also protects against them. Potential applications include autonomous land vehicles and automated industrial process systems.
Transient fault behavior in a microprocessor: A case study
An experimental analysis is described which studies the susceptibility of a microprocessor based jet engine controller to upsets caused by current and voltage transients. A design automation environment which allows the run time injection of transients and the tracing from their impact device to the pin level is described. The resulting error data are categorized by the charge levels of the injected transients by location and by their potential to cause logic upsets, latched errors, and pin errors. The results show a 3 picoCouloumb threshold, below which the transients have little impact. An Arithmetic and Logic Unit transient is most likely to result in logic upsets and pin errors (i.e., impact the external environment). The transients in the countdown unit are potentially serious since they can result in latched errors, thus causing latent faults. Suggestions to protect the processor against these errors, by incorporating internal error detection and transient suppression techniques, are also made.
High-Speed Ring Bus
The high-speed ring bus at the Jet Propulsion Laboratory (JPL) allows for future growth trends in spacecraft seen with future scientific missions. This innovation constitutes an enhancement of the 1393 bus as documented in the Institute of Electrical and Electronics Engineers (IEEE) 1393-1999 standard for a spaceborne fiber-optic data bus. It allows for high-bandwidth and time synchronization of all nodes on the ring. The JPL ring bus allows for interconnection of active units with autonomous operation and increased fault handling at high bandwidths. It minimizes the flight software interface with an intelligent physical layer design that has few states to manage as well as simplified testability. The design will soon be documented in the AS-1393 standard (Serial Hi-Rel Ring Network for Aerospace Applications). The framework is designed for "Class A" spacecraft operation and provides redundant data paths. It is based on "fault containment regions" and "redundant functional regions (RFR)" and has a method for allocating cables that completely supports the redundancy in spacecraft design, allowing for a complete RFR to fail. This design reduces the mass of the bus by incorporating both the Control Unit and the Data Unit in the same hardware. The standard uses ATM (asynchronous transfer mode) packets, standardized by ITU-T, ANSI, ETSI, and the ATM Forum. The IEEE-1393 standard uses the UNI form of the packet and provides no protection for the data portion of the cell. The JPL design adds optional formatting to this data portion. This design extends fault protection beyond that of the interconnect. This includes adding protection to the data portion that is contained within the Bus Interface Units (BIUs) and by adding to the signal interface between the Data Host and the JPL 1393 Ring Bus. Data transfer on the ring bus does not involve a master or initiator. Following bus protocol, any BIU may transmit data on the ring whenever it has data received from its host. There is no centralized arbitration or bus granting. The JPL design provides for autonomous synchronization of the nodes on the ring bus. An address-synchronous latency adjust buffer (LAB) has been designed that cannot get out of synchronization and needs no external input. Also, a priority-driven cable selection behavior has been programmed into each unit on the ring bus. This makes the bus able to connect itself up, according to a maximum redundancy priority system, without the need for computer intervention at startup. Switching around a failed or switched-off unit is also autonomous. The JPL bus provides a map of all the active units for the host computer to read and use for fault management. With regard to timing, this enhanced bus recognizes coordinated timing on a spacecraft as critical and addresses this with a single source of absolute and relative time, which is broadcast to all units on the bus with synchronization maintained to the tens of nanoseconds. Each BIU consists of up to five programmable triggers, which may be programmed for synchronization of events within the spacecraft of instrument. All JPL-formatted data transmitted on the ring bus are automatically time-stamped.
Soil Moisture Active Passive Mission: Fault Management Design Analyses
As a general trend, the complexities of modern spacecraft are increasing to include more ambitious mission goals with tighter timing requirements and on-board autonomy. As a byproduct, the protective features that monitor the performance of these systems have also increased in scope and complexity. Given cost and schedule pressures, there is an increasing emphasis on understanding the behavior of the system at design time. Formal test-driven verification and validation (V&V) is rarely able to test the significant combinatorics of states, and often finds problems late in the development cycle forcing design changes that can be costly. This paper describes the approach the SMAP Fault Protection team has taken to address some of the above-mentioned issues.
Single-chip microcontrollers for switchgear control
A switchgear controller utilizing a microcontroller is described. The primary goal was to mimic the functions and performance of the generic controller board with a microcontroller board which will cause the power automation system to consume less power. The code for the microcontroller implementation on a development board has been developed, and the signal conditioning for the signals to the microcontroller has been designed and tested. The implementation of this decision system for data gathering, command control, fault detection, and circuit protection, when compared to other implementations, provides more functions and better response while reducing weight, volume, and power consumption.
On reliability modeling and analysis of ultrareliable fault-tolerant digital systems.
The processes of protective redundancy, namely, standby replacement (SR) redundancy and hybrid redundancy (a combination of SR and multiple-line voting redundancy), find application in the architecture of fault-tolerant digital computers and enable them to be ultrareliable and self-repairing. The claims to ultrareliability lead to the challenge of quantitatively evaluating and assigning a value to the probability of survival as a function of the mission durations intended. This note presents various mathematical models, and derives and displays quantitative evaluations of system reliability as a function of various mission parameters of interest to the system designer.
Design Guidelines for Shielding Effectiveness, Current Carrying Capability, and the Enhancement of Conductivity of Composite Materials
These guidelines address the electrical properties of composite materials which may have an effect on electromagnetic compatibility (EMC). The main topics of the guidelines include the electrical shielding, fault current return, and lightning protection capabilities of graphite reinforced polymers, since they are somewhat conductive but may require enhancement to be adequate for EMC purposes. Shielding effectiveness depends heavily upon the conductivity of the material. Graphite epoxy can provide useful shielding against RF signals, but it is approximately 1,000 times more resistive than good conductive metals. The reduced shielding effectiveness is significant but is still useful in many cases. The primary concern is with gaps and seams in the material just as it is with metal. Current carrying capability of graphite epoxy is adequate for dissipation static charges, but fault currents through graphite epoxy may cause fire at the shorting contact and at joints. The effect of lightning on selected graphite epoxy material and mating surfaces is described, and protection methods are reviewed.