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This viewgraph presentation reviews a study that aimed at a characterization of the Quasi-CW Laser Diode Arrays. NASA's requirements for high reliability, high performance satellite laser instruments have driven the investigation of many critical components; specifically, 808 nm laser diode array (LDA) pump devices. Performance and comprehensive characterization data of Quasi-CW, High-power, laser diode arrays is presented
The NASA/Goddard Space Flight Center (NASA/GSFC) is in the business of performing world-class, space-based, scientific research on various spacecraft platforms, which now include small satellites (SmallSats). In order to perform world class science on a SmallSat, NASA/GSFC requires that their components be highly reliable, high performing, have low power consumption, at the lowest cost possible. The Propulsion Branch (Code 597) at NASA/GSFC has conducted a SmallSat propulsion system survey to determine their availability and level of development. Based on publicly available information and unique features, this paper discusses some of the existing SmallSat propulsion systems.. The systems described in this paper do not indicate or imply any endorsement by NASA or NASA/GSFC over those not included.
NASA's requirements for high reliability, high performance satellite laser instruments have driven the investigation of many critical components; specifically, 808 nm laser diode array (LDA) pump devices. Performance of Quasi-CW, High-power, laser diode arrays under extended use is presented. We report the optical power over several hundred million pulse operation and the effect of power cycling and temperature cycling of the laser diode arrays. Data on the initial characterization of the devices is also presented.
The Second Target Station (STS) project at the Spallation Neutron Source (SNS) is being developed to provide world-leading cold neutron brightness for next-generation neutron scattering experiments. The STS Accelerator Systems (AS) scope includes the design and implementation of the Ring-to-Second Target (RTST) proton beam transport line, which extracts 1.3 GeV proton beam pulses from the existing Ring-to-Beam Transport (RTBT) system and delivers them to the STS target. The RTST design emphasizes operational reliability [high reliability], low activation [minimum activation of components and the tunnel], maintainability, and compatibility with existing SNS infrastructure through extensive reuse of proven RTBT systems and components. The beamline includes a new extraction region, a transport lattice consisting of dipole, quadrupole, and corrector magnets, beam instrumentation systems, vacuum systems, personnel protection systems, and radiation shielding systems. Beam optics and particle tracking studies were performed using PyORBIT to validate extraction trajectories, beam transport, and target beam spot requirements [60–90 cm² beam spot area]. This paper presents the optics design philosophy, extraction system architecture, transport lattice design, instrumentation strategy, vacuum system approach, and radiation protection integration for the RTST beamline. Particle tracking simulations indicate successful beam transport without beam loss under nominal operating conditions. The RTST is designed to transport 1.3 GeV proton beam pulses at repetition rates up to 15 Hz, delivering nominal beam power of 700 kW to the Second Target Station.
The production of failure-free hardware is discussed. The elements required to achieve such hardware are: technical expertise to design, analyze, and fully understand the design; use of high reliability parts and materials control in the manufacturing process; and testing to understand the system and weed out defects. The durability of the Hughes family of satellites is highlighted.
A high-speed, reliable ball bearing has been designed for at least fifteen years of operation in space effectors, MWA's, and RWA's. Advanced bearing concepts have been used in this design, such as: no ball retainer, which eliminates all retainer-related problems; an external lubricazing system that will supply the lubricant at a specified flow rate; and a cartridge assembly that will allow the instrument user to purchase a ready to use bearing assembly, with lubricator. Currently, two assemblies are on life test at 12,000 RPM and have accumulated over 20,000 hours each, with consistent low-torque losses. This paper will describe each of the salient features.
High points, or features that protrude above the surface of the material, on porous transport layers (PTLs) and gas diffusion layers (GDLs) can be critical features that may affect the manufacturing process and the performance of the device containing the feature. High points on PTLs and GDLs may stress the membrane of a polymer electrolyte membrane (PEM) during lamination and cell operation of a PEM electrolyzer or fuel cell. Additionally, high points on GDLs may impact the reliability of the manufacturing process. Thus, understanding these critical features and developing procedures to detect them are a key part of developing quality control techniques for PTLs and GDLs. This work evaluates the effectiveness of the Keyence VR6200 benchtop-scale structured light optical profilometer for detection of surface protrusions on PTLs and GDLs. Standard testing procedures for detecting and measuring high points were created for use on both material types. These procedures were evaluated using Gage Repeatability and Reproducibility (Gage R&R), where the repeatability, reproducibility, and effectiveness of the system to detect and measure high points were quantified. We have shown with high statistical power that the system is very effective in detection and measurement of high points, with Gage R&R contributions measured to be 2.2% and 3.6% for PTLs and GDLs, respectively.
Hybrid Power Management (HPM) is the integration of diverse, state-of-the-art power devices in an optimal configuration for space and terrestrial applications (s ee figure). The appropriate application and control of the various power devices significantly improves overall system performance and efficiency. The basic vehicle architecture consists of a primary power source, and possibly other power sources, that provides all power to a common energy storage system that is used to power the drive motors and vehicle accessory systems. This architecture also provides power as an emergency power system. Each component is independent, permitting it to be optimized for its intended purpose. The key element of HPM is the energy storage system. All generated power is sent to the energy storage system, and all loads derive their power from that system. This can significantly reduce the power requirement of the primary power source, while increasing the vehicle reliability. Ultracapacitors are ideal for an HPM-based energy storage system due to their exceptionally long cycle life, high reliability, high efficiency, high power density, and excellent low-temperature performance. Multiple power sources and multiple loads are easily incorporated into an HPM-based vehicle. A gas turbine is a good primary power source because of its high efficiency, high power density, long life, high reliability, and ability to operate on a wide range of fuels. An HPM controller maintains optimal control over each vehicle component. This flexible operating system can be applied to all vehicles to considerably improve vehicle efficiency, reliability, safety, security, and performance. The HPM-based vehicle architecture has many advantages over conventional vehicle architectures. Ultracapacitors have a much longer cycle life than batteries, which greatly improves system reliability, reduces life-of-system costs, and reduces environmental impact as ultracapacitors will probably never need to be replaced and disposed of. The environmentally safe ultracapacitor components reduce disposal concerns, and their recyclable nature reduces the environmental impact. High ultracapacitor power density provides high power during surges, and the ability to absorb high power during recharging. Ultracapacitors are extremely efficient in capturing recharging energy, are rugged, reliable, maintenance-free, have excellent lowtemperature characteristic, provide consistent performance over time, and promote safety as they can be left indefinitely in a safe, discharged state whereas batteries cannot.
Potential users of plastic encapsulated microcircuits (PEMs) need to be reminded that unlike the military system of producing robust high-reliability microcircuits that are designed to perform acceptably in a variety of harsh environments, PEMs are primarily designed for use in benign environments where equipment is easily accessed for repair or replacement. The methods of analysis applied to military products to demonstrate high reliability cannot always be applied to PEMs. This makes it difficult for users to characterize PEMs for two reasons: 1. Due to the major differences in design and construction, the standard test practices used to ensure that military devices are robust and have high reliability often cannot be applied to PEMs that have a smaller operating temperature range and are typically more frail and susceptible to moisture absorption. In contrast, high-reliability military microcircuits usually utilize large, robust, high-temperature packages that are hermetically sealed. 2. Unlike the military high-reliability system, users of PEMs have little visibility into commercial manufacturers proprietary design, materials, die traceability, and production processes and procedures. There is no central authority that monitors PEM commercial product for quality, and there are no controls in place that can be imposed across all commercial manufacturers to provide confidence to high-reliability users that a common acceptable level of quality exists for all PEMs manufacturers. Consequently, there is no guaranteed control over the type of reliability that is built into commercial product, and there is no guarantee that different lots from the same manufacturer are equally acceptable. And regarding application, there is no guarantee that commercial products intended for use in benign environments will provide acceptable performance and reliability in harsh space environments. The qualification and screening processes contained in this document are intended to detect poor-quality lots and screen out early random failures from use in space flight hardware. However, since it cannot be guaranteed that quality was designed and built into PEMs that are appropriate for space applications, users cannot screen in quality that may not exist. It must be understood that due to the variety of materials, processes, and technologies used to design and produce PEMs, this test process may not accelerate and detect all failure mechanisms. While the tests herein will increase user confidence that PEMs with otherwise unknown reliability can be used in space environments, such testing may not guarantee the same level of reliability offered by military microcircuits. PEMs should only be used where due to performance needs there are no alternatives in the military high-reliability market, and projects are willing to accept higher risk.
The reliability of one lot of high K multilayer ceramic capacitors was evaluated using accelerated life testing. The degradation in insulation resistance was characterized as a function of voltage and temperature. The times to failure at a voltage-temperature stress conformed to a lognormal distribution with a standard deviation approximately 0.5.
High density PWB (printed wiring board) with microvia technology is required for implementation of high density and high I/O area array packages (AAP). COTS (commercial off-the-shelf) AAP packaging technologies in high reliability versions with 1.27 mm pitch are now being considered for use in a number of NASA systems including Space Shuttle and Mars Rovers. NASA functional system designs are requiring more and more dense AAP packages and board space, which makes board microvia technology very attractive for effectively routing a large number of package inputs/outputs. However, the reliability of the fine feature microvias including via in pads is unknown for space applications. Understanding process and QA (quality assurance) indicators for reliability are important for low risk insertion of these newly available packages and PWBs. This paper presents literature search as well as test results for a high density board subjected to various thermal cycle and reflow profiles representative of tin-lead and lead-free solder reflow. Microvias sizes ranged from two to six mil with and without filling. Daisy chain microvias monitored during the test and PWBs were cross-sectioned to determine failure and locations. Optical and SEM photographs as well as resistance changes during cycling and Tg/Td (glass transition/decomposition temperature) characterisations are presented.
A manual was written to introduce the CARE III (Computer-Aided Reliability Estimation) capability to reliability and design engineers who are interested in predicting the reliability of highly reliable fault-tolerant systems. It was also structured to serve as a quick-look reference manual for more experienced users. The guide covers CARE III modeling and reliability predictions for execution in the CDC CYber 170 series computers, DEC VAX-11/700 series computer, and most machines that compile ANSI Standard FORTRAN 77.
The application of refrigeration at low temperatures ranging from production of liquid helium for medical imaging systems to cooling of infrared sensors on surveillance satellites is discussed. Cooling below about 15 K with regenerative refrigerators is difficult because of the decreasing thermal mass of the regenerator compared to that of the working material. In order to overcome this difficulty with helium gas as the working material, a heat exchanger plus a Joule-Thomson or other exponder is used. Regenerative magnetic refrigerators with magnetic solids as the working material have the same regenerator problem as gas refrigerators. This problem provides motivation for the development of nonregenerative magnetic refrigerators that span approximately 1 K to approximately 0 K. Particular emphasis is placed on high reliability and high efficiency. Calculations indicate considerable promise in this area. The principles, the potential, the problems, and the progress towards development of successful 4 to 20 K magnetic refrigerators are discussed.
High-reliability high-performance deployable monogroove and dual-slot heat pipe radiator systems to meet the requirements for electric power in future space missions, such as the 300-kW(e) electric powder demand projected for NASA's Space Station, are discussed. Analytical model trade studies of various configurations show the advantages of the dual-slot heat pipe radiator for high temperature applications as well as its weight reduction potential over the 50-350 F temperature range. The ammonia-aluminum monogroove heat pipe, limited to below-180 F operating temperatures, is under development, and can employ methanol-stainless steel heat pipes to achieve operating temperatures in excess of 300 F. Dual-slot heat pipe configuration proof-of-concept testing was begun in 1985.
A radiator system concept is described that meets the heat rejection requirements of the NASA Space Station solar dynamic power modules. The heat pipe radiator is a high-reliability, high-performance approach that is capable of erection in space and is maintainable on orbit. Results are present of trade studies that compare the radiator system area and weight estimates for candidate advanced high performance heat pipes. The results indicate the advantages of the dual-slot heat pipe radiator for high temperature applications as well as its weight-reduction potential over the range of temperatures to be encountered in the solar dynamic heat rejection systems.
The Diagnostic Emulation Technique was developed within the System Validation Methods Branch as a part of the development of methods for the analysis of the reliability of highly reliable, fault tolerant digital avionics systems. This is a general technique which allows for the emulation of a digital hardware system. The technique is general in the sense that it is completely independent of the particular target hardware which is being emulated. Parts of the system are described and emulated at the logic or gate level, while other parts of the system are described and emulated at the functional level. This algorithm allows for the insertion of faults into the system, and for the observation of the response of the system to these faults. This allows for controlled and accelerated testing of system reaction to hardware failures in the target machine. This document describes in detail how the algorithm was implemented at NASA Langley Research Center and gives instructions for using the system.
The rapid advance of cockpit automation in the last decade has outstripped the ability of the human factors profession to understand the changes in human functions required. High technology cockpits require less physical (observable) workload, but are highly demanding of cognitive functions such as planning, alternative selection, and monitoring. Furthermore, automation creates opportunity for new and more serious forms of human error, and many pilots are concerned about the possibility of complacency affecting their performance. On the positive side, the equipment works as advertized with high reliability, offering highly efficient, computer-based flight. These findings from the cockpit studies probably apply equally to other industries, such as nuclear power production, other modes of transportation, medicine, and manufacturing, all of which traditionally have looked to aviation for technological leadership. The challenge to the human factors profession is to aid designers, operators, and training departments in exploiting the positive side of automation, while seeking solutions to the negative side. Viewgraphs are given.
The environmental control and life support system on a spacecraft must maintain a safe and comfortable environment in which the crew can live and work. The system's functions include supplying the crew with oxygen and water, as well as removing carbon dioxide, water vapor, and trace contaminants from cabin air. Although open-loop systems have been used in the past, logistics and safety factors of current and future missions in space make near-complete recycling of the cabin's air and water desirable. The recycling process may include separation and reduction of carbon dioxide, removal of trace gas-phase contaminants, recovery and purification of humidity condensate, purification and polishing of wastewater streams, and other processes. Several of these operations can be performed totally or in part by adsorption processes. Adsorption processes are frequently good candidates for separation and purification in space by virtue of such characteristics as gravity independence, high reliability, relatively high energy efficiency, design flexibility, technological maturity, and regenerability. For these reasons, adsorption has historically played a key role in life support on U.S. and Russian piloted spacecraft. This article focuses on three current spacecraft life support applications that often use adsorption technology: carbon dioxide separation from cabin air, gas-phase trace contaminant control, and potable water recovery from waste streams. In each application, adsorption technology has been selected for use on the International Space Station. The requirements, science, and hardware for each application are discussed. Eventually, human space exploration may lead to construction of planetary habitats. These habitats may have additional applications, such as control of greenhouse gas composition and purification of hydroponic solutions, and may have different requirements and resources available to them, such as gases present in the planetary atmosphere. Adsorption separation and purification processes may continue to fulfill environmental control and life support needs well into the future.