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NASA NTRS2010

LISA Technology Development and Risk Reduction at NASA

The Laser Interferometer Space Antenna (LISA) is a joint ESA-NASA project to design, build and operate a space-based gravitational wave detector based on a laser interferometer. LISA relies on several technologies that are either new to spaceflight or must perform at levels not previously demonstrated in a spaceflight environment. The ESA-led LISA Pathfinder mission is the main effort to demonstrate LISA technology. NASA also supports complementary ground-based technology development and risk reduction activities. This presentation will report the status of NASA work on micronewton thrusters, the telescope, the optical pointing subsystem and mission formulation. More details on some of these topics will be given in posters. Other talks and posters will describe NASA-supported work on the laser subsystem, the phasemeter, and aspects of the interferometry. Two flight-qualified clusters of four colloid micronewton thrusters, each capable of thrust Levels between 5 and 30 microNewton with a resolution less than 0.l microNewton and a thrust noise less than 0.1 microNewton/vHz (0.001 to 4 Hz), have been integrated onto the LISA Pathfinder spacecraft. The complementary ground-based development focuses on lifetime demonstration. Laboratory verification of failure models and accelerated life tests are just getting started. LISA needs a 40 cm diameter, afocal telescope for beam expansion/reduction that maintains an optical pathlength stability of approximately 1 pm/vHz in an extremely stable thermal environment. A mechanical prototype of a silicon carbide primary-secondary structure has been fabricated for stability testing. Two optical assemblies must point at different distant spacecraft with nanoradian accuracy over approximately 1 degree annual variation in the angle between the distant spacecraft. A candidate piezo-inchworm actuator is being tested in a suitable testbed. In addition to technology development, NASA has carried out several studies in support of the mission formulation. The results of systems engineering work on flight software, avionics and reliability will be summarized.

Stebbins, Robin T.↗
NASA NTRS2012

The Development of Models for Carbon Dioxide Reduction Technologies for Spacecraft Air Revitalization

Through the respiration process, humans consume oxygen (O2) while producing carbon dioxide (CO2) and water (H2O) as byproducts. For long term space exploration, CO2 concentration in the atmosphere must be managed to prevent hypercapnia. Moreover, CO2 can be used as a source of oxygen through chemical reduction serving to minimize the amount of oxygen required at launch. Reduction can be achieved through a number of techniques. NASA is currently exploring the Sabatier reaction, the Bosch reaction, and co- electrolysis of CO2 and H2O for this process. Proof-of-concept experiments and prototype units for all three processes have proven capable of returning useful commodities for space exploration. All three techniques have demonstrated the capacity to reduce CO2 in the laboratory, yet there is interest in understanding how all three techniques would perform at a system level within a spacecraft. Consequently, there is an impetus to develop predictive models for these processes that can be readily rescaled and integrated into larger system models. Such analysis tools provide the ability to evaluate each technique on a comparable basis with respect to processing rates. This manuscript describes the current models for the carbon dioxide reduction processes under parallel developmental efforts. Comparison to experimental data is provided were available for verification purposes.

Swickrath, Michael J.↗
NASA NTRS2007

The Impact of Atmospheric InfraRed Sounder (AIRS) Profiles on Short-term Weather Forecasts

The Atmospheric Infrared Sounder (AIRS), together with the Advanced Microwave Sounding Unit (AMSU), represents one of the most advanced spacebased atmospheric sounding systems. The combined AlRS/AMSU system provides radiance measurements used to retrieve temperature profiles with an accuracy of 1 K over 1 km layers under both clear and partly cloudy conditions, while the accuracy of the derived humidity profiles is 15% in 2 km layers. Critical to the successful use of AIRS profiles for weather and climate studies is the use of profile quality indicators and error estimates provided with each profile Aside form monitoring changes in Earth's climate, one of the objectives of AIRS is to provide sounding information of sufficient accuracy such that the assimilation of the new observations, especially in data sparse region, will lead to an improvement in weather forecasts. The purpose of this paper is to describe a procedure to optimally assimilate highresolution AIRS profile data in a regional analysis/forecast model. The paper will focus on the impact of AIRS profiles on a rapidly developing east coast storm and will also discuss preliminary results for a 30-day forecast period, simulating a quasi-operation environment. Temperature and moisture profiles were obtained from the prototype version 5.0 EOS science team retrieval algorithm which includes explicit error information for each profile. The error profile information was used to select the highest quality temperature and moisture data for every profile location and pressure level for assimilation into the ARPS Data Analysis System (ADAS). The AIRS-enhanced analyses were used as initial fields for the Weather Research and Forecast (WRF) system used by the SPORT project for regional weather forecast studies. The ADASWRF system will be run on CONUS domain with an emphasis on the east coast. The preliminary assessment of the impact of the AIRS profiles will focus on quality control issues associated with AIRS, intelligent use of the quality indicators, and forecast verification.

Chou, Shih-Hung↗
NASA NTRS1998

Assessment of the 60 Km Rapid Update Cycle (RUC) with Near Real-Time Aircraft Reports

NASA is developing the Center-TBACON Advisory System (CTAS), a set of Air Traffic Management (ATM) Decision Support Tools (DST) to enable controllers to increase airspace capacity and flight efficiency. A crucial component of the CTAS, or any ATM DST, is the computation of the time-of-flight of aircraft along flight path segments which requires accurate knowledge of the wind through which the aircraft are flying. CTAS currently uses wind information from the Rapid Update Cycle (RUC), a numerical prediction model run operationally by the National Weather Service (NWS) National Center for Environmental Prediction (NCEP). There exists near real-time wind observations from commercial aircraft that can be used to increase the accuracy of the RUC wind forecasts via the FAA Integrated Terminal Weather System (ITWS) Terminal Winds (TW) algorithm. This report presents a study based on the application of the ITWS TW algorithm as an improvement to the baseline RUC product. Terminal Winds generally does not support the full Center airspace; the domain of the prototype MIT/LLITWS TW system was increased to cover the Denver Center airspace to support this study. This study has three goals: 1) determine the errors in the baseline 60-kilometer resolution RUC forecast wind fields relative to the needs of en route DSTs such as CTAS; 2) determine the benefit of using the TW algorithm to refine the RUC forecast wind fields with near real-tlme Meteorological Data Collection and Reporting System (MDCRS) aircraft reports, and 3) identify factors that influence wind field errors in order to improve accuracy and estimate errors in real time. The data for this study were collected over a one-year period for the Denver Center airspace and over one miIlion verification observations were used. This study is part of a larger effort funded by NASA which includes the NOAA/FSL.

Cole, R. E.↗
NASA NTRS1996

Quantitative Measures for Software Independent Verification and Validation

As software is maintained or reused, it undergoes an evolution which tends to increase the overall complexity of the code. To understand the effects of this, we brought in statistics experts and leading researchers in software complexity, reliability, and their interrelationships. These experts' project has resulted in our ability to statistically correlate specific code complexity attributes, in orthogonal domains, to errors found over time in the HAL/S flight software which flies in the Space Shuttle. Although only a prototype-tools experiment, the result of this research appears to be extendable to all other NASA software, given appropriate data similar to that logged for the Shuttle onboard software. Our research has demonstrated that a more complete domain coverage can be mathematically demonstrated with the approach we have applied, thereby ensuring full insight into the cause-and-effects relationship between the complexity of a software system and the fault density of that system. By applying the operational profile we can characterize the dynamic effects of software path complexity under this same approach We now have the ability to measure specific attributes which have been statistically demonstrated to correlate to increased error probability, and to know which actions to take, for each complexity domain. Shuttle software verifiers can now monitor the changes in the software complexity, assess the added or decreased risk of software faults in modified code, and determine necessary corrections. The reports, tool documentation, user's guides, and new approach that have resulted from this research effort represent advances in the state of the art of software quality and reliability assurance. Details describing how to apply this technique to other NASA code are contained in this document.

Lee, Alice↗
NASA NTRS2012

Preparation for the Proof of Concept Flight of the Veggie Plant Growth Chamber

Veggie is a small plant growth chamber designed and built by ORBITEC that will fly to the International Space Station on SpaceX-3, scheduled for the summer of 2013. Ultimately Veggie will be used for research, education and outreach, and crew recreation. We want to demonstrate the functionality of this hardware by testing a scenario that could allow the crew to grow and consume fresh vegetables. Veggie will be collapsed and transported flat in a cargo transfer bag, and deployed on orbit, where it will be installed in an EXPRESS rack. The chamber consists of three subsystems: an LED light cap, a transparent bellows, and a root mat reservoir assembly. The bellows and flexible support arms allow the distance between plants and light cap to be adjusted for different ages and types of plants. Researchers at Kennedy Space Center and ORBITEC have been working to develop the plant growth interfaces for the proof of concept flight. We have developed a rooting pillow, consisting of a small bag containing media, time release fertilizer, seeds, and a wicking surface to conduct water from the root mat reservoir. Prototype pillows have been tested and results have influenced the design of flight pillows, which will be modified for microgravity from flight-approved materials. Several studies have been conducted selecting species and comparing media types in analog systems. Water content seems to be the most important factor differentiating media types in these small growth volumes (100 mL). Media type also influenced microbial levels on plants. Since produce sanitizing agents are not currently approved for growing food crops on orbit, plants and media types having very low microbial levels are being selected. Lettuce, mizuna, and other salad greens typically have microbial counts less than 10(exp 4) colony forming units and thus are good candidates for spaceflight. As we approach flight verification testing, we will finalize species, media selection, harvesting, and microbial sampling procedures. Next steps include testing of Veggie flight and ground hardware and associated equipment. This research was funded by NASA.

Massa, Gioia↗
NASA NTRS2019

Mars Small-Spacecraft Human Exploration Resource Prospector with Aero-braking (SHERPA): Demonstrating an End-to-End Mission to Phobos Distant Retrograde Orbit

This paper summarizes an end-to-end mission design concept exploring the feasibility of using small satellites together with aero-capture technology to achieve Mars orbit insertion, and subsequent injection into a Phobos-stabilized (or distant retrograde) orbit. The science and mission objectives are to carry out a survey of the mineralogy and morphology of Phobos, to answer basic questions concerning its origin and formation, to test the cohesiveness of Phobos regolith, and to search for potential landing sites for future human or robotic spacecraft. The Mars Small-Spacecraft Human Exploration Resource Prospector with Aero-braking (SHERPA) spacecraft is based on a combination flight-tested prototype vehicle and instruments, and first principle sizing of consumables. The resulting system is fitted with an inflatable aerodynamic decelerator to effect aero-capture into a Mars elliptical orbit, on its way to achieving Phobos orbit. A computational fluid dynamics tool is used to analyze the flow-field and identify potential hot spots during aerodynamic flight. This work advocates for the use of small satellites to test out technologies and operational concepts used in sustained human exploration of Mars, and to carry out scientific exploration of the Mars system. Consistent with a systems engineering approach, this work combines elements of the NASA Human Exploration and Operations Mission Directorate, the Space Technology Mission Directorate, and the Science Mission Directorate, and proposes a scenario for science acquisition, technology verification, trajectory validation, and in-situ resource exploration. We believe these type of missions are essential forerunners to human crewed missions to Mars.

Mission Design↗
NASA NTRS2017

Wearable Biosensor Monitor to Support Autonomous Crew Health and Readiness to Perform

For future human exploration missions, NASA needs a health monitoring system composed of hardware that is compact, fully interoperable with an integrated data management system, and requires minimal consumables. Such a system will be achieved through the integration of small, easy to use biomedical sensors that will have the ability to measure, store and transmit physiological parameters during operational and ambulatory activity. Since 2012, the Canadian Space Agency (CSA) has been active in funding the development of wearable biomonitoring sensors. The Astroskin is the first prototype and consists of a shirt-based garment and headband with embedded sensors, and associated software and technology that measure vital signs, sleep quality and activity level of the wearer. NASA and CSA have been collaborating since 2014 to test and validate this system in a lab environment at Ames Research Center and more recently in the Human Exploration Research Analog (HERA) located at Johnson Spaceflight Center. Specific objectives of the HERA study were: 1) to assess the performance of the Astroskin biosensor system for long-term health monitoring (24-hours) capabilities and during exercise as a measure of crew fitness; 2) to obtain crew feedback on comfort and usability of the Astroskin system; 3) to demonstrate performance of Bluetooth communication during real-time transmission and for verification of data in this environment; and 4) to obtain baseline data for further development of algorithms and tools that facilitate decision support for diagnosing and monitoring of a sick or injured crewmember. HERA Campaign 3 included four missions (each 30-days in duration) with four crewmembers assigned to each mission. A total of 9 men and 7 women participated in the Astroskin evaluation that included continuous physiological monitoring (24-hours) on mission days MD-11, MD1 (high workload), MD15 (low workload), MD19, MD29, and MD+7. Mission days 19 and 29 also included 30 minutes of sub-maximal exercise on a cycle ergometer. Following each 24-hour monitoring session crew physiological data were downloaded to laptops and each crewmember completed a 28 question survey on their experiences with the Astroskin hardware and software. This presentation will focus on lessons learned from the HERA missions. Specifically it will address Astroskin system performance in terms of data loss and data quality (no comparison to lab standard devices), wireless communication with the onboard mobile device, crew usability and comfort, and future development of a next generation biomonitoring system.

crew fitness↗
NASA NTRS1992

Free-free and fixed base modal survey tests of the Space Station Common Module Prototype

This paper describes the testing aspects and the problems encountered during the free-free and fixed base modal surveys completed on the original Space Station Common Module Prototype (CMP). The CMP is a 40-ft long by 14.5-ft diameter 'waffle-grid' cylinder built by the Boeing Company and housed at the Marshall Space Flight Center (MSFC) near Huntsville, AL. The CMP modal survey tests were conducted at MSFC by the Dynamics Test Branch. The free-free modal survey tests (June '90 to Sept. '90) included interface verification tests (IFVT), often referred to as impedance measurements, mass-additive testing and linearity studies. The fixed base modal survey tests (Feb. '91 to April '91), including linearity studies, were conducted in a fixture designed to constrain the CMP in 7 total degrees-of-freedom at five trunnion interfaces (two primary, two secondary, and the keel). The fixture also incorporated an airbag off-load system designed to alleviate the non-linear effects of friction in the primary and secondary trunnion interfaces. Numerous test configurations were performed with the objective of providing a modal data base for evaluating the various testing methodologies to verify dynamic finite element models used for input to coupled load analysis.

Driskill, T. C.↗
NASA NTRS2004

Design and Experimental Verification of Deployable/Inflatable Ultra-Lightweight Structures

Because launch cost of a space structural system is often proportional to the launch volume and mass and there is no significant gravity in space, NASA's space exploration programs and various science missions have stimulated extensive use of ultra-lightweight deployable/inflatable structures. These structures are named here as Highly Flexible Structures (HFSs) because they are designed to undergo large displacements, rotations, and/or buckling without plastic deformation under normal operation conditions. Except recent applications to space structural systems, HFSs have been used in many mechanical systems, civil structures, aerospace vehicles, home appliances, and medical devices to satisfy space limitations, provide special mechanisms, and/or reduce structural weight. The extensive use of HFSs in today's structural engineering reveals the need of a design and analysis software and a database system with design guidelines for practicing engineers to perform computer-aided design and rapid prototyping of HFSs. Also to prepare engineering students for future structural engineering requires a new and easy-to- understand method of presenting the complex mathematics of the modeling and analysis of HFSs. However, because of the high flexibility of HFSs, many unique challenging problems in the modeling, design and analysis of HFSs need to be studied. The current state of research on HFSs needs advances in the following areas: (1) modeling of large rotations using appropriate strain measures, (2) modeling of cross-section warpings of structures, (3) how to account for both large rotations and cross- section warpings in 2D (two-dimensional) and 1D structural theories, (4) modeling of thickness thinning of membranes due to inflation pressure, pretension, and temperature change, (5) prediction of inflated shapes and wrinkles of inflatable structures, (6) development of efficient numerical methods for nonlinear static and dynamic analyses, and (7) filling the gap between geometrically exact elastic analysis and elastoplastic analysis. The objectives of this research project were: (1) to study the modeling, design, and analysis of deployable/inflatable ultra-lightweight structures, (2) to perform numerical and experimental studies on the static and dynamic characteristics and deployability of HFSs, (3) to derive guidelines for designing HFSs, (4) to develop a MATLAB toolbox for the design, analysis, and dynamic animation of HFSs, and (5) to perform experiments and establish an adequate database of post-buckling characteristics of HFSs.

Pai, P. Frank↗
NASA NTRS1993

NTP comparison process

The systems engineering process for the concept definition phase of the program involves requirements definition, system definition, and consistent concept definition. The requirements definition process involves obtaining a complete understanding of the system requirements based on customer needs, mission scenarios, and nuclear thermal propulsion (NTP) operating characteristics. A system functional analysis is performed to provide a comprehensive traceability and verification of top-level requirements down to detailed system specifications and provides significant insight into the measures of system effectiveness to be utilized in system evaluation. The second key element in the process is the definition of system concepts to meet the requirements. This part of the process involves engine system and reactor contractor teams to develop alternative NTP system concepts that can be evaluated against specific attributes, as well as a reference configuration against which to compare system benefits and merits. Quality function deployment (QFD), as an excellent tool within Total Quality Management (TQM) techniques, can provide the required structure and provide a link to the voice of the customer in establishing critical system qualities and their relationships. The third element of the process is the consistent performance comparison. The comparison process involves validating developed concept data and quantifying system merits through analysis, computer modeling, simulation, and rapid prototyping of the proposed high risk NTP subsystems. The maximum amount possible of quantitative data will be developed and/or validated to be utilized in the QFD evaluation matrix. If upon evaluation of a new concept or its associated subsystems determine to have substantial merit, those features will be incorporated into the reference configuration for subsequent system definition and comparison efforts.

Corban, Robert↗
NASA NTRS2014

Advanced Extravehicular Activity Pressure Garment Requirements Development

The NASA Johnson Space Center advanced pressure garment technology development team is addressing requirements development for exploration missions. Lessons learned from the Z‐2 high fidelity prototype development have reiterated that clear low‐level requirements and verification methods reduce risk to the government, improve efficiency in pressure garment design efforts, and enable the government to be a smart buyer. The expectation is to provide requirements at the specification level that are validated so that their impact on pressure garment design is understood. Additionally, the team will provide defined verification protocols for the requirements. However, in reviewing exploration space suit high level requirements there are several gaps in the team's ability to define and verify related lower level requirements. This paper addresses the efforts in requirement areas such as mobility/fit/comfort and environmental protection (dust, radiation, plasma, secondary impacts) to determine the by what method the requirements can be defined and use of those methods for verification. Gaps exist at various stages. In some cases component level work is underway, but no system level effort has begun, in other cases no effort has been initiated to close the gap. Status of ongoing efforts and potential approaches to open gaps are discussed.

Ross, Amy↗
NASA NTRS2015

Advanced Extra-Vehicular Activity Pressure Garment Requirements Development

The NASA Johnson Space Center advanced pressure garment technology development team is addressing requirements development for exploration missions. Lessons learned from the Z-2 high fidelity prototype development have reiterated that clear low-level requirements and verification methods reduce risk to the government, improve efficiency in pressure garment design efforts, and enable the government to be a smart buyer. The expectation is to provide requirements at the specification level that are validated so that their impact on pressure garment design is understood. Additionally, the team will provide defined verification protocols for the requirements. However, in reviewing exploration space suit high level requirements there are several gaps in the team's ability to define and verify related lower level requirements. This paper addresses the efforts in requirement areas such as mobility/fit/comfort and environmental protection (dust, radiation, plasma, secondary impacts) to determine the method by which the requirements can be defined and use of those methods for verification. Gaps exist at various stages. In some cases component level work is underway, but no system level effort has begun; in other cases no effort has been initiated to close the gap. Status of on-going efforts and potential approaches to open gaps are discussed.

Ross, Amy↗
NASA NTRS2004

Advanced Manufacturing Techniques Demonstrated for Fabricating Developmental Hardware

NASA Glenn Research Center's Engineering Development Division has been working in support of innovative gas turbine engine systems under development by Glenn's Combustion Branch. These one-of-a-kind components require operation under extreme conditions. High-temperature ceramics were chosen for fabrication was because of the hostile operating environment. During the designing process, it became apparent that traditional machining techniques would not be adequate to produce the small, intricate features for the conceptual design, which was to be produced by stacking over a dozen thin layers with many small features that would then be aligned and bonded together into a one-piece unit. Instead of using traditional machining, we produced computer models in Pro/ENGINEER (Parametric Technology Corporation (PTC), Needham, MA) to the specifications of the research engineer. The computer models were exported in stereolithography standard (STL) format and used to produce full-size rapid prototype polymer models. These semi-opaque plastic models were used for visualization and design verification. The computer models also were exported in International Graphics Exchange Specification (IGES) format and sent to Glenn's Thermal/Fluids Design & Analysis Branch and Applied Structural Mechanics Branch for profiling heat transfer and mechanical strength analysis.

Redding, Chip↗
NASA NTRS2003

Development of Methodologies for IV and V of Neural Networks

Non-deterministic systems often rely upon neural network (NN) technology to "lean" to manage flight systems under controlled conditions using carefully chosen training sets. How can these adaptive systems be certified to ensure that they will become increasingly efficient and behave appropriately in real-time situations? The bulk of Independent Verification and Validation (IV&V) research of non-deterministic software control systems such as Adaptive Flight Controllers (AFC's) addresses NNs in well-behaved and constrained environments such as simulations and strict process control. However, neither substantive research, nor effective IV&V techniques have been found to address AFC's learning in real-time and adapting to live flight conditions. Adaptive flight control systems offer good extensibility into commercial aviation as well as military aviation and transportation. Consequently, this area of IV&V represents an area of growing interest and urgency. ISR proposes to further the current body of knowledge to meet two objectives: Research the current IV&V methods and assess where these methods may be applied toward a methodology for the V&V of Neural Network; and identify effective methods for IV&V of NNs that learn in real-time, including developing a prototype test bed for IV&V of AFC's. Currently. no practical method exists. lSR will meet these objectives through the tasks identified and described below. First, ISR will conduct a literature review of current IV&V technology. TO do this, ISR will collect the existing body of research on IV&V of non-deterministic systems and neural network. ISR will also develop the framework for disseminating this information through specialized training. This effort will focus on developing NASA's capability to conduct IV&V of neural network systems and to provide training to meet the increasing need for IV&V expertise in such systems.

Taylor, Brian↗
NASA NTRS1994

Using virtual reality for science mission planning: A Mars Pathfinder case

NASA's Mars Pathfinder Project requires a Ground Data System (GDS) that supports both engineering and scientific payloads with reduced mission operations staffing, and short planning schedules. Also, successful surface operation of the lander camera requires efficient mission planning and accurate pointing of the camera. To meet these challenges, a new software strategy that integrates virtual reality technology with existing navigational ancillary information and image processing capabilities. The result is an interactive workstation based applications software that provides a high resolution, 3-dimensial, stereo display of Mars as if it were viewed through the lander camera. The design, implementation strategy and parametric specification phases for the development of this software were completed, and the prototype tested. When completed, the software will allow scientists and mission planners to access simulated and actual scenes of Mars' surface. The perspective from the lander camera will enable scientists to plan activities more accurately and completely. The application will also support the sequence and command generation process and will allow testing and verification of camera pointing commands via simulation.

Kim, Jacqueline H.↗
DOE OSTI2024

Heterogeneous Integration Technologies for High-temperature, High-density, Low-profile Power Modules of Wide Bandgap Devices in Electric Drive Applications (Final Technical Report)

The goal of this project is to develop packaging technologies for making high-temperature, high-density, and low-profile wide-bandgap (WBG) power electronics modules for electric drives. These modules are aimed at enabling the DOE’s University Consortium to reach its 2025 inverter targets of ≥ 100 kW/L and ≤ 2.7 $/kW. The specific objectives are to: design and fabricate SiC half-bridge power modules with double-sided cooling and parasitic inductances < 5 nH, heat flux density > 400 W/cm 2 , and working junction temperature of 200 o C; design, fabricate, and deliver a gate driver with double-sided cooled modules for the construction of a 100 kW/L inverter at Oak Ridge National Lab; and design and prototype intelligent gate drivers with integrated current sensor and a low-profile DC-DC power supply with air-core transformer for testing power modules at 200 o C junction temperature. We followed an iterative technical approach of design, simulation, fabrication, and testing of various versions of modules, current sensors, and power supply. The state-of-the-art silicon carbide devices rated at 1.2 kV and 149 A were packaged by sintered-silver bonding on an aluminum nitride direct-bond-copper substrate for high thermal conductivity, high working temperature, and high joint reliability. Porous silver posts were used to interconnect the device’s source pads to the other direct-bond-copper substrate for low mechanical stresses, ease of manufacturing, and double-sided cooling. A current sensor based on package parasitic inductance was developed to measure switching current. A dynamic feedback scheme was developed to compensate the effect of parasitic resistance and temperature variation. A constant-current class-E dc-dc converter with air-core transformer was developed. Air-core transformer was used due to the unavailability of magnetic core at high temperatures. Gate driver and power supply were integrated with the double-side cooled, high temperature SiC power modules for testing the modules at 200 o C junction temperature. Double-pulse and continuous testing of the integrated technologies validated the design and fabrication of the three component technologies. Throughout the project, we overcame the challenge for design verification caused by low prototyping yield, which then helped train the graduate students, the future workforce, to learn the engineering know-how for low-cost manufacturing of reliable products. Below is a summary of the major accomplishments of this project: development of a prototyping process for fabricating double-side cooled (1200 V, 149 A) SiC phase-leg modules capable of working to 200 o C Tj; simulation and experimental verification of the improvement of thermo-mechanical reliability of the double-side cooled SiC phase-leg module by using rigid encapsulant; design and experimental validation of a current sensor based on package parasitic inductance and a compensation solution for eliminating the effect of parasitic resistance; design and experimental validation of a low-profile power supply with six-output air-core transformer for gate driver; functional demonstration of a SiC phase-leg module integrated with its gate driver, current sensor, and an air-core power supply at 200 o C Tj in a double-pulse switching test setup and Buck converter continuous test setup; successful completion of six PhD and two MS students who are or will work at Apple Inc., Tesla Inc., Wolfspeed Inc., Microchip Inc., Monolithic Power Systems Inc., and LG Magna Inc.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
NASA NTRS2016

Space Suit Portable Life Support System (PLSS) 2.0 Pre-Installation Acceptance (PIA) Testing

Following successful completion of the space suit Portable Life Support System (PLSS) 1.0 development and testing in 2011, the second system-level prototype, PLSS 2.0, was developed in 2012 to continue the maturation of the advanced PLSS design which is intended to reduce consumables, improve reliability and robustness, and incorporate additional sensing and functional capabilities over the current Space Shuttle/International Space Station Extravehicular Mobility Unit (EMU) PLSS. PLSS 2.0 represents the first attempt at a packaged design comprising first generation or later component prototypes and medium fidelity interfaces within a flight-like representative volume. Pre-Installation Acceptance (PIA) is carryover terminology from the Space Shuttle Program referring to the series of test sequences used to verify functionality of the EMU PLSS prior to installation into the Space Shuttle airlock for launch. As applied to the PLSS 2.0 development and testing effort, PIA testing designated the series of 27 independent test sequences devised to verify component and subsystem functionality, perform in situ instrument calibrations, generate mapping data to define set-points for control algorithms, evaluate hardware performance against advanced PLSS design requirements, and provide quantitative and qualitative feedback on evolving design requirements and performance specifications. PLSS 2.0 PIA testing was carried out from 3/20/13 - 3/15/14 using a variety of test configurations to perform test sequences that ranged from stand-alone component testing to system-level testing, with evaluations becoming increasingly integrated as the test series progressed. Each of the 27 test sequences was vetted independently, with verification of basic functionality required before completion. Because PLSS 2.0 design requirements were evolving concurrently with PLSS 2.0 PIA testing, the requirements were used as guidelines to assess performance during the tests; after the completion of PIA testing, test data served to improve the fidelity and maturity of design requirements as well as plans for future advanced PLSS functional testing.

Watts, Carly↗