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At least 271 records · Page 15

Utilization of Machine Learning Techniques for Managing the Tracking and Data Relay Satellite Constellation

National Aeronautics and Space Administration’s (NASA) Goddard Space Flight Center (GSFC) operates a constellation of ten geosynchronous Tracking and Data Relay Satellites (TDRS). The TDRS constellation consists of multiple geosynchronous communication relay satellites located around the equator so they can provide continual coverage of any mission in low earth orbit. The TDRS are located primarily in three oceanic regions around the earth. NASA’s White Sands Complex provides the ground communication support for TDRS located over the Atlantic and Pacific Oceans. Another TDRS ground station in Guam supports the TDRS over the Indian Ocean. With these satellites the TDRS network can provide continuous coverage of satellites in low-earth orbit. The NASA Space Network (SN) project office at GSFC manages the constellation of spacecraft. Major customers of the TDRS constellation include, but are not limited to, the International Space Station and the Hubble Space Telescope. The TDRS constellation has three generations of satellites and has been active for over 30 years providing reliable communication links between customer satellites and corresponding ground stations. However, one of the major concerns for TDRS, and in any space mission, is to ensure the health and safety of the spacecraft. Generally, engineers use telemetry data to monitor and analyze the performance and state of health of the spacecraft. Telemetry data contains hundreds of parameters that monitor each important component in the spacecraft, which can be utilized to recognize and characterize the behavior of the spacecraft. Each parameter contains considerable information to represent time-dependent properties of each spacecraft subsystem and component. During the entire life of a TDRS spacecraft, thousands of gigabytes of telemetry data are transmitted in real-time from the spacecraft to the ground station at the White Sands Complex in Las Cruces, New Mexico, and recorded as historical data sets for engineers to process and analyze the events that occurred on-orbit. These parameters contain the function of multiple spacecraft subsystems, such as the attitude control system (ACS), Thermal, Electrical Power Subsystem (EPS), etc. . The first and second generations have exceeded their required lifetime and NASA is keen to manage these spacecrafts carefully in order to maximize the remaining life using the spacecraft telemetry. The challenge is to know when the risk of losing a spacecraft in geosynchronous orbit exceeds the benefit of continued operations for customer support. In the TDRS fleet, the EPS is the most critical subsystem related to spacecraft operations. Failure of the EPS would strand a spacecraft in geosynchronous orbit. Since EPS provides power to the spacecraft, component failures ultimately lead to the inability to support the spacecraft loads and the communications payload. For instance, TDRS-8 has several anomalies in EPS including the Bus Voltage Limiter (BVL) shunt current, solar array loss of circuits, and failed battery cells. Any of these anomalies can cause critical issues to the spacecraft. Therefore, developing a system to analyze and perform early detection of a potential anomaly is an important issue in telemetry data analysis. In recent years, Telemetry Mining (TM) has been proposed to process telemetry data by using Data Mining (DM) techniques such as classification, clustering, regression and anomaly detection. Anomaly detection, also known as outlier detection, has been widely used in many data mining areas such as remote sensing, medical data processing and digital image processing. The goal of anomaly detection is to detect abnormal data, which contains a relatively low probability of occurrence among the entire data set. Early detection of anomalies is one of the most significant issues in managing the spacecraft configuration. If anomalies can be detected early enough, then the redundant resources can be used to extend the life of the operational spacecraft. We present an unsupervised anomaly detection method to process the EPS data extracted from TDRS-8. This is different from traditional analytical methods, which use telemetry data to illustrate behavior and physical meaning of each spacecraft component. TM connects multiple parameters as a vector and then conducts data analysis on this high dimension telemetry vector. This method is looking at the properties of a high dimensional vector that is able to consider the relationship between different parameters in the anomaly detection problem. This kind of method performs much better than the traditional limit checking method. In addition, we propose a new approach of real-time anomaly detection to process telemetry data in real-time, which can then be applied to spacecraft monitoring with high reliability, low cost and high accuracy.

Machine Learning (ML)↗

Magnetospheric Atmospheric X-ray Imaging Experiment (MAXIE)

This report summarizes the activities sponsored by the Office of Naval Research for the Magnetospheric Atmospheric X-ray Imaging Experiment (MAXIE). The MAXIE instrument was developed as a joint activity of Lockheed, The Aerospace Corporation, and the University of Bergen, Norway. Lockheed was responsible for the overall management of the program, interfacing with the appropriate government agencies, the overall electrical and mechanical design, flight software, environmental testing, spacecraft integration activities, on orbit checkout, and data processing activities. The Magnetospheric Atmospheric X-ray Imaging Experiment (MAXIE), the ONR 401 experiment, is the first in a new class of satellite-borne remote sensing instruments. The primary innovation is the ability to obtain rapid, sequential, images with high sensitivity of the earth's X ray aurora from a low altitude polar orbiting satellite. These images can be used to identify dynamic temporal variations in the three-dimensional (energy and position) distribution of electron precipitation into the atmosphere. MAXIE was launched on the TIROS NOAA-13 satellite on 9 August 1993. The experiment performed well during its turn-on sequence; however, the spacecraft bus failed on 21 August 1993. New spacebased technologies successfully used in MAXIE were mixed-mode ASIC microcircuits, a zero torque scanning system with associated viscoelastic damping, a paraffin stow release mechanism, a parallel integrating PHA processor, a low noise Si(Li) sensor telescope, and an advanced thermal cooling system. MAXIE's on orbit operation, control of penetrating particle backgrounds, and scientific data indicated good overall performance.

Imhof, W. L.↗

Antenna for Measuring Electric Fields Within the Inner Heliosphere

A document discusses concepts for the design of an antenna to be deployed from a spacecraft for measuring the ambient electric field associated with plasma waves at a location within 3 solar radii from the solar photosphere. The antenna must be long enough to extend beyond the photoelectron and plasma sheaths of the spacecraft (expected to be of the order of meters thick) and to enable measurements at frequencies from 20 Hz to 10 MHz without contamination by spacecraft electric-field noise. The antenna must, therefore, extend beyond the thermal protection system (TPS) of the main body of the spacecraft and must withstand solar heating to a temperature as high as 2,000 C while not conducting excessive heat to the interior of the spacecraft. The TPS would be conical and its axis would be pointed toward the Sun. The antenna would include monopole halves of dipoles that would be deployed from within the shadow of the TPS. The outer potion of each monopole would be composed of a carbon-carbon (C-C) composite surface exposed to direct sunlight (hot side) and a C-C side in shadow (cold side) with yttria-stabilized zirconia spacers in-between. The hot side cannot view the spacecraft bus, while the cold side can. The booms also can be tilted to minimize heat input to spacecraft bus. This design allows one to reduce heat input to the spacecraft bus to acceptable levels.

Sittler, Edward Charles↗

CoNNeCT Baseband Processor Module

A document describes the CoNNeCT Baseband Processor Module (BPM) based on an updated processor, memory technology, and field-programmable gate arrays (FPGAs). The BPM was developed from a requirement to provide sufficient computing power and memory storage to conduct experiments for a Software Defined Radio (SDR) to be implemented. The flight SDR uses the AT697 SPARC processor with on-chip data and instruction cache. The non-volatile memory has been increased from a 20-Mbit EEPROM (electrically erasable programmable read only memory) to a 4-Gbit Flash, managed by the RTAX2000 Housekeeper, allowing more programs and FPGA bit-files to be stored. The volatile memory has been increased from a 20-Mbit SRAM (static random access memory) to a 1.25-Gbit SDRAM (synchronous dynamic random access memory), providing additional memory space for more complex operating systems and programs to be executed on the SPARC. All memory is EDAC (error detection and correction) protected, while the SPARC processor implements fault protection via TMR (triple modular redundancy) architecture. Further capability over prior BPM designs includes the addition of a second FPGA to implement features beyond the resources of a single FPGA. Both FPGAs are implemented with Xilinx Virtex-II and are interconnected by a 96-bit bus to facilitate data exchange. Dedicated 1.25- Gbit SDRAMs are wired to each Xilinx FPGA to accommodate high rate data buffering for SDR applications as well as independent SpaceWire interfaces. The RTAX2000 manages scrub and configuration of each Xilinx.

Yamamoto, Clifford K↗

The electrical power subsystem of the Pioneer F/G spacecraft.

The Pioneer F/G spacecraft is the first to use radioisotope thermoelectric generators (RTG's) for a long duration interplanetary mission. This paper describes the design of the spacecraft power subsystem which meets the unique requirements of such a mission. The primary power source consists of four SNAP 19 RTG's. The 4.2 volt dc outputs of the RTG's are inverted to higher voltage ac by four inverters which are connected in parallel at their outputs. A power control unit (PCU) regulates the ac output of the inverters such that the RTG's are operated at near maximum power voltage throughout the mission. The PCU also contains charge and discharge controls for a silver cadmium battery which supplements the RTG's if load requirements temporarily exceed RTG power output. Battery reliability is enhanced by overcharge and cell reversal protection electronics which are provided for each cell. Multiple, low voltage, regulated dc outputs which supply power to the spacecraft subsystems are provided by a central transformer-rectifier-filter unit (CTRF). The CTRF operates directly from the regulated ac bus.

Reppucci, G. M.↗

Load converter interactions with the secondary system in the Space Station Freedom power management and distribution DC test bed

The NASA LeRC in Cleveland, Ohio, is responsible for the design, development, and assembly of the Space Station Freedom (SSF) Electrical Power System (EPS). In order to identify and understand system level issues during the SSF Program design and development phases, a system Power Management and Distribution (PMAD) DC test bed was assembled. Some of the objectives of this test bed facility are the evaluation of, system efficiency, power quality, system stability, and system protection and reconfiguration schemes. In order to provide a realistic operating scenario, dc Load Converter Units are used in the PMAD dc test bed to characterize the user interface with the power system. These units are dc to dc converters that provide the final system regulation before power is delivered to the load. This final regulation is required on the actual space station because the majority of user loads will require voltage levels different from the secondary bus voltage. This paper describes the testing of load converters in an end to end system environment (from solar array to loads) where their interactions and compatibility with other system components are considered. Some of the system effects of interest that are presented include load converters transient behavior interactions with protective current limiting switchgear, load converters ripple effects, and the effects of load converter constant power behavior with protective features such as foldback.

Lebron, Ramon C.↗

Load converter interactions with the secondary system in the Space Station Freedom power management and distribution dc test bed

The NASA LeRC in Cleveland, Ohio, is responsible for the design, development, and assembly of the Space Station Freedom (SSF) Electrical Power System (EPS). In order to identify and understand system level issues during the SSF program design and development phases, a system Power Management and Distribution (PMAD) dc test bed was assembled. Some of the objectives of this test bed facility are the evaluation of, system efficiency, power quality, system stability, and system protection and reconfiguration schemes. In order to provide a realistic operating scenario, dc Load Converter Units are used in the PMAD dc test bed to characterize the user interface with the power system. These units are dc to dc converters that provide the final system regulation before power is delivered to the load. This final regulation is required on the actual space station because the majority of user loads will require voltage levels different from the secondary bus voltage. This paper describes the testing of load converters in an end to end system environment (from solar array to loads) where their interactions and compatibility with other system components are considered. Some of the system effects of interest that are presented include load converters transient behavior interactions with protective current limiting switchgear, load converters ripple effects, and the effects of load converter constant power behavior with protective features such as foldback.

Lebron, Ramon C.↗

Design of a reconfigurable modular manipulator system

Using manipulators with a fixed configuration for specific tasks is appropriate when the task requirements are known beforehand. However, in less predictable situations, such as an outdoor construction site or aboard a space station, a manipulator system requires a wide range of capabilities, probably beyond the limitations of a single, fixed-configuration manipulator. To fulfill this need, researchers have been working on a Reconfigurable Modular Manipulator System (RMMS). Researchers have designed and are constructing a prototype RMMS. The prototype currently consists of two joint modules and four link modules. The joints utilize a conventional harmonic drive and torque motor actuator, with a small servo amplifier included in the assembly. A brushless resolver is used to sense the joint position and velocity. For coupling the modules together, a standard electrical connector and V-band clamps for mechanical connection are used, although more sophisticated designs are under way for future versions. The joint design yields an output torque to 50 ft-lbf at joint speeds up to 1 radian/second. The resolver and associated electronics have resolutions of 0.0001 radians, and absolute accuracies of plus or minus 0.001 radians. Manipulators configured from these prototype modules will have maximum reaches in the 0.5 to 2 meter range. The real-time RMMS controller consists of a Motorola 68020 single-board computer which will perform real time servo control and path planning of the manipulator. This single board computer communicates via shared memory with a SUN3 workstation, which serves as a software development system and robot programming environment. Researchers have designed a bus communication network to provide multiplexed communication between the joint modules and the computer controller. The bus supports identification of modules, sensing of joint states, and commands to the joint actuator. This network has sufficient bandwidth to allow servo sampling rates in excess of 500 Hz.

Schmitz, D.↗

Control Demonstration of Multiple Doubly Fed Induction Motors for Hybrid Electric Propulsion

The Convergent Aeronautics Solutions (CAS) High Voltage Hybrid Electric Propulsion (HVHEP) activity was formulated to support the move into future hybrid-electric aircraft. The goal of this high-voltage activity is to develop a new alternating current (AC) power architecture to support the needs of higher efficiency and lower emissions aircraft. This proposed architecture will adopt the use of the doubly fed induction machine (DFIM) for propulsor drive motor application. The DFIMs are attractive for several reasons, including but not limited to, the ability to self-start, the ability to operate subsynchronously and supersynchronously, and the requirement for power converters rated at a fraction of those required in a corresponding direct current system, dependent on the range of operation. The focus of this report is based specifically on the presentation and analysis of a novel strategy, which allows for independent operation of multiple doubly fed induction motors from a common AC bus

David J Sadey↗

The 10 kW power electronics for hydrogen arcjets

A combination of emerging mission considerations such as 'launch on schedule', resource limitations, and the development of higher power spacecraft busses has resulted in renewed interest in high power hydrogen arcjet systems with specific impulses greater than 1000 s for Earth-space orbit transfer and maneuver applications. Solar electric propulsion systems with about 10 kW of power appear to offer payload benefits at acceptable trip times. This work outlines the design and development of 10 kW hydrogen arcjet power electronics and results of arcjet integration testing. The power electronics incorporated a full bridge switching topology similar to that employed in state of the art 5 kW power electronics, and the output filter included an output current averaging inductor with an integral pulse generation winding for arcjet ignition. Phase shifted, pulse width modulation with current mode control was used to regulate the current delivered to arcjet, and a low inductance power stage minimized switching transients. Hybrid power Metal Oxide Semiconductor Field Effect Transistors were used to minimize conduction losses. Switching losses were minimized using a fast response, optically isolated, totem-pole gate drive circuit. The input bus voltage for the unit was 150 V, with a maximum output voltage of 225 V. The switching frequency of 20 kHz was a compromise between mass savings and higher efficiency. Power conversion efficiencies in excess of 0.94 were demonstrated, along with steady state load current regulation of 1 percent. The power electronics were successfully integrated with a 10 kW laboratory hydrogen arcjet, and reliable, nondestructive starts and transitions to steady state operation were demonstrated. The estimated specific mass for a flight packaged unit was 2 kg/kW.

Hamley, John A.↗

Modular Pulsed Plasma Electric Propulsion System for Cubesats

Current capabilities of CubeSats must be improved in order to perform more ambitious missions. Electric propulsion systems will play a key role due to their large specific impulse. Compared to other propulsion alternatives, their simplicity allows an easier miniaturization and manufacturing of autonomous modules into the nano and pico-satellite platform. Pulsed Plasma Thrusters (PPTs) appear as one of the most promising technologies for the near term. The utilization of solid and non-volatile propellants, their low power requirements and their proven reliability in the large scale make them great candidates for rapid implementation. The main challenges are the integration and miniaturization of all the electronic circuitry into a printed circuit board (PCB) that can satisfy the strict requirements that CubeSats present. NASA Ames and the George Washington University have demonstrated functionality and control of three discrete Micro-Cathode Arc Thrusters (CAT) using a bench top configuration that was compatible with the ARC PhoneSat Bus. This demonstration was successfully conducted in a vaccum chamber at the ARC Environmental Test Laboratory. A new effort will integrate a low power Plasma Processing Unit and two plasma thrusters onto a single printed circuit board that will utilize less than 13 U of Bus volume. The target design will be optimized for the accommodation into the PhoneSatEDISON Demonstration of SmallSatellite Networks (EDSN) bus as it uses the same software interface application, which was demonstrated in the previous task. This paper describes the design, integration and architecture of the proposed propulsion subsystem for a planned Technology Demonstration Mission. In addition, a general review of the Pulsed Plasma technology available for CubeSats is presented in order to assess the necessary challenges to overcome further development.

PCB↗

High Input Voltage, Silicon Carbide Power Processing Unit Performance Demonstration

A silicon carbide brassboard power processing unit has been developed by the NASA Glenn Research Center in Cleveland, Ohio. The power processing unit operates from two sources - a nominal 300-Volt high voltage input bus and a nominal 28-Volt low voltage input bus. The design of the power processing unit includes four low voltage, low power supplies that provide power to the thruster auxiliary supplies, and two parallel 7.5 kilowatt power supplies that are capable of providing up to 15 kilowatts of total power at 300-Volts to 500-Volts to the thruster discharge supply. Additionally, the unit contains a housekeeping supply, high voltage input filter, low voltage input filter, and master control board, such that the complete brassboard unit is capable of operating a 12.5 kilowatt Hall Effect Thruster. The performance of unit was characterized under both ambient and thermal vacuum test conditions, and the results demonstrate the exceptional performance with full power efficiencies exceeding 97. With a space-qualified silicon carbide or similar high voltage, high efficiency power device, this design could evolve into a flight design for future missions that require high power electric propulsion systems.

Technology↗

Chandra Space Flight Software: Using Software to Autonomously Operation the Largest and Most Sensitive X-Ray Telescope in the World

Chandra is the world's largest and most sensitive X-ray telescope. The Chandra X-ray Observatory is the third in NASA's family of "Great Observatories." The Chandra X-ray Observatory, launched by Space Shuttle Columbia on July 23, 1999, is NASA's newest Great Observatory. The Chandra space flight software is the operational software, which controls and directs the Chandra X-ray Observatory. The Chandra flight software has executed faultlessly for over 13,000 hours on-orbit. The Chandra flight software directly controls the Pointing, Aspect Determination, Electrical Power Subsystem, Propulsion system, and the Command, Communications, and Data Management subsystems. The software controls the spacecraft operations during all phases of the mission. The software also performs thermal control of the telescope to maintain pointing accuracy and monitors radiation levels throughout the orbit so that the Science Instruments can be safed if radiation thresholds are exceeded. The efficient operation of Chandra flight software has enabled the gathering of crucial science data. The Chandra flight software fault protection is the key to early detection and prevention of science instrument or spacecraft damage in an operating platform/environment, which is completely unforgiving. Permanently open Sun Shade Door and ACIS focal plane radiator sensitivity exposes science instruments and mirrors to damage for pointing anomalies causing an attitude excursion. The Chandra flight software must prevent these attitude excursions from occurring for ANY failure. Another example is that the power system has an unregulated bus, which imposes severe operating requirements on Chandra flight software to control array pointing and battery connection/disconnect using a unique algorithmic and logic approach. The Chandra flight software has enabled a truly autonomous vehicle with greater than 99% of all mission data collected as planned. Less than 15% of spacecraft operations are conducted in view (1 hour out of 8) leading to very extended periods without ground contact. The Chandra flight software implements the flexible mission plan during this out of view period, manages the solid state recorder capacity, controls all pointing and maneuvers, provides fault detection for all satellite subsystems, and initiates communications with the ground at the appropriate time. This paper will describe the software architecture features, key design elements and software testing techniques that have facilitated Chandra's success.

Crumbley, Tim↗

High Input Voltage, Silicon Carbide Power Processing Unit Performance Demonstration

A silicon carbide brassboard power processing unit has been developed by the NASA Glenn Research Center in Cleveland, Ohio. The power processing unit operates from two sources: a nominal 300 Volt high voltage input bus and a nominal 28 Volt low voltage input bus. The design of the power processing unit includes four low voltage, low power auxiliary supplies, and two parallel 7.5 kilowatt (kW) discharge power supplies that are capable of providing up to 15 kilowatts of total power at 300 to 500 Volts (V) to the thruster. Additionally, the unit contains a housekeeping supply, high voltage input filter, low voltage input filter, and master control board, such that the complete brassboard unit is capable of operating a 12.5 kilowatt Hall effect thruster. The performance of the unit was characterized under both ambient and thermal vacuum test conditions, and the results demonstrate exceptional performance with full power efficiencies exceeding 97%. The unit was also tested with a 12.5kW Hall effect thruster to verify compatibility and output filter specifications. With space-qualified silicon carbide or similar high voltage, high efficiency power devices, this would provide a design solution to address the need for high power electric propulsion systems.

Power↗

Development and Integration of an Advanced Stirling Convertor Linear Alternator Model for a Tool Simulating Convertor Performance and Creating Phasor Diagrams

A simple model of the Advanced Stirling Convertors (ASC) linear alternator and an AC bus controller has been developed and combined with a previously developed thermodynamic model of the convertor for a more complete simulation and analysis of the system performance. The model was developed using Sage, a 1-D thermodynamic modeling program that now includes electro-magnetic components. The convertor, consisting of a free-piston Stirling engine combined with a linear alternator, has sufficiently sinusoidal steady-state behavior to allow for phasor analysis of the forces and voltages acting in the system. A MATLAB graphical user interface (GUI) has been developed to interface with the Sage software for simplified use of the ASC model, calculation of forces, and automated creation of phasor diagrams. The GUI allows the user to vary convertor parameters while fixing different input or output parameters and observe the effect on the phasor diagrams or system performance. The new ASC model and GUI help create a better understanding of the relationship between the electrical component voltages and mechanical forces. This allows better insight into the overall convertor dynamics and performance.

Metscher, Jonathan F.↗

Development and Integration of an Advanced Stirling Convertor Linear Alternator Model for a Tool Simulating Convertor Performance and Creating Phasor Diagrams

A simple model of the Advanced Stirling Convertors (ASC) linear alternator and an AC bus controller has been developed and combined with a previously developed thermodynamic model of the convertor for a more complete simulation and analysis of the system performance. The model was developed using Sage, a 1-D thermodynamic modeling program that now includes electro-magnetic components. The convertor, consisting of a free-piston Stirling engine combined with a linear alternator, has sufficiently sinusoidal steady-state behavior to allow for phasor analysis of the forces and voltages acting in the system. A MATLAB graphical user interface (GUI) has been developed to interface with the Sage software for simplified use of the ASC model, calculation of forces, and automated creation of phasor diagrams. The GUI allows the user to vary convertor parameters while fixing different input or output parameters and observe the effect on the phasor diagrams or system performance. The new ASC model and GUI help create a better understanding of the relationship between the electrical component voltages and mechanical forces. This allows better insight into the overall convertor dynamics and performance.

Metscher, Jonathan F.↗

The electrical power subsystem design for the high energy solar physics spacecraft concepts

This paper discusses the Electrical Power Subsystem (EPS) requirements, architecture, design description, performance analysis, and heritage of the components for two spacecraft concepts for the High Energy Solar Physics (HESP) Mission. It summarizes the mission requirements and the spacecraft subsystems and instrument power requirements, and it describes the EPS architecture for both options. A trade study performed on the selection of the solar cells - body mounted versus deployed panels - and the optimum number of panels is also presented. Solar cell manufacturing losses, array manufacturing losses, and the radiation and temperature effects on the GaAs/Ge and Si solar cells were considered part of the trade study and are included in this paper. Solar cell characteristics, cell circuit description, and the solar array area design are presented, as is battery sizing analysis performed based on the power requirements during launch and initial spacecraft operations. This paper discusses Earth occultation periods and the battery power requirements during this period as well as shunt control, battery conditioning, and bus regulation schemes. Design margins, redundancy philosophy, and predicted on-orbit battery and solar cell performance are summarized. Finally, the heritage of the components and technology risk assessment are provided.

Kulkarni, Milind↗

Metallography of Battery Resistance Spot Welds

Li-ion cells provide an energy dense solution for systems that require rechargeable electrical power. However, these cells can undergo thermal runaway, the point at which the cell becomes thermally unstable and results in hot gas, flame, electrolyte leakage, and in some cases explosion. The heat and fire associated with this type of event is generally violent and can subsequently cause damage to the surrounding system or present a dangerous risk to the personnel nearby. The space flight environment is especially sensitive to risks particularly when it involves potential for fire within the habitable volume of the International Space Station (ISS). In larger battery packs such as Robonaut 2 (R2), numerous Li-ion cells are placed in parallel-series configurations to obtain the required stack voltage and desired run-time or to meet specific power requirements. This raises a second and less obvious concern for batteries that undergo certification for space flight use: the joining quality at the resistance spot weld of battery cells to component wires/leads and battery tabs, bus bars or other electronic components and assemblies. Resistance spot welds undergo materials evaluation, visual inspection, conductivity (resistivity) testing, destructive peel testing, and metallurgical examination in accordance with applicable NASA Process Specifications. Welded components are cross-sectioned to ensure they are free of cracks or voids open to any exterior surface. Pore and voids contained within the weld zone but not open to an exterior surface, and are not determined to have sharp notch like characteristics, shall be acceptable. Depending on requirements, some battery cells are constructed of aluminum canisters while others are constructed of steel. Process specific weld schedules must be developed and certified for each possible joining combination. The aluminum canisters' positive terminals were particularly difficult to weld due to a bi-metal strip that comes ultrasonically pre-welded by the manufacturer. This was further complicated as the maximum electrode force was limited to low-electrode force to prevent deflection of the aluminum can during welding. Other Li-ion cells are comprised of smaller diameter cylindrical steel canisters which are inherently capable of handling greater force from the electrodes. Allowing higher-electrode forces aids greatly in insuring a consistent resistance network for the weld. Overall lessons learned: developing good jigs is critical to insure the parts and electrodes are planer to one another and the location of the weld sites remains accurate and repeatable; maintaining strict control over materials is critical--materials must be of a specific hardness and chemical composition to insure that a weld schedule is repeatable; accuracy of the die used to stamp the projections is critical and worth the investment; and proper seasoning of the electrodes is critical to producing consistent welds--once the electrodes have been properly seasoned, cleaning/dressing should be avoided until it is absolutely necessary.

Martinez, J. E.↗