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NASA NTRS1996

Construction of a Piezoresistive Neural Sensor Array

The construction of a piezoresistive - piezoelectric sensor (or actuator) array is proposed using 'neural' connectivity for signal recognition and possible actuation functions. A closer integration of the sensor and decision functions is necessary in order to achieve intrinsic identification within the sensor. A neural sensor is the next logical step in development of truly 'intelligent' arrays. This proposal will integrate 1-3 polymer piezoresistors and MLC electroceramic devices for applications involving acoustic identification. The 'intelligent' piezoresistor -piezoelectric system incorporates printed resistors, composite resistors, and a feedback for the resetting of resistances. A model of a design is proposed in order to simulate electromechanical resistor interactions. The goal of optimizing a sensor geometry for improving device reliability, training, & signal identification capabilities is the goal of this work. At present, studies predict performance of a 'smart' device with a significant control of 'effective' compliance over a narrow pressure range due to a piezoresistor percolation threshold. An interesting possibility may be to use an array of control elements to shift the threshold function in order to change the level of resistance in a neural sensor array for identification, or, actuation applications. The proposed design employs elements of: (1) conductor loaded polymers for a 'fast' RC time constant response; and (2) multilayer ceramics for actuation or sensing and shifting of resistance in the polymer. Other material possibilities also exist using magnetoresistive layered systems for shifting the resistance. It is proposed to use a neural net configuration to test and to help study the possible changes required in the materials design of these devices. Numerical design models utilize electromechanical elements, in conjunction with structural elements in order to simulate piezoresistively controlled actuators and changes in resistance of sensors. The construction of these devices may show significant improvement in ability to interrogate signals and in the control of effective compliance. This work focuses on the development a variety of series/parallel interconnected piezoresistive control elements for the neural sensing function.

Carlson, W. B.↗

NASA NTRS1997

Robot Position Sensor Fault Tolerance

Robot systems in critical applications, such as those in space and nuclear environments, must be able to operate during component failure to complete important tasks. One failure mode that has received little attention is the failure of joint position sensors. Current fault tolerant designs require the addition of directly redundant position sensors which can affect joint design. A new method is proposed that utilizes analytical redundancy to allow for continued operation during joint position sensor failure. Joint torque sensors are used with a virtual passive torque controller to make the robot joint stable without position feedback and improve position tracking performance in the presence of unknown link dynamics and end-effector loading. Two Cartesian accelerometer based methods are proposed to determine the position of the joint. The joint specific position determination method utilizes two triaxial accelerometers attached to the link driven by the joint with the failed position sensor. The joint specific method is not computationally complex and the position error is bounded. The system wide position determination method utilizes accelerometers distributed on different robot links and the end-effector to determine the position of sets of multiple joints. The system wide method requires fewer accelerometers than the joint specific method to make all joint position sensors fault tolerant but is more computationally complex and has lower convergence properties. Experiments were conducted on a laboratory manipulator. Both position determination methods were shown to track the actual position satisfactorily. A controller using the position determination methods and the virtual passive torque controller was able to servo the joints to a desired position during position sensor failure.

Aldridge, Hal A.↗

NASA NTRS1997

Fiber-Optic Temperature Sensor Using a Thin-Film Fabry-Perot Interferometer

A fiber-optic temperature sensor was developed that is rugged, compact, stable, and can be inexpensively fabricated. This thin-film interferometric temperature sensor was shown to be capable of providing a +/- 2 C accuracy over the range of -55 to 275 C, throughout a 5000 hr operating life. A temperature-sensitive thin-film Fabry-Perot interferometer can be deposited directly onto the end of a multimode optical fiber. This batch-fabricatable sensor can be manufactured at a much lower cost than can a presently available sensor, which requires the mechanical attachment of a Fabry-Perot interferometer to a fiber. The principal disadvantage of the thin-film sensor is its inherent instability, due to the low processing temperatures that must be used to prevent degradation of the optical fiber's buffer coating. The design of the stable thin-film temperature sensor considered the potential sources of both short and long term drifts. The temperature- sensitive Fabry-Perot interferometer was a silicon film with a thickness of approx. 2 microns. A laser-annealing process was developed which crystallized the silicon film without damaging the optical fiber. The silicon film was encapsulated with a thin layer of Si3N4 over coated with aluminum. Crystallization of the silicon and its encapsulation with a highly stable, impermeable thin-film structure were essential steps in producing a sensor with the required long-term stability.

Beheim, Glenn↗

NASA NTRS1997

Chemical Gas Sensors for Aeronautic and Space Applications

Aeronautic and space applications require the development of chemical sensors with capabilities beyond those of commercially available sensors. Two areas of particular interest are safety monitoring and emission monitoring. In safety monitoring, detection of low concentrations of hydrogen at potentially low temperatures is important while for emission monitoring the detection of nitrogen oxides, hydrogen, hydrocarbons and oxygen is of interest. This paper discusses the needs of aeronautic and space applications and the point-contact sensor technology being developed to address these needs. The development of these sensors is based on progress in two types of technology: (1) Micromachining and microfabrication technology to fabricate miniaturized sensors. (2) The development of high temperature semiconductors, especially silicon carbide. The detection of each type of gas involves its own challenges in the fields of materials science and fabrication technology. The number of dual-use commercial applications of this microfabricated gas sensor technology make this general area of sensor development a field of significant interest.

Hunter, Gary W.↗

NASA NTRS1998

Neural Network-Based Sensor Validation for Turboshaft Engines

Sensor failure detection, isolation, and accommodation using a neural network approach is described. An auto-associative neural network is configured to perform dimensionality reduction on the sensor measurement vector and provide estimated sensor values. The sensor validation scheme is applied in a simulation of the T700 turboshaft engine in closed loop operation. Performance is evaluated based on the ability to detect faults correctly and maintain stable and responsive engine operation. The set of sensor outputs used for engine control forms the network input vector. Analytical redundancy is verified by training networks of successively smaller bottleneck layer sizes. Training data generation and strategy are discussed. The engine maintained stable behavior in the presence of sensor hard failures. With proper selection of fault determination thresholds, stability was maintained in the presence of sensor soft failures.

Moller, James C.↗

NASA NTRS2000

The Video Guidance Sensor: Space, Earth, Ground, and Sea

Engineers at the Marshall Space Flight Center (MSFC) have been developing and testing video-based sensors for automated spacecraft guidance for several years. The next generation of Video Guidance Sensor (VGS) is being designed to be faster and more capable than ever. It will have applications to relative position measurement in any field of endeavor. The system works by sequentially firing two different wavelengths of laser diodes at the target (which has retroreflectors) and processing the two images. Since the target only reflects one wavelength, it shows up well in one image and not at all in the other. Because the target's dimensions are known, the relative positions and attitudes of the target and the sensor can be computed from the spots reflected from the target. The current sensor operates at 5 Hz at ranges from 1 to 110 meters with a 20 deg. field-of-view. The Video Guidance Sensor (VGS) developed over the past several years has performed well in testing and met the objective of being used as the terminal guidance sensor for an automated rendezvous and capture system. The first VGS was successfully tested in closed-loop 3-degree-of-freedom (3-DOF) tests in 1989 and then in 6-DOF open-loop tests in 1992 and closed-loop tests in 1993-4. Development and testing continued, and in 1995 approval was given to test the VGS in an experiment on the Space Shuttle. The VGS flew in 1997 and in 1998, performing well during both flight experiments. During the development and testing before, during, and after the flight experiments, numerous areas for improvement were found. The next generation of VGS is being designed to operate at up to 100 Hz tracking rates and at ranges from 0.5 to 200 meters. In addition to its use as a spacecraft guidance sensor, it could be used as an alignment aid for an operator of a remote system (giving position and attitude feedback data), as a feedback system for a robotic arm, or for automated vehicle guidance. The next generation VGS, with its higher tracking rates, smaller size, and lower power could be used in more places than the original VGS, and by using LED's instead of laser diodes, the system would be eye-safe at any range. More potential applications include aerial station keeping (keeping 2 or more autonomous aircraft within particular relative positions), under-water robotics, and the guidance of ground vehicles in predefined areas equipped with sets of targets.

Howard, Richard T.↗

NASA NTRS2001

Video-Based Sensor for Robotic Position and Attitude determination

NASA's Marshall Space Flight Center (MSFC) has, for the last ten years, developed various video-based sensors for use in automated docking systems. The latest generation of sensor will operate at rates of up to 100 Hz, determining the relative position (X, Y, and Z) and attitude (Roll, Pitch, and Yaw) between the sensor and a small 3-dimensional target, making it suitable for applications in robotic sensing. The Advanced Video Guidance Sensor (AVGS) is designed to track multiple targets at different ranges and determine the position and attitude of each one. The previous generation of video sensor, the Video Guidance Sensor (VGS), was flown twice on the Space Shuttle to test its performance on orbit. One of the tests performed was determining the relative positions and attitudes between the VGS and its target, which was moved to various positions using the Remote Manipulator System (RMS). The RMS position data and VGS measured data were analyzed after the flights, with good correlation between the position and attitude data of the two data sets. The test using the RMS gives a good idea of the ability of the use of the AVGS as a sensor for end-effector position and attitude determination.

Howard, Richard T.↗

NASA NTRS2001

A Wind Tunnel Study on the Mars Pathfinder (MPF) Lander Descent Pressure Sensor

The primary focus of this study was to determine the accuracy of the Mars Pathfinder lander local pressure readings in accordance with the actual ambient atmospheric pressures of Mars during parachute descent. In order to obtain good measurements, the plane of the lander pressure sensor opening should ideally be situated so that it is parallel to the freestream. However, due to two unfavorable conditions, the sensor was positioned in locations where correction factors are required. One of these disadvantages is due to the fact that the parachute attachment point rotated the lander's center of gravity forcing the location of the pressure sensor opening to be off tangent to the freestream. The second and most troublesome factor was that the lander descends with slight oscillations that could vary the amplitude of the sensor readings. In order to accurately map the correction factors required at each sensor position, an experiment simulating the lander descent was conducted in the Martian Surface Wind Tunnel at NASA Ames Research Center. Using a 115 scale model at Earth ambient pressures, the test settings provided the necessary Reynolds number conditions in which the actual lander was possibly subjected to during the descent. In the analysis and results of this experiment, the readings from the lander sensor were converted to the form of pressure coefficients. With a contour map of pressure coefficients at each lander oscillatory position, this report will provide a guideline to determine the correction factors required for the Mars Pathfinder lander descent pressure sensor readings.

Soriano, J. Francisco↗

NASA NTRS2001

A Thin Film Multifunction Sensor for Harsh Environments

The status of work at NASA Glenn Research Center to develop a minimally intrusive integrated sensor to provide realtime measurement of strain, heat flux and flow in high temperature environments is presented in this paper. The sensor can be beneficial as a single package to characterize multiple stress and strain modes simultaneously on materials and components during engine development and validation. A major technical challenge is to take existing individual gauge designs and modify them into one integrated thin film sensor. Ultimately, the goal is to develop the ability to deposit the sensors directly onto internal engine parts or on a small thin substrate that can be attached to engine components. Several prototype sensors constructed of platinum, platinum-rhodium alloy, and alumina on constant-strain alumina beams have been built and bench-tested. The technical challenges of the design. construction, and testing are discussed. Data from the preliminary testing of the sensor array is presented. The future direction for the sensor development is discussed as well.

Wrbanek, John D.↗

NASA NTRS2001

Thin Film Sensors for Surface Measurements

Advanced thin film sensors that can provide accurate surface temperature, strain, and heat flux measurements have been developed at NASA Glenn Research Center. These sensors provide minimally intrusive characterization of advanced propulsion materials and components in hostile, high-temperature environments as well as validation of propulsion system design codes. The sensors are designed for applications on different material systems and engine components for testing in engine simulation facilities. Thin film thermocouples and strain gauges for the measurement of surface temperature and strain have been demonstrated on metals, ceramics and advanced ceramic-based composites of various component configurations. Test environments have included both air-breathing and space propulsion-based engine and burner rig environments at surface temperatures up to 1100 C and under high gas flow and pressure conditions. The technologies developed for these sensors as well as for a thin film heat flux gauge have been integrated into a single multifunctional gauge for the simultaneous real-time measurement of surface temperature, strain, and heat flux. This is the first step toward the development of smart sensors with integrated signal conditioning and high temperature electronics that would have the capability to provide feedback to the operating system in real-time. A description of the fabrication process for the thin film sensors and multifunctional gauge will be provided. In addition, the material systems on which the sensors have been demonstrated, the test facilities and the results of the tests to-date will be described. Finally, the results will be provided of the current effort to demonstrate the capabilities of the multifunctional gauge.

Martin, Lisa C.↗

NASA NTRS2003

Concepts and Development of Bio-Inspired Distributed Embedded Wired/Wireless Sensor Array Architectures for Acoustic Wave Sensing in Integrated Aerospace Vehicles

This paper discusses the modeling of acoustic emissions in plate structures and their sensing by embedded or surface bonded piezoelectric sensor arrays. Three different modeling efforts for acoustic emission (AE) wave generation and propagation are discussed briefly along with their advantages and disadvantages. Continuous sensors placed at right angles on a plate are being discussed as a new approach to measure and locate the source of acoustic waves. Evolutionary novel signal processing algorithms and bio-inspired distributed sensor array systems are used on large structures and integrated aerospace vehicles for AE source localization and preliminary results are presented. These systems allow for a great reduction in the amount of data that needs to be processed and also reduce the chances of false alarms from ambient noises. It is envisioned that these biomimetic sensor arrays and signal processing techniques will be useful for both wireless and wired sensor arrays for real time health monitoring of large integrated aerospace vehicles and earth fixed civil structures. The sensor array architectures can also be used with other types of sensors and for other applications.

Ghoshal, Anindya↗

NASA NTRS2003

Offset of a Drag-Free Sensor from the Center of Gravity of Its Satellite

The drag-free satellite is one that encloses a proof mass, shielding it from atmospheric drag and solar radiation pressure (SRP). By sensing the location of the proof mass in the body and using thrusters to force the spacecraft to follow the proof mass in a closed-loop fashion, the effects of drag and SRP may be eliminated from the spacecraft orbit. Thus, several benefits may be gained, including improved ephemeris propagation and reduced operational costs. The package including the proof mass and the location sensing equipment may be considered as a single sensor; if generalized, such a sensor could be manufactured and used more easily in satellite designs, similar to how current missions use, for example, rate gyros and magnetometers. The flight heritage of the technology has been such that the proof mass sensor is a primary facet of the mission, allowing it to dominate design considerations. In particular, this paper discusses the effects that may be expected if a generalized drag-free sensor is placed some distance away from the spacecraft center of gravity. The proof mass will follow a given gravitational orbit, and a separation from the spacecraft center of gravity places the spacecraft itself in a different orbit from the proof mass, requiring additional fuel just to maintain function of the drag- free sensor. Conclusions include some guiding principles for determining whether certain mission characteristics may restrict or preclude the use of drag-free sensors for that mission. These principles may be used both by mission planners considering drag-free missions and by hardware designers considering or pursuing the development of such generalized sensors.

Starin, Scott R.↗

NASA NTRS1997

A Disturbance Rejection Approach to Actuator and Sensor Placement

For various reasons as discussed for instance in, the selection of actuator and sensor positions is still ad hoc. This is especially true for flexible structures where many candidate configurations can exist. This study is an attempt to make the selection process more methodical. One approach to actuator and sensor placement is to optimize a closed loop performance metric directly by selecting the actuators, sensors, and controller gains simultaneously. This direct approach makes sense if the desired closed loop performance is well defined. Since the individual actuator and sensor contributions to the closed loop performance metric is complex, the solution strategy usually employs non linear programming with many design and numerical iterations. A second approach is to select actuators and/or sensors based on open loop properties so that closed loop performance is indirectly optimized. Since the individual sensor and actuator contributions to the open loop metric is simple, nonlinear optimization is usually not needed. This approach will suggest efficient actuator and sensor configurations for any type of control law. The method suggested in this study falls into the latter class of approaches.

Lim, K. B.↗

NASA NTRS1993

Development of a piezopolymer pressure sensor for a portable fetal heart rate monitor

A piezopolymer pressure sensor has been developed for service in a portable fetal heart rate monitor, which will permit an expectant mother to perform the fetal nonstress test, a standard predelivery test, in her home. Several sensors are mounted in an array on a belt worn by the mother. The sensor design conforms to the distinctive features of the fetal heart tone, namely, the acoustic signature, frequency spectrum, signal amplitude, and localization. The components of a sensor serve to fulfill five functions: signal detection, acceleration cancellation, acoustical isolation, electrical shielding, and electrical isolation of the mother. A theoretical analysis of the sensor response yields a numerical value for the sensor sensitivity, which is compared to experiment in an in vitro sensor calibration. Finally, an in vivo test on patients within the last six weeks of term reveals that nonstress test recordings from the acoustic monitor compare well with those obtained from conventional ultrasound.

Heart Rate, Fetal/physiology↗

NASA NTRS2005

Simulation and ground testing with the Advanced Video Guidance Sensor

The Advanced Video Guidance Sensor (AVGS), an active sensor system that provides near-range 6-degree-of-freedom sensor data, has been developed as part of an automatic rendezvous and docking system for the Demonstration of Autonomous Rendezvous Technology (DART). The sensor determines the relative positions and attitudes between the active sensor and the passive target at ranges up to 300 meters. The AVGS uses laser diodes to illuminate retro-reflectors in the target, a solid-state imager to detect the light returned from the target, and image capture electronics and a digital signal processor to convert the video information into the relative positions and attitudes. The development of the sensor, through initial prototypes, final prototypes, and three flight units, has required a great deal of testing at every phase, and the different types of testing, their effectiveness, and their results, are presented in this paper, focusing on the testing of the flight units. Testing has improved the sensor's performance.

Howard, Richard T.↗

NASA NTRS2004

Resolving the Issues with Flywheel Position Sensors

For the past few years, the Advanced Electrical Systems Branch here at NASA Glenn has been pursuing research in the area of flywheels. The purpose of these pursuits has been t o explore the potential for flywheels to replace current battery-powered systems in space. So far it has been learned that flywheels offer large momentum storage capacity, comparatively small volume, high durability, and near- complete discharge capabilities, all of which are advancements over the existing nickel hydrogen and nickel cadmium batteries. Another significant advantage of flywheels is the potential they offer for combining the function of attitude control with energy storage. During the summer of 2004, I worked with Dr. Barbara Kenny in the Advanced Electrical Systems Branch, supporting the work she is doing by analyzing and testing some new components for the new Generation-2 flywheel. To monitor the speed and angular position of the flywheel rotor, a once-around (OAR) signal along with a sensorless algorithm is used. The OAR signal is used for the magnetic bearings that keep the flywheel suspended for frictionless operation. The sensorless algorithm is used for the flywheel motor/generator control. The OAR is generated from position sensors that monitor a circular plate. The plate has a cut down the middle such that one half of the circle is on a slightly lower level than the other. Every half-turn, or 180, the sensors detect the "cut" on the plate, and trigger the OAR, telling the computer that the rotor has made half a revolution. This, however, doesn't provide needed detailed information about the angular position of the rotor, since it only provides a signal alert every half- revolution. This is enough information for the magnetic bearing control but is insufficient for the motor/generator control. A new resolver was designed such that it would give continuous angle information rather than the 180 degree information of the OAR. The new resolver has two separate observable pieces: a flat middle section to monitor vertical motion, and an angled section around the circumference, which, when observed from above, produces a sine-wave displacement through the entire 360" revolution. My first job when I arrived this summer was to calibrate the sensors that would be mounted on the inside of the flywheel casing to monitor the position (angular and vertical) of the shaft. After calibration, I used the sensors to evaluate voltage outputs created by position differences between two pairs of sensors on the angled portion of the resolver for eight different angular positions, moving the resolver vertically and laterally through its entire potential range of motion. The results of these tests will be used to determine the rotor angular (and axial) position from the sensor readings once the new flywheel unit is assembled. The sensorless algorighm mentioned above consists of two operations: the signal injection method and the back electro-motive force (EMF). The signal injection is meant to work at low speeds, while the back EMF algorithm is meant to work at higher speeds. Both work together to determine the correct estimate of rotor position and speed based on the measured motor/generator current. It was determined that we wanted to know exactly how accurate our estimation methods were, and so a resolver (a commercially available mechanical sensor mounted to the motor/generator shaft to measure rotor position and speed) and a "Resolver to Digital" (R2D) circuit board was purchased to make the comparison to the existing estimation. My work related to the R2D board has included the following: creating two connector cables (one to power the circuit and one to get readable output off the board), writing Simulink code to process the board's output, and building a dSpace panel to control and monitor the circuit. The next step in the process will be to perform tests to compare the estimated rotor position and speed from the sensorless algorithm to the actual rotor and speed from the resolver signal.

Fehrmann, Elizabeth A.↗

NASA NTRS1999

Sensor Lead Wires Positioned on SiC-based Monolithic Ceramic and Fiber- reinforced Ceramic Matrix Composite Subcomponents with Flat and Curved Surfaces

There is strong interest in the development of silicon carbide-based monolithic ceramic and composite materials and components for demanding, high-temperature applications. Thorough characterization of material properties, including high-temperature testing under simulated or actual operating conditions, is a high priority for programs involved in developing these silicon carbide- (SiC) based materials and components. Members of the Sensors and Electronics Technology Branch at the NASA Lewis Research Center are developing minimally intrusive methods of measuring the properties (such as the surface temperature, strain, and heat flux characteristics) of components and subelements that are being tested or operated in hostile, high-temperature environments. Their primary goal is to instrument the test article or operating component with durable sensors that have a minimal effect on test conditions such as the gas flow across the surface of the item and the material response (including the through-thickness conduction of heat). Therefore, the main thrust of their work has been the development of thin-film sensors (e.g., thermocouples or strain gauges) for use on various advanced material test articles, including SiC/SiC composite components. There was a need for a better method of securing sensor lead wires on SiC-based components and subelements that would be tested at temperatures to 1000 C (or higher), to enhance the durability of the overall minimally intrusive sensor system. To address this need, Lewis researchers devised an alternative approach for positioning the sensor lead wires (which are connected to the thin-film sensors) on SiC or SiC/SiC components. A reaction-forming method of joining was used to strongly bond hoop-shaped monolithic SiC and SiC/SiC composite attachments of various sizes to both flat and curved surfaces of SiC/SiC composite subelements (see the photos). This approach is based on an affordable, robust ceramic joining technology, named ARCJoinT, which was developed at Lewis for the joining of SiC-based ceramics and fiber-reinforced composites.

Kiser, James D.↗

NASA NTRS2000

Packaging Technology Developed for High-Temperature SiC Sensors and Electronics

A ceramic- and thick-film-materials-based prototype electronic package designed for silicon carbide (SiC) high-temperature sensors and electronics has been successfully tested at 500 C in an oxygen-containing air environment for 500 hours. This package was designed, fabricated, assembled, and electronically evaluated at the NASA Glenn Research Center at Lewis Field with an in-house-fabricated SiC semiconductor test chip. High-temperature electronics and sensors are necessary for harsh-environment space and aeronautical applications, such as space missions to the inner solar system or the emission control electronics and sensors in aeronautical engines. Single-crystal SiC has such excellent physical and chemical material properties that SiC-based semiconductor electronics can operate at temperatures over 600 C, which is significantly higher than the limit for Si-based semiconductor devices. SiC semiconductor chips were recently demonstrated to be operable at temperatures as high as 600 C, but only in the probe station environment because suitable packaging technology for sensors and electronics at temperatures of 500 C and beyond did not exist. Thus, packaging technology for SiC-based sensors and electronics is immediately needed for both application and commercialization of high-temperature SiC sensors and electronics. In response to this need, researchers at Glenn designed, fabricated, and assembled a prototype electronic package for high-temperature electronics, sensors, and microelectromechanical systems (MEMS) using aluminum nitride (AlN) substrate and gold (Au) thick-film materials. This prototype package successfully survived a soak test at 500 C in air for 500 hours. Packaging components tested included thick-film high-temperature metallization, internal wire bonds, external lead bonds, and a SiC diode chip die-attachment. Each test loop, which was composed of thick-film printed wire, wire bond, and lead bond was subjected to a 50-mA direct current for 250 hours at 500 C.

Chen, Liang-Yu↗