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Health Monitoring System Technology Assessments: Cost Benefits Analysis

The subject of sensor-based structural health monitoring is very diverse and encompasses a wide range of activities including initiatives and innovations involving the development of advanced sensor, signal processing, data analysis, and actuation and control technologies. In addition, it embraces the consideration of the availability of low-cost, high-quality contributing technologies, computational utilities, and hardware and software resources that enable the operational realization of robust health monitoring technologies. This report presents a detailed analysis of the cost benefit and other logistics and operational considerations associated with the implementation and utilization of sensor-based technologies for use in aerospace structure health monitoring. The scope of this volume is to assess the economic impact, from an end-user perspective, implementation health monitoring technologies on three structures. It specifically focuses on evaluating the impact on maintaining and supporting these structures with and without health monitoring capability.

Kent, Renee M.↗

Urban Air Mobility (UAM) Market Study

The Booz Allen Team explored market size and potential barriers to Urban Air Mobility (UAM) by focusing on three potential markets – Airport Shuttle, Air Taxi, and Air Ambulance. We found that the Airport Shuttle and Air Taxi markets are viable, with a significant total available market value in the U.S. of $500 billion, for a fully unconstrained scenario. In this unconstrained best-case scenario, passengers would have the ability to access and fly a UAM at any time, from any location to any destination, without being hindered by constraints such as weather, infrastructure, or traffic volume. Significant legal and regulatory, weather, certification, public perception, and infrastructure constraints exist, which reduce the market potential for these applications to only about 0.5% of the total available market, or $2.5 billion, in the near term. However, we determined that these constraints can be addressed through ongoing intra-governmental partnerships, government and industry collaboration, strong industry commitment, and existing legal and regulatory enablers. We found that the Air Ambulance market is not a viable market if served by electric vertical takeoff and landing (eVTOL) vehicles due to technology constraints but may potentially be viable if a hybrid VTOL aircraft are utilized. The barriers and challenges we characterized in this study can be stratified according to their applicability or potential mitigation through technology as well as market maturity (Figure 1). In the near term, high cost of service will be a key economic challenge. We found potential for significant reduction in service cost through increased vehicle and component efficiency, and automation in a more mature market scenario. Weather conditions also pose a challenge to the UAM market, though there is potential for mitigation of some of these impacts through technology such as sensors enabling operations in low visibility. However, even in a mature market with advanced technology, disruptions are still likely to occur due to weather events such as thunderstorms and strong winds. High density operations will likely stress the current Air Traffic Management (ATM) system in the near term, but technology and new initiatives such as the Air Traffic Management -eXploration project (ATM-X) will enable safe and efficient integration of UAM into the National Airspace System (NAS). Current battery technology creates a barrier in the near term, especially for the Air Ambulance market, as battery weight and extensive recharging times would be needed for these operations. Advancements in battery technology, as well as use of hybrid VTOLs, could significantly reduce this barrier in the longer term. As UAM emerges as a viable mode of transportation in the near term, adverse energy and environmental impacts, particularly noise, may impact community acceptance and potentially persist as the market matures into larger-scale operations. For non-technology related challenges, we found that infrastructure constraints will create a significant barrier to UAM in the near term but could be addressed in the longer term through development and expansion of vertiports. Competition from existing modes of transportation such as ride-sharing (e.g., Lyft, Uber) and ground taxi’s pose a key barrier to UAM in the short term, which will likely evolve into competition from other emerging technologies such as autonomous cars and electric trains in the longer term. Weather events will influence other components of the operation such as passenger comfort (e.g., extreme temperatures, turbulence) and infrastructure (e.g., winter weather causing cracks and degradation in vertiports). There is also potential for these impacts to be heightened in the longer term from the increased frequency of adverse weather such as thunderstorms due to changing climatic conditions. We also found that the public has strong concerns about safety as a passenger in a piloted UAM, including “lasing” of pilots, unruly passengers, and sabotage. They would prefer that all passengers pass through a security screening process before boarding a vehicle. They would also prefer to use UAM for longer regional trips, such as flying from Washington, DC to Baltimore, MD or San Diego, CA to Los Angeles, CA. A longer term automated UAM vehicle market will face challenges due to public apprehension about automation and unmanned operations, and a preference to fly with passengers they know in an autonomous (unmanned) operational scenario.

Rohit Goyal↗

Microchemical and Gaseous Sensors Using Carbon Nanotubes and MEMS Fabrication Technology

The objective of this research is to use a combination of carbon nanotubes and silicon-based microfabrication and micromachining processes to produce unique micro-sized chemical and gaseous sensors. Polished quartz substrate is used. Interdigitated structure is used for the sensing elements. Metallic catalysts for the growth of the carbon nanotube include copper, iron, nickel, and cobalt. Various thicknesses of the metallic catalysts are used in this study varying between 5 to 20 microns. Depositing of the metallic catalyst is accomplished using an ion-beam sputtering thin film technique and a shadow mask. Single wall carbon nanotubes are successfully formed over the metallic catalyst layer. Preliminary measurements of the carbon nanotubes show this nanotube contained film over the sensing elements which had a resistance value of 400 ohms at room temperature. This is a more conductive film comparing to metal oxide films, such as SnO2 or ZnO, that are now widely used in gaseous sensor research. Evaluation of the carbon nanotube film for potential gaseous sensing will be carried out.

Liu, Chung-Chiun↗

Transmittance Measurement of a Heliostat Facility used in the Preflight Radiometric Calibration of Earth-Observing Sensors

Ball Aerospace and Technologies Corporation in Boulder, Colorado, has developed a heliostat facility that will be used to determine the preflight radiometric calibration of Earth-observing sensors that operate in the solar-reflective regime. While automatically tracking the Sun, the heliostat directs the solar beam inside a thermal vacuum chamber, where the sensor under test resides. The main advantage to using the Sun as the illumination source for preflight radiometric calibration is because it will also be the source of illumination when the sensor is in flight. This minimizes errors in the pre- and post-launch calibration due to spectral mismatches. It also allows the instrument under test to operate at irradiance values similar to those on orbit. The Remote Sensing Group at the University of Arizona measured the transmittance of the heliostat facility using three methods, the first of which is a relative measurement made using a hyperspectral portable spectroradiometer and well-calibrated reference panel. The second method is also a relative measurement, and uses a 12-channel automated solar radiometer. The final method is an absolute measurement using a hyperspectral spectroradiometer and reference panel combination, where the spectroradiometer is calibrated on site using a solar-radiation-based calibration.

Czapla-Myers, J.↗

Digest of NASA earth observation sensors

A digest of technical characteristics of remote sensors and supporting technological experiments uniquely developed under NASA Applications Programs for Earth Observation Flight Missions is presented. Included are camera systems, sounders, interferometers, communications and experiments. In the text, these are grouped by types, such as television and photographic cameras, lasers and radars, radiometers, spectrometers, technology experiments, and transponder technology experiments. Coverage of the brief history of development extends from the first successful earth observation sensor aboard Explorer 7 in October, 1959, through the latest funded and flight-approved sensors under development as of October 1, 1972. A standard resume format is employed to normalize and mechanize the information presented.

Drummond, R. R.↗

Orion Relative Navigation Flight Software Analysis and Design

The Orion relative Navigation System has sought to take advantage of the latest developments in sensor and algorithm technology while living under the constraints of mass, power, volume, and throughput. In particular, the only sensor specifically designed for relative navigation is the Vision Navigation System (VNS), a lidar-based sensor. But it uses the Star Trackers, GPS (when available) and IMUs, which are part of the overall Orion navigation sensor suite, to produce a relative state accurate enough to dock with the ISS. The Orion Relative Navigation System has significantly matured as the program has evolved from the design phase to the flight software implementation phase. With the development of the VNS system and the STORRM flight test of the Orion Relative Navigation hardware, much of the performance of the system will be characterized before the first flight. However challenges abound, not the least of which is the elimination of the RF range and range-rate system, along with the development of the FSW in the Matlab/Simulink/Stateflow environment. This paper will address the features and the rationale for the Orion Relative Navigation design as well as the performance of the FSW in a 6-DOF environment as well as the initial results of the hardware performance from the STORRM flight.

D'Souza, Chris↗

Damage Detection Sensor System for Aerospace and Multiple Applications

NASA has identified structural health monitoring and damage detection and verification as critical needs in multiple technology roadmaps. The sensor systems can be customized for detecting location, damage size, and depth, with velocity options and can be designed for particular environments for monitoring of impact or physical damage to a structure. The damage detection system has been successfully demonstrated in a harsh environment and remote integration tested over 1000 miles apart. Multiple applications includes: Spacecraft and Aircraft; Inflatable, Deployable and Expandable Structures; Space Debris Monitoring; Space Habitats; Military Shelters; Solar Arrays, Smart Garments and Wearables, Extravehicular activity (EVA) suits; Critical Hardware Enclosures; Embedded Composite Structures; and Flexible Hybrid Printed Electronics and Systems. For better implementation and infusion into more flexible architectures, important and improved designs in advancing embedded software and GUI interface, and increasing flexibility, modularity, and configurable capabilities of the system are currently being carried out.

Williams, Martha↗

A fiber-optic current sensor for aerospace applications

A robust, accurate, broad-band, alternating current sensor using fiber optics is being developed for space applications at power frequencies as high as 20 kHz. It can also be used in low and high voltage 60 Hz terrestrial power systems and in 400 Hz aircraft systems. It is intrinsically electromagnetic interference (EMI) immune and has the added benefit of excellent isolation. The sensor uses the Faraday effect in optical fiber and standard polarimetric measurements to sense electrical current. The primary component of the sensor is a specially treated coil of single-mode optical fiber, through which the current carrying conductor passes. Improved precision is accomplished by temperature compensation by means of signals from a novel fiber-optic temperature sensor embedded in the sensing head. The technology contained in the sensor is examined and the results of precision tests conducted at various temperatures within the wide operating range are given. The results of early EMI tests are also given.

Patterson, Richard L.↗

A fiber-optic current sensor for aerospace applications

A robust, accurate, broadband, alternating current sensor using fiber optics is being developed for space applications at power frequencies as high as 20 kHz. It can also be used in low and high voltage 60-Hz terrestrial power systems and in 400-Hz aircraft systems. It is intrinsically electromagnetic interference (EMI) immune and has the added benefit of excellent isolation. The sensor uses the Faraday effect in optical fiber and standard polarimetric measurements to sense electrical current. The primary component of the sensor is a specially treated coil of single-mode optical fiber, through which the current carrying conductor passes. Improved precision is accomplished by temperature compensation by means of signals from a novel fiber-optic temperature sensor embedded in the sensing head. The technology used in the sensor is examined and the results of precision tests conducted at various temperatures within the wide operating range are given. The results of early EMI tests are also given.

Patterson, Richard L.↗

Collaboration of the NASA Glenn Research Center and Rolls-Royce Developed Thin Film Multilayered Dielectrics for Harsh Environments

The use of thin films to electrically insulate thin film sensors on engine components minimizes the intrusiveness of the sensors and allows a more accurate measurement of the environment. A variety of insulating films were investigated for preventing electrical shorting caused by insulator failure between the sensor and the component. By alternating layers of sputtered high-temperature ceramics, a sequence of insulating layers was devised that (1) prevents pinholes from forming completely through the insulator and (2) maintains high electrical resistivity at high temperatures. The total thickness is only a fraction of that needed for conventional insulating techniques. The Sensors and Electronics Technology Branch of the NASA Glenn Research Center has an in-house effort to develop thin film sensors for surface measurement in propulsion system research. Thin film sensors do not require special machining of the components on which they are mounted, and they are considerably thinner (less than 10 mm thick) than wire or foil sensors. The thin film sensors are thus much less disturbing to the operating environment and have a minimal impact on the physical characteristics of the supporting component. To further this research, NASA Glenn and Rolls-Royce (Derby, UK), with assistance from the Ohio Aerospace Institute (OAI) and the Akima Corporation, pursued a joint investigation using multilayered thin film dielectrics as a reliable insulator in harsh environments. The use of a multilayered scheme is thought to be promising for the fabrication of electrically insulating thin films. A major cause of conduction in thin film dielectrics is the presence of defects, such as pinholes, that propagate through the film to the underlying substrate surface. By alternating the insulating material, each new growth pattern would deviate from the previous one, eliminating direct pathways for conduction to the substrate. The film depositions and testing were conducted in the Instrument Research Laboratory at Glenn. The multilayered insulator test samples were made from alumina and stainless steel shims that were first covered with a sputtered underlayer of either yttria-stabilized zirconia or chromium carbide, and then overcoated with a sputtered top layer of alumina. An example of a test sample is shown in the following photograph. Each multilayered insulator sample was 5 mm thick, at least an order of magnitude thinner than conventional insulators. The insulating properties of the samples were tested in a high-temperature air oven to determine their suitability. The multilayer insulators tested showed a stabilized film at temperatures in excess of 800 C (1472 F). The underlying materials in these multilayers allow thermal expansion stresses produced during the heating to be graded. The chromium carbide-alumina multilayer had the best adhesion at high temperatures, presumably from the induced chemical bonding between the substrate and the chromium carbide underlayer. However, the zirconia-alumina multilayer proved to have slightly better insulating properties when adhering. The application of the zirconia-alumina insulator has been demonstrated on a nickel-alloy fan blade, as shown. The insulators using thin film sensors still need to be tested in a relevant high-temperature combustion environment.

Wrbanek, John D.↗

NDE Activity at Jet Propulsion Laboratory

None, This is a viewgraph outline from an oral presentation. From Intro.: Our speaker will review the NDE technology under development at the Jet Propulsion Laboratory (JPL). Emphasis will be given to Ultrasonics and application of sensors to space technology. Further, the efforts of JPL in technology transfer to the industry in the area of NDE will be covered.

NDE NDE technology defects detection Yoseph Bar-Co↗

Accelerating the Deployment of Space-Based Quantum Sensors

The Space Science and Technology Partnership Forum (S&T Forum), comprised of an interagency team from the National Aeronautics and Space Administration, the National Reconnaissance Office, and the United States Space Force, presents findings and recommendations from a study on the state of quantum sensors for space applications, enabling component technologies, facilities, and developers across government, industry, and academia. The following five areas of quantum sensing technology (listed in alphabetical order) were identified as being of near-term interest to all three S&T Forum agencies: atomic clocks, atom interferometers, quantum magnetometers, Rydberg sensors, and single photon detectors. This paper focuses on two recommendations: 1) increased collaboration between the S&T Forum, industry, and academia on the development of enabling components for the five quantum sensing technology areas, and 2) challenges and future opportunities to take quantum sensors from the laboratory to space. Through this study, the S&T Forum found a diverse and broad community of quantum sensing developers in the United States that are leading efforts in research, testing, manufacturing, and qualification of quantum sensors and their enabling component technologies. There are common needs across quantum sensing technology areas. To address the common needs, the S&T Forum agencies are encouraged to utilize existing models and mechanisms to enable co-development of enabling component technologies and to explore new avenues for engagement with the quantum sensing community.

Grace C Ray↗

Accelerating the Deployment of Space-Based Quantum Sensors

The Space Science and Technology Partnership Forum (S&T Forum), comprised of an interagency team from the National Aeronautics and Space Administration, the National Reconnaissance Office, and the United States Space Force, presents findings and recommendations from a study on the state of quantum sensors for space applications, enabling component technologies, facilities, and developers across government, industry, and academia. The following five areas of quantum sensing technology (listed in alphabetical order) were identified as being of near-term interest to all three S&T Forum agencies: atomic clocks, atom interferometers, quantum magnetometers, Rydberg sensors, and single photon detectors. This paper focuses on two recommendations: 1) increased collaboration between the S&T Forum, industry, and academia on the development of enabling components for the five quantum sensing technology areas, and 2) challenges and future opportunities to take quantum sensors from the laboratory to space. Through this study, the S&T Forum found a diverse and broad community of quantum sensing developers in the United States that are leading efforts in research, testing, manufacturing, and qualification of quantum sensors and their enabling component technologies. There are common needs across quantum sensing technology areas. To address the common needs, the S&T Forum agencies are encouraged to utilize existing models and mechanisms to enable co-development of enabling component technologies and to explore new avenues for engagement with the quantum sensing community.

Grace C Ray↗

IVHM for the 3rd Generation RLV Program: Technology Development

The objective behind the Integrated Vehicle Health Management (IVHM) project is to develop and integrate the technologies which can provide a continuous, intelligent, and adaptive health state of a vehicle and use this information to improve safety and reduce costs of operations. Technological areas discussed include: developing, validating, and transfering next generation IVHM technologies to near term industry and government reusable launch systems; focus NASA on the next generation and highly advanced sensor and software technologies; and validating IVHM systems engineering design process for future programs.

Kahle, Bill↗

Lightweight Sun-Position Sensor Developed

An orbiting spacecraft needs to be able to accurately locate the position of the Sun so that the solar arrays can be pointed toward the Sun. This not only maximizes the production of power, but it also helps the arrays find their orientation in space so that they can accurately point antennae at ground stations. As part of the work on the (now postponed) Mars-2001 Surveyor Lander, NASA Glenn Research Center engineers developed a new Sun sensor that is far lighter and simpler than earlier designs. This sensor uses the technology of a linear photodiode array to find the position of the Sun in one axis. Two of these sensors, used together, can locate the x and y coordinates of the Sun relative to the spacecraft. These sensors have a mass of only 18 g each, nearly an order of magnitude lighter than earlier designs. (This mass does not include the electronic circuit to read the photodiode output, which is on the experiment microcontroller.) Near the center of the field of view, the Sun position can be found to 0.15

Landis, Geoffrey A.↗

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.↗

An Overview of Wide Bandgap Silicon Carbide Sensors and Electronics Development at NASA Glenn Research Center

A brief overview is presented of the sensors and electronics development work ongoing at NASA Glenn Research Center which is intended to meet the needs of future aerospace applications. Three major technology areas are discussed: 1) high temperature SiC electronics, 2) SiC gas sensor technology development, and 3) packaging of harsh environment devices. Highlights of this work include world-record operation of SiC electronic devices including 500?C JFET transistor operation with excellent properties, atomically flat SiC gas sensors integrated with an on-chip temperature detector/heater, and operation of a packaged AC amplifier. A description of the state-of-the-art is given for each topic. It is concluded that significant progress has been made and that given recent advancements the development of high temperature smart sensors is envisioned.

Hunter, Gary W.↗

Wireless Sensor Needs in the Space Shuttle and CEV Structures Communities

This presentation will clarify some of the structural measurement needs of NASA's Space Shuttle and Crew Exploration Vehicles. Emerging technologies in wireless sensor systems can be of some advantage in both Programs. The presentation will address how wireless instrumentation has helped in the past and what has gone unmeasured on Shuttle due to various limitations. Finally, it will address the needs of the CEV program that can be met with reliable wireless systems, if modular avionics interfaces are provided to accommodate the usual evolving needs of an ambitious space vehicle development program. Examples of the advantages of flight data to support flight certification engineering analyses and of areas where add-on wireless instrumentation can be used will be shown. Without flight instrumentation, it is necessary to retain the conservative assumptions used in the design process. It will be shown how the lessons learned on Space Shuttle for wired and wireless structural measurements apply to the Orion Crew Exploration Vehicle (CEV), which is currently being designed.

James, George H., III↗