Wire stripper protects cable shielding
Four-blade stripper removes insulation from end or middle of wire without damaging shielding.
Economu, M. A.↗
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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.
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Heat Transfer Study for HTS Power Transfer Cables
Thermal losses are a key factor in the successful application of high temperature superconducting (HTS) power cables. Existing concepts and prototypes rely on the use of multilayer insulation (MLI) systems that are subject to large variations in actual performance. The small space available for the thermal insulation materials makes the application even more difficult because of bending considerations, mechanical loading, and the arrangement between the inner and outer piping. Each of these mechanical variables affects the heat leak rate. These factors of bending and spacing are examined in this study. Furthermore, a maintenance-free insulation system (high vacuum level for 20 years or longer) is a practical requirement. A thermal insulation system simulating a section of a flexible FITS power cable was constructed for test and evaluation on a research cryostat. This paper gives experimental data for the comparison of ideal MLI, MLI on rigid piping, and MLI between flexible piping. A section of insulated flexible piping was tested under cryogenic vacuum conditions including simulated bending and spacers.
Augustynowicz, S.↗
Development of a flat cable system
A flat conductor cabling system for electrical/electronic interwiring is described. Six major items comprise the system: the cables, splices - one for flat cable to round wires and one for flat cable to flat cable; a series of flat cable connectors; the distributor, which is used for interconnecting the circuits; and a repair technique for the falt cable. Polyarylene, a new high performance melt-processable insulation material, permits the design of a completely standardized, modular flat conductor flat cable. The development of an advanced heat-shrinkable plastics technology involving the use of selectively bonded plastic film has resulted in the multiple termination module, used for making high-reliability sealed solder terminations to either flat conductor cable or round wires. All necessary tools and application equipment are included in the system design.
Neel, R. M.↗
Shielded Aluminum Flat-Conductor Cable
Thin wiring harness stores compactly. Flat aluminum conductors glued between layers of polyimide. Aluminum shield surrounds insulated conductors. Outer layer polyimide. Aluminum shield reduces flexibility of cable and cable withstand only limited number of repetitions of sharp bending at same spot.
Farina, S.↗
Shielded conductor cable system
A cable system carries one or more insulated conductors completely enclosed within a shield having one end connected to ground. A lightning protector network connects the other end of the shield to ground. The protector network is normally open circuited and becomes only short circuited in response to a momentary abnormal surge voltage induced in the shield. The protector network's open to short impedance change completes a conductive circuit path between the shield and the two grounded ends for conducting a shield current which has the desired effect of protecting the signal carrying conductors in the cable from the large surge voltage.
Castle, K. D.↗
In-Situ Detection of Process-Induced Porosity During Cure of Out-of-Autoclave Composites
Composite materials offer unique benefits in aerospace applications, including high strength-to-weight ratio, and are becoming increasingly used by industry manufacturers. Current manufacturing and processing methods can lead to defects in the composites, which are identified after fabrication using inspection methods. This study utilized a high-temperature ultrasonic inspection system to detect process-induced porosity in an out-of-autoclave (OOA) composite panel during cure. In order to perform ultrasonic scans in-situ during cure, the system needed to be able to operate at oven temperatures up to 200 °C. There are no commercially available ultrasonic scanning systems that can operate continuously at these temperatures, so an enclosure was fabricated to insulate the ultrasonic system in the curing oven. The enclosure housed a MISTRAS® motorized X-Y raster scanner and contact transducer (Olympus® X2002). The Olympus® X2002 contact transducer is a continuous high-temperature delay line transducer with a center frequency of 2.25 MHz. In order to prevent the inside of the enclosure from reaching high temperatures, a sparge pipe inside the cooling enclosure was connected to a liquid nitrogen (LN2) tank outside of the oven via insulated hoses. The cooling system was automatically controlled by a temperature controller that was programmed to open a solenoid valve along the hose at 31 ℃ and close at 28 ℃ inside the cooling enclosure. When the solenoid valve was open, LN2 would flow from the LN2 tank and vaporize prior to reaching cooling enclosure. A U-shaped sparge pipe had holes drilled along its length to uniformly introduce cold nitrogen gas into the cooling enclosure. This prevented the motors from ever reaching the maximum desired operating temperature of 38 ℃. In the bottom of the enclosure, the tool plate was placed with the composite facing the outside of the enclosure, exposing it to the temperatures of the oven. The tool plate was 63.5 mm thick borosilicate glass, which was chosen for its low ultrasonic attenuation and moderate thermal conductivity. A thin layer of ultrasonic couplant was placed on the tool plate. The transducer sent and received ultrasonic waves through the tool plate into the composite. A MISTRAS® Remote UT System performed all wave generation, analog to digital conversion, and data acquisition and processing. The transducer was connected directly to the Remote UT System via a high-temperature BNC cable (CD International, RG-316). Polyimide insulated copper wire was used to connect the scanner to a 2-axis motor drive, which was connected to the Remote UT System. The motor drive and Remote UT System were located outside the industrial oven. A diagram of the ultrasonic system is shown in Figure 1. Figure 1: Diagram of ultrasonic in-situ defect detection system. In this study, a porosity gradient was introduced into the carbon fiber reinforced polymer (CFRP) composite through a misfit of the part and caul plate. A 24-ply quasi-isotropic ([0/90, ±45]12S) composite panel was laid up using Newport® AS4C-M/NB321 out-of-autoclave (OOA) plain weave (PW) prepreg (42% resin content, 195 g/m2). The first 16 plies were 203 mm × 203 mm. Ply drops were incorporated into the panel by decreasing the length of plies 17-24. The sizes of each ply are included in Table 1. All plies were centered along their length (x-axis) creating a trapezoidal type cross-section. Table 1: Ply sizes Plies Length (mm) Width (mm) 1-16 203 203 17-18 102 203 19-20 85 203 21-22 68 203 23-24 51 203 A 15-5 stainless steel caul plate (Size: 203 × 203 × 1.2 mm) was placed on the laminate. The composite and caul plate were vacuum bagged to the tool plate. Per the product datasheet, Newport 321 can be cured between 121 °C and 149 °C, depending on service temperature, with a hold for 90-120 minutes. Based on prior thermal testing of the cooling enclosure, the desired composite temperature cycle could be attained when the air temperature of the oven was ramped to 160 °C at a rate of 1.7 °C/min with a 3 hour hold. The extended hold was not necessary to cure the composite, but did allow for additional scans at the cure temperature during preliminary testing. The composite panel was under vacuum pressure for the entire cure cycle. Under vacuum, the caul plate deformed causing high and low pressure regions. The low-pressure regions formed high porosity in the composite part. The ultrasonic data collected showed that the inspection system was able to monitor the evolution of porosity within the composite throughout the cure cycle. Fifty scans of a 203 mm × 51 mm (8 in. × 2 in.) area of the composite were completed throughout the cure cycle. The scan speed was set to 43 mm/s in the x-direction and 36 mm/s in the y-direction, with a 1.0 mm/pixel resolution in both directions. Each scan took approximately five minutes to complete. Figure 2 shows C-scan amplitude data (top view) from one scan during the cure cycle. The color map indicates the maximum amplitude (%) measured with a time gate that contains reflections from the back surface (furthest from the transducer in contact with the caul plate) of the composite. Because porosity in the composite increases the ultrasonic attenuation in the composite part, a higher amplitude (red) indicates low porosity and a lower amplitude (blue) indicates high porosity. The regions where the caul plate was applying increased pressure (center and ends of the panel) resulted in reduced porosity, whereas the ply drop regions had reduced pressure and thus had higher porosity. Figure 2: Amplitude C-scan (top view) of OOA composite from one scan during the 160 °C temperature hold. Higher amplitude (red) indicates low porosity. Lower amplitude (blue) indicates high porosity. A B-scan is a two-dimensional image plotting the ultrasonic signals from a single y-position at every x-location of the composite panel. The travel time (μs) of the ultrasonic wave (representing the through-thickness location) is plotted along the y-axis, and the ultrasonic wave signal is represented as a contour map. Based on the B-scan data, the location of the defects with respect to the composite thickness was able to be determined. The ply drop regions had high porosity near the front (tool plate) surface of the composite (Figure 3). Figure 3: B-scan (cross-section view) of OOA composite from one scan during the 160 °C temperature hold. Using the data obtained from amplitude C-scans and B-scans throughout the cure cycle, the high and low porosity regions within the composite laminate were detected and localized with high spatial resolution. This paper will discuss the evolution of porosity content in the OOA composite during cure. OOA tests aided the transition of this system to an autoclave, which is the primary method of curing aerospace-grade thermoset composites.
Tyler B. Hudson↗
Flight Set 360L002 (STS-27) field joint protection system, volume 7
This report contains the pre-launch functioning data of the Field Joint Protection System (JPS) used on STS-27. Also included is the post flight condition of the JPS components following the launch and recovery of the two redesigned solid rocket motors (RSRM) boosters. The JPS components are: (1) field joint heaters; (2) field joint sensors; (3) field joint moisture seal; (4) moisture seal Kevlar retaining straps; (5) field joint external insulation; (6) vent valve; (7) power cables; and (8) igniter heater.
Hale, Elgie↗
Thermal protection systems for equipment pallets to be launched in Shuttle Orbiter
The thermal insulation for the OSS-1 Orbiter pallet is described and a design concept for future pallets is presented consisting of two independent thermal zones and new thermal insulation approaches. The application of these concepts is expected to reduce the effort required to integrate the payloads to their pallets and thereby reduce dollar costs and shorten time schedules. A stand-off insulation also is described for certain pallet areas to enclose the cabling and fluid lines in a controlled temperature environment. Methods for interfacing the payload and pallet insulations are presented and a number of areas are identified where the introduction of standards in the fabrication of thermal insulation can yield further savings.
Ruccia, F. E.↗
Power Cable Mass Estimation for Electric Aircraft Propulsion
Electric aircraft propulsion relies on power transmission cables to carry energy through the vehicle's electrical power train. The mass of these cables is an important consideration in overall aircraft weight, and hence cable design methods that can offer lower weight cables offer a significant opportunity.This paper compares three strategies for cable design: selection of cables from off-the-shelf options, design based on steady-state thermal limits, and design based on transient thermal limits. The thermal models consider both conductor diameter and insulation thickness, as well as a comparison between multiple conductor materials. The thermal analysis evaluates the transfer of waste heat from the conductor to the insulation and from the insulation to the air via convection. Optimizations to minimize cable mass by changing conductor radius and material properties were performed using all three modeling approaches and the results show that both custom sized cables using both steady-state and transient based model offer potential mass savings.
Electrical↗
Stripping the Sheath From Stranded Cables
Device similar to tubing cutter removes tough plastic cover. Insulation stripper is 3 in. (7.6 cm) long and 1.5 (3.8 cm) in diameter. Two rollers are small-diameter bearings. Cutter blade journaled for rotation between pair of similar bearings. Bearings either pin or ball types of suitable dimensions.
Prisk, A. L.↗
Cryogenic Pressure Seal for Wires
High-pressure-seal formed by forcing polyurethane into space surrounding wire or cable in special fitting. Wire or cable routed through fitting then through a tightly fitting cap. Wire insulation left intact. Cap filled with sealant and forced onto the fitting: this pushes sealant into fitting so it seals wire or cable in fitting as well as in cap.
Ciana, J. J.↗
Flat-conductor cable has rotary and linear flexibility
Report describes capabilities and limitations of flat-conductor cable /FCC/ relative to flexure in bending, folding, rotating, and extending, it also compares FCC mechanical and endurance characteristics with round-wire cable, and compares qualities of various types of insulation for FCC. Several configurations exemplify FCC flexibility.
Carden, J. R.↗
Rotary stripper for shielded and unshielded FCC
Rotary stripper removes narrow strips of insulation and shielding to any desired depth. Unshielded cables are stripped on both sides with one stroke, shielded cables are stripped in steps of different depths.
Angele, W.↗
Termination of flat conductor cable to NASA/MSFC plugs
Data, supplemented with artwork, are presented on the major steps involved with terminating flat conductor cable (FCC) to MSFC's FCC plugs. Cable and shield preparation steps include material cutting, insulation stripping, and plating of exposed conductors. Methods and equipment required to terminate FCC to each of four MSFC plugs are described.
Angele, W.↗
Electrically Small Microstrip Quarter-Wave Monopole Antennas
Microstrip-patch-style antennas that generate monopole radiation patterns similar to those of quarter-wave whip antennas can be designed to have dimensions smaller than those needed heretofore for this purpose, by taking advantage of a feed configuration different from the conventional one. The large sizes necessitated by the conventional feed configuration have, until now, made such antennas impractical for frequencies below about 800 MHz: for example, at 200 MHz, the conventional feed configuration necessitates a patch diameter of about 8 ft (.2.4 m) . too large, for example, for mounting on the roof of an automobile or on a small or medium-size aircraft. By making it possible to reduce diameters to between a tenth and a third of that necessitated by the conventional feed configuration, the modified configuration makes it possible to install such antennas in places where they could not previously be installed and thereby helps to realize the potential advantages (concealment and/or reduction of aerodynamic drag) of microstrip versus whip antennas. In both the conventional approach and the innovative approach, a microstrip-patch (or microstrip-patch-style) antenna for generating a monopole radiation pattern includes an electrically conductive patch or plate separated from an electrically conductive ground plane by a layer of electrically insulating material. In the conventional approach, the electrically insulating layer is typically a printed-circuit board about 1/16 in. (.1.6 mm) thick. Ordinarily, a coaxial cable from a transmitter, receiver, or transceiver is attached at the center on the ground-plane side, the shield of the cable being electrically connected to the ground plane. In the conventional approach, the coaxial cable is mated with a connector mounted on the ground plane. The center pin of this connector connects to the center of the coaxial cable and passes through a hole in the ground plane and a small hole in the insulating layer and then connects with the patch above one-third of the radial distance from the center. The modified feed configuration of the innovative approach is an inductive-short-circuit configuration that provides impedance matching and that has been used for many years on other antennas but not on microstrip-style monopole antennas. In this configuration, the pin is connected to both the conductive patch and the ground plane. As before, the shield of the coaxial cable is connected to the ground plane, but now the central conductor is connected to a point on the pin between the ground plane and the conductive plate (see figure). The location of the connection point on the pin is chosen so that together, the inductive short circuit and the conductive plate or patch act as components of a lumped-element resonant circuit that radiates efficiently at the resonance frequency and, at the resonance frequency, has an impedance that matches that of the coaxial cable. It should be noted that the innovative design entails two significant disadvantages. One disadvantage is that the frequency bandwidth for efficient operation is only about 1/20 to 1/15 that of a whip antenna designed for the same nominal frequency. The other disadvantage is that the estimated gain is between 3-1/2 and 4-1/2 dB below that of the whip antenna. However, if an affected radio-communication system used only a few adjacent frequency channels and the design of the components of the system other than the antenna provided adequate power or gain margin, then these disadvantages could be overcome.
Young, W. Robert↗
Testing of flat conductor cable to Underwriters Laboratory standards UL719 and UL83
The flat conductor cable (FCC) which was tested consisted of three AWG No. 12 flat copper conductors laminated between two films of polyethylene terephthalate (Mylar) insulation with a self-extinguishing polyester adhesive. Results of the tests conducted on this cable, according to specifications, warrants the use of this FCC for electrical interconnections in a surface nonmetallic protective covering.
Loggins, R. W.↗
The LSLE echocardiograph - Commercial hardware aboard Spacelab
The Life Sciences Laboratory Equipment Echocardiograph, a commercial 77020AC Ultrasound Imaging System modified to meet NASA's spacecraft standards, is described. The assembly consists of four models: display and control, scanner, scan converter, and physioamplifiers. Four separate processors communicate over an IEE-488 bus, and the system has more than 6000 individual components on 35 printed circuit cards. Three levels of self test are provided: a short test during power up, a basic test initiated by a front panel switch, and interactive tests for specific routines. Default mode operation further enhances reliability. Modifications of the original system include the replacement of ac power supplies with dc to dc converters, a slide-out keyboard (to prevent accidental operation), Teflon insulated wire, and additional shielding for the ultrasound transducer cable.
Schwarz, R.↗
Radiation-induced insulator discharge pulses in the CRRES internal discharge monitor satellite experiment
The Internal Discharge Monitor (IDM) was designed to observe electrical pulses from common electrical insulators in space service. The sixteen insulator samples included twelve planar printed circuit boards and four cables. The samples were fully enclosed, mutually isolated, and space radiation penetrated 0.02 cm of aluminum before striking the samples. Pulsing began on the seventh orbit, the maximum pulse rate occurred on the seventeenth orbit when 13 pulses occurred, and the pulses slowly diminished to about one per 3 orbits six months later. After 8 months, the radiation belts abruptly increased and the pulse rates attained a new high. These pulse rates were in agreement with laboratory experience on shorter time scales. Several of the samples never pulsed. If the pulses were not confined within IDM, the physical processes could spread to become a full spacecraft anomaly. The IDM results indicate the rate at which small insulator pulses occur. Small pulses are the seeds of larger satellite electrical anomalies. The pulse rates are compared with space radiation intensities, L shell location, and spectral distributions from the radiation spectrometers on the Combined Release and Radiation Effects Satellite.
Frederickson, A. R.↗