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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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At least 91 records · Page 5

All sources NASA NTRS DOE OSTI

NASA NTRS1979

Automated Array Assembly Task In-depth Study of Silicon Wafer Surface Texturizing

Several aspects of silicon wafer surface texturizing were studied. A low cost cleaning method that utilizes recycled Freon in an ultrasonic vapor degreaser to remove organic and inorganic contaminants from the surface of silicon wafers as received from silicon suppliers was investigated. The use of clean dry air and high throughout wafer batch drying techniques was shown to lower the cost of wafer drying. A two stage texturizing process was examined for suitability in large scale production. Also, an in-depth gettering study with the two stage texturizing process was performed for the enhancement of solar cell efficiency, minimization of current versus voltage curve dispersion, and improvement in process reproducibility. The 10% efficiency improvement goal was exceeded for the near term implementation of flat plate photovoltaic cost reduction.

Jones, G. T.↗

NASA NTRS1979

Automated array assembly, phase 2

Tasks of scaling up the tandem junction cell (TJC) from 2 cm x 2 cm to 6.2 cm and the assembly of several modules using these large area TJC's are described. The scale-up of the TJC was based on using the existing process and doing the necessary design activities to increase the cell area to an acceptably large area. The design was carried out using available device models. The design was verified and sample large area TJCs were fabricated. Mechanical and process problems occurred causing a schedule slippage that resulted in contract expiration before enough large-area TJCs were fabricated to populate the sample tandem junction modules (TJM). A TJM design was carried out in which the module interconnects served to augment the current collecting buses on the cell. No sample TJMs were assembled due to a shortage of large-area TJCs.

Carbajal, B. G.↗

NASA NTRS1980

The automated array assembly task of the low-cost silicon solar array project, phase 2

Several specific processing steps as part of a total process sequence for manufacturing silicon solar cells were studied. Ion implantation was identified as the preferred process step for impurity doping. Unanalyzed beam ion implantation was shown to have major cost advantages over analyzed beam implantation. Further, high quality cells were fabricated using a high current unanalyzed beam. Mechanically masked plasma patterning of silicon nitride was shown to be capable of forming fine lines on silicon surfaces with spacings between mask and substrate as great as 250 micrometers. Extensive work was performed on advances in plated metallization. The need for the thick electroless palladium layer was eliminated. Further, copper was successfully utilized as a conductor layer utilizing nickel as a barrier to copper diffusion into the silicon. Plasma etching of silicon for texturing and saw damage removal was shown technically feasible but not cost effective compared to wet chemical etching techniques.

Coleman, M. G.↗

NASA NTRS1980

Automated array assembly, phase 2

A manufacturing sequence which is capable of mass producing silicon solar cells is described. The sequence was arrived at after the evaluation of many processes and three related manufacturing sequences which are discussed.

Daiello, R. V.↗

NASA NTRS1980

Automated array assembly task development of low-cost polysilicon solar cells

Development of low cost, large area polysilicon solar cells was conducted in this program. Three types of polysilicon materialk were investigated. A theoretical and experimenal comparison between single crystal silicon and polysilicon solar cell efficiency was performed. Significant electrical performance differences were observed between types of wafer material, i.e. fine grain and coarse grain polysilicon and single crystal silicon. Efficiency degradation due to grain boundaries in fin grain and coarse grain polysilicon was shown to be small. It was demonstrated that 10 percent efficient polysilicon solar cells can be produced with spray on n+ dopants. This result fulfills an important goal of this project, which is the production of batch quantity of 10 percent efficient polysilicon solar cells.

Jones, G. T.↗

NASA NTRS1989

Formulation of design guidelines for automated robotic assembly in outerspace

The approach for arriving at design guidelines for assembly by robots in outerspace is illustrated. The use of robots in a zero gravity environment necessitates that extra factors over and above normal design guidelines be taken into account. Besides, many of the guidelines for assembly by robots on earth do not apply in space. However, considering the axioms for normal design and assembly as one set, guidelines for design and robotic assembly as another, and guidelines for design and assembly in space as the third set, unions and intersections of these sets can generate guidelines for two or more of these conditions taken together - say design and manual assembly in space. Therein lies the potential to develop expert systems in the future, which would use an exhaustive database and similar guidelines to arrive at those required by a superposition of these conditions.

Dwivedi, Suren N.↗

NASA NTRS1991

Panel installation development in Automated Structures Assembly Lab

The design requirements for panel installation process are listed and photographs are presented of the following: panel latches to truss via adaptors; panel end effector; arm retrieving panel from canister; arm installing panel; and facility view with panel installed.

Cuong Quach↗

NASA NTRS2008

Automating System Assembly of Aerospace Systems

One of the major challenges in modern aerospace designs is the integration and assembly of independently developed components. We have formalized this as the system assembly problem: from a sea of available components, which should be selected and how should they be connected, integrated, and assembled so that the overall system requirements are satisfied in a certifiable way? We present a powerful framework for automatically solving the system assembly problem directly from system requirements by using formal verification technology. We also present a case study where we applied our work to large-scale industrial examples from the Boeing Dreamliner.

Manolios, Panagiotis↗

NASA NTRS1979

Automatic in-orbit assembly of large space structures

The automated assembly of a large number of components required for the on-orbit erection of large tetrahedral space platforms is described. The assembly machine is a huge jig in which a multitude of mechanisms must operated continuously in the thermo vacuum environment of space and under the control of computers programmed to command every step of each motion. The concepts are presented to determine the most reliable solution. Continuous operation of mechanisms in space presents many unresolved problems, with regard to lubrication of unprotected devices, such as chain drives, which must maintain reasonable positioning tolerances.

Jacquemin, G. G.↗

NASA NTRS1991

Executive system software design and expert system implementation

The topics are presented in viewgraph form and include: software requirements; design layout of the automated assembly system; menu display for automated composite command; expert system features; complete robot arm state diagram and logic; and expert system benefits.

Cheryl L Allen↗

NASA NTRS2006

Experimental Demonstration of Technologies for Autonomous On-Orbit Robotic Assembly

The Modular Reconfigurable High Energy (MRHE) program aimed to develop technologies for the automated assembly and deployment of large-scale space structures and aggregate spacecraft. Part of the project involved creation of a terrestrial robotic testbed for validation and demonstration of these technologies and for the support of future development activities. This testbed was completed in 2005, and was thereafter used to demonstrate automated rendezvous, docking, and self-assembly tasks between a group of three modular robotic spacecraft emulators. This paper discusses the rationale for the MRHE project, describes the testbed capabilities, and presents the MRHE assembly demonstration sequence.

LeMaster, Edward A.↗

NASA NTRS1981

Interlocking wedge joint is easily assembled

Wedge joint links structural members in manual, remote, or automated assemblies. Joint is simple enough to be assembled by undersea divers, workers in nuclear reactors, and other wearing gloves or bulky clothing. Combination of wedging angles on parts overcomes structural misalinements and forces assembly into true position as locking sleeve moves into place. Joint transmits tension, compression, bending moments and torsion and is inherently insensitive to thermal excursions, vibration, and machining tolerance buildup.

Long, M. J.↗

NASA NTRS1987

Simplified Explosive Joining of Tubes to Fittings

Technique simplifies tube-to-fitting joining, as compared to fusion welding, and provides improvement on standard procedures used to join tubes explosively to tube fittings. Special tool inserted into tube to be joined. Tool allows strip of ribbon explosive to be placed right at joint. Ribbon explosive and mild detonating fuse allows use of smaller charge. Assembled tool storable, and process amenable to automation. Assembly of components, insertion of tool into weld site, and joining operation mechanized without human contact. Used to assemble components in nuclear reactors or in other environments hostile to humans.

Bement, L. J.↗

NASA NTRS1981

Automated solar panel assembly line

The initial stage of the automated solar panel assembly line program was devoted to concept development and proof of approach through simple experimental verification. In this phase, laboratory bench models were built to demonstrate and verify concepts. Following this phase was machine design and integration of the various machine elements. The third phase was machine assembly and debugging. In this phase, the various elements were operated as a unit and modifications were made as required. The final stage of development was the demonstration of the equipment in a pilot production operation.

Somberg, H.↗

NASA NTRS1980

Recent advances in structural technology for large deployable and erectable spacecraft

Ultra-low mass deployable and erectable truss structure designs for spacecraft are identified using computerized structural sizing techniques. Extremely slender strut proportions are shown to characterize minimum mass spacecraft which are designed for Shuttle transport to orbit. Analytical results are presented which demonstrate discrete element effects using a recently developed buckling theory for periodic lattice type structures. An analysis of fabrication imperfection effects on the surface accuracy of four different antenna reflector structures is summarized. This study shows the tetrahedral truss to have the greatest potential of the structures examined for application to accurate or large reflectors. A deployable module which can be efficiently transported is identified and shown to have significant potential for application to future antenna requirements. Recent investigations of erectable structure assembly are reviewed. Initial experiments simulating astronaut assembly by extra-vehicular activity (EVA) show that a pair of astronauts can achieve assembly times of 2-5 min/strut. Studies indicate that an automated assembler can achieve times of less than 1 min/strut on an around-the-clock basis.

Bush, H. G.↗

NASA NTRS1980

Deployable and erectable concepts for large spacecraft

Computerized structural sizing techniques were used to determine structural proportions of minimum mass tetrahedral truss platforms designed for low Earth and geosynchronous orbit. Optimum (minimum mass) deployable and erectable, hexagonal shaped spacecraft are sized to satisfy multiple design requirements and constraints. Strut dimensions characterizing minimum mass designs are found to be significantly more slender than those conventionally used for structural applications. Comparison studies show that mass characteristics of deployable and erectable platforms are approximately equal and that the shuttle flights required by deployable trusses become excessive above certain critical stiffness values. Recent investigations of eractable strut assembly are reviewed. Initial erectable structure assembly experiments show that a pair of astronauts can achieve EVA assembly times of 2-5 min/strut and studies indicate that an automated assembler can achieve times of less than 1 min/strut for around the clock operation.

Bush, H. G.↗

NASA NTRS2018

Discrete Assemblers Utilizing Conventional Motion Systems

An alternative to additive manufacturing is disclosed, introducing an end-to-end workflow in which discrete building blocks are reversibly joined to produce assemblies called digital materials. Described is the design of the bulk-material building blocks and the devices that are assembled from them. Detailed is the design and implementation of an automated assembler, which takes advantage of the digital material structure to avoid positioning errors within a large tolerance. To generate assembly sequences, a novel CAD/CAM workflow is described for designing, simulating, and assembling digital materials. The structures assembled using this process have been evaluated, showing that the joints perform well under varying conditions and that the assembled structures are functionally precise.

Langford, William Kai↗

DOE OSTI2025

Robotic Assembly of Multi-Chip Modules Using Artificial Intelligence

With many properties of dark matter remaining a mystery, the OSCURA experiment aims to detect light dark matter particles using 1,536 Multi-Chip Modules (MCMs), containing a total of 24,576 skipper CCDs. Currently, each MCM is assembled by hand a time-consuming and error-prone process that can be automated. In this ongoing work, we present an automated assembly robot that leverages modern computer vision and artificial intelligence to assemble the OSCURA MCMs. This approach reduces cost, time, and error in the packaging of OSCURA sensors.

Arteaga, Matthew [Northern Illinois U.; Fermilab]↗