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At least 145 records · Page 8

Electronic manufacturing and packaging in Japan

This report summarizes the status of electronic manufacturing and packaging technology in Japan in comparison to that in the United States, and its impact on competition in electronic manufacturing in general. In addition to electronic manufacturing technologies, the report covers technology and manufacturing infrastructure, electronics manufacturing and assembly, quality assurance and reliability in the Japanese electronics industry, and successful product realization strategies. The panel found that Japan leads the United States in almost every electronics packaging technology. Japan clearly has achieved a strategic advantage in electronics production and process technologies. Panel members believe that Japanese competitors could be leading U.S. firms by as much as a decade in some electronics process technologies. Japan has established this marked competitive advantage in electronics as a consequence of developing low-cost, high-volume consumer products. Japan's infrastructure, and the remarkable cohesiveness of vision and purpose in government and industry, are key factors in the success of Japan's electronics industry. Although Japan will continue to dominate consumer electronics in the foreseeable future, opportunities exist for the United States and other industrial countries to capture an increasingly large part of the market. The JTEC panel has identified no insurmountable barriers that would prevent the United States from regaining a significant share of the consumer electronics market; in fact, there is ample evidence that the United States needs to aggressively pursue high-volume, low-cost electronic assembly, because it is a critical path leading to high-performance electronic systems.

Kelly, Michael J.↗

Column Grid Array Rework for High Reliability

Due to requirements for reduced size and weight, use of grid array packages in space applications has become common place. To meet the requirement of high reliability and high number of I/Os, ceramic column grid array packages (CCGA) were selected for major electronic components used in next MARS Rover mission (specifically high density Field Programmable Gate Arrays). ABSTRACT The probability of removal and replacement of these devices on the actual flight printed wiring board assemblies is deemed to be very high because of last minute discoveries in final test which will dictate changes in the firmware. The questions and challenges presented to the manufacturing organizations engaged in the production of high reliability electronic assemblies are, Is the reliability of the PWBA adversely affected by rework (removal and replacement) of the CGA package? and How many times can we rework the same board without destroying a pad or degrading the lifetime of the assembly? To answer these questions, the most complex printed wiring board assembly used by the project was chosen to be used as the test vehicle, the PWB was modified to provide a daisy chain pattern, and a number of bare PWB s were acquired to this modified design. Non-functional 624 pin CGA packages with internal daisy chained matching the pattern on the PWB were procured. The combination of the modified PWB and the daisy chained packages enables continuity measurements of every soldered contact during subsequent testing and thermal cycling. Several test vehicles boards were assembled, reworked and then thermal cycled to assess the reliability of the solder joints and board material including pads and traces near the CGA. The details of rework process and results of thermal cycling are presented in this paper.

high reliability↗

Upgrades of edge, divertor and scrape-off layer diagnostics of W7-X for OP1.2

In this work, Wendelstein 7-X (W7-X) is the world’s largest superconducting nuclear fusion experiment of the optimized stellarator type. In the first Operation Phase (OP1.1) helium and hydrogen plasmas were studied in limiter configuration. The heating energy was limited to 4 MJ and the main purpose of that campaign was the integral commissioning of the machine and diagnostics, which was achieved very successfully. Already from the beginning a comprehensive set of diagnostics was available to study the plasma. On the path towards high-power, high-performance plasmas, W7-X will be stepwise upgraded from an inertially cooled (OP1.2, limited to 80 MJ) to an actively cooled island divertor (OP2, 10 MW steady-state plasma operation). The machine is prepared for OP1.2 with 10 inertially cooled divertor units, and the experimental campaign has started recently.The paper describes a subset of diagnostics which will be available for OP1.2 to study the plasma edge, divertor and scrape-off layer physics including those already available for OP1.1, plus modifications, upgrades and new systems. In conclusion, the focus of this summary will be on technical and engineering aspects, like feasibility and assembly but also on reliability, thermal loads and shielding against magnetic fields.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

Simple two-speed tape transport drive

High data rate storage system B tape transport fits to existing hysteresis motor thus reducing flutter, lowering assembly cost, simplifying assembly process and increasing reliability. Motor may be used on any tape recorder or similar device having two speed ratio of up to 32 to 1.

Clurman, S. P.↗

Fault-tolerant computer system

More reliable computers could be assembled by connecting four proposed VSLI "building block" circuits with built-in error detection to standard microprocessors and memory devices to form self checking computer module. Each building block detects its own malfunctions and single bit errors found in memory.

Avizienis, A. A.↗

Standards for Epoxies Used in Microelectronics

Improved qualification standards and test procedures for epoxy adhesives used in assembly of high-reliability hybrid microcircuits listed in new report. Objective of standards to resolve problems in areas of outgassing, bond shear strength, corrosivity, volume resistivity, ionic impurities, electrical stability, and frequency of qualification testing. pp

Caruso, S. V.↗

The 8.4-GHz low-noise maser pump source assembly

Improved pump source assemblies and new 8.4-GHz low noise traveling-wave masers (TWMs) were installed at the same time at Deep Space Stations 14 and 43 as part of the Mark IVA DSCC Antenna Microwave Subsystems upgrade. The pump source assemblies are part of the new 8.4-GHz TWMs, which are identified as Block IIA Low-Noise TWMs. Improved reliability of the pump source assemblies was required to meet stress analysis criteria.

Cardenas, R.↗

Advanced life support control/monitor instrumentation concepts for flight application

Development of regenerative Environmental Control/Life Support Systems requires instrumentation characteristics which evolve with successive development phases. As the development phase moves toward flight hardware, the system availability becomes an important design aspect which requires high reliability and maintainability. This program was directed toward instrumentation designs which incorporate features compatible with anticipated flight requirements. The first task consisted of the design, fabrication and test of a Performance Diagnostic Unit. In interfacing with a subsystem's instrumentation, the Performance Diagnostic Unit is capable of determining faulty operation and components within a subsystem, perform on-line diagnostics of what maintenance is needed and accept historical status on subsystem performance as such information is retained in the memory of a subsystem's computerized controller. The second focus was development and demonstration of analog signal conditioning concepts which reduce the weight, power, volume, cost and maintenance and improve the reliability of this key assembly of advanced life support instrumentation. The approach was to develop a generic set of signal conditioning elements or cards which can be configured to fit various subsystems. Four generic sensor signal conditioning cards were identified as being required to handle more than 90 percent of the sensors encountered in life support systems. Under company funding, these were detail designed, built and successfully tested.

Heppner, D. B.↗

Robustness

Robustness is a buzz word common to all newly proposed space systems design as well as many new commercial products. The image that one conjures up when the word appears is a 'Paul Bunyon' (lumberjack design), strong and hearty; healthy with margins in all aspects of the design. In actuality, robustness is much broader in scope than margins, including such factors as simplicity, redundancy, desensitization to parameter variations, control of parameter variations (environments flucation), and operational approaches. These must be traded with concepts, materials, and fabrication approaches against the criteria of performance, cost, and reliability. This includes manufacturing, assembly, processing, checkout, and operations. The design engineer or project chief is faced with finding ways and means to inculcate robustness into an operational design. First, however, be sure he understands the definition and goals of robustness. This paper will deal with these issues as well as the need for the requirement for robustness.

Ryan, R.↗

JTEC Panel report on electronic manufacturing and packaging in Japan

This report summarizes the status of electronic manufacturing and packaging technology in Japan in comparison to that in the United States, and its impact on competition in electronic manufacturing in general. In addition to electronic manufacturing technologies, the report covers technology and manufacturing infrastructure, electronics manufacturing and assembly, quality assurance and reliability in the Japanese electronics industry, and successful product realization strategies. The panel found that Japan leads the United States in almost every electronics packaging technology. Japan clearly has achieved a strategic advantage in electronics production and process technologies. Panel members believe that Japanese competitors could be leading U.S. firms by as much as a decade in some electronics process technologies.

Kelly, Michael J.↗

Electrical Connectors

Betaflex connectors are sockets that connect multichip modules and high density ceramic packages to printed circuit boards. They incorporate shape memory alloy technology, developed under NASA contract. Aimed at computer, telecommunication, avionics and military markets, the connectors enable designers to gain up to 40 percent more board space and provide 100 signal lines to the inch. When the nickel titanium element in the connector is heated by a low voltage power supply, the connector's spring is opened allowing the circuit board to be inserted with zero force. This makes assembly easier and more reliable. Beta Phase was taken over by Mopex, BPS and currently manufactures these connectors.

Source record↗

Spaceflight Ground Support Equipment Reliability & System Safety Data

Presented were Reliability Analysis, consisting primarily of Failure Modes and Effects Analysis (FMEA), and System Safety Analysis, consisting of Preliminary Hazards Analysis (PHA), performed to ensure that the CoNNeCT (Communications, Navigation, and Networking re- Configurable Testbed) Flight System was safely and reliably operated during its Assembly, Integration and Test (AI&T) phase. A tailored approach to the NASA Ground Support Equipment (GSE) standard, NASA-STD-5005C, involving the application of the appropriate Requirements, S&MA discipline expertise, and a Configuration Management system (to retain a record of the analysis and documentation) were presented. Presented were System Block Diagrams of selected GSE and the corresponding FMEA, as well as the PHAs. Also discussed are the specific examples of the FMEAs and PHAs being used during the AI&T phase to drive modifications to the GSE (via "redlining" of test procedures, and the placement of warning stickers to protect the flight hardware) before being interfaced to the Flight System. These modifications were necessary because failure modes and hazards were identified during the analysis that had not been properly mitigated. Strict Configuration Management was applied to changes (whether due to upgrades or expired calibrations) in the GSE by revisiting the FMEAs and PHAs to reflect the latest System Block Diagrams and Bill Of Material. The CoNNeCT flight system has been successfully assembled, integrated, tested, and shipped to the launch site without incident. This demonstrates that the steps taken to safeguard the flight system when it was interfaced to the various GSE were successful.

Fernandez, Rene↗

Vacuum Assisted Filtered Salt Sampling Progress

Several different design iterations for a filtered salt sampling technique have been tested in non-radiological molten salts. A piston vacuum assembly was designed and reliably and repeatably used to take salt samples through multiple different porous quartz frit sizes (as small as 5 – 10 µm). This design has been modified slightly and sent into the HFEF hot cell for upcoming testing with used fuel electrorefiner salt.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Reliable vision-guided grasping

Automated assembly of truss structures in space requires vision-guided servoing for grasping a strut when its position and orientation are uncertain. This paper presents a methodology for efficient and robust vision-guided robot grasping alignment. The vision-guided grasping problem is related to vision-guided 'docking' problems. It differs from other hand-in-eye visual servoing problems, such as tracking, in that the distance from the target is a relevant servo parameter. The methodology described in this paper is hierarchy of levels in which the vision/robot interface is decreasingly 'intelligent,' and increasingly fast. Speed is achieved primarily by information reduction. This reduction exploits the use of region-of-interest windows in the image plane and feature motion prediction. These reductions invariably require stringent assumptions about the image. Therefore, at a higher level, these assumptions are verified using slower, more reliable methods. This hierarchy provides for robust error recovery in that when a lower-level routine fails, the next-higher routine will be called and so on. A working system is described which visually aligns a robot to grasp a cylindrical strut. The system uses a single camera mounted on the end effector of a robot and requires only crude calibration parameters. The grasping procedure is fast and reliable, with a multi-level error recovery system.

Nicewarner, Keith E.↗

Reliable vision-guided grasping

Automated assembly of truss structures in space requires vision-guided servoing for grasping a strut when its position and orientation are uncertain. This paper presents a methodology for efficient and robust vision-guided robot grasping alignment. The vision-guided grasping problem is related to vision-guided 'docking' problems. It differs from other hand-in-eye visual servoing problems such as tracking in that the distance from the target is a relevant servo parameter. The methodology described in this paper is a hierarchy of levels in which the vision/robot interface is decreasingly 'intelligent', and increasingly fast. Speed is achieved primarily by information reduction. This reduction exploits the use of region-of-interest windows in the image plane and feature motion prediction. These reductions invariably require stringent assumptions about the image. Therefore, at a higher level, these assumptions are verified using slower, more reliable methods. This hierarchy provides for robust error recovery in that when a lower-level routine fails, the next-higher routine will be called and so on. A working system is described which visually aligns a robot to grasp a cylindrical strut. The system uses a single camera mounted on the end effector of a robot and requires only crude calibration parameters. The grasping procedure is fast and reliable, with a multi-level error recovery system.

Nicewarner, Keith E.↗

A Motor Drive Electronics Assembly for Mars Curiosity Rover: An Example of Assembly Qualification for Extreme Environments

This paper describes the technology development and infusion of a motor drive electronics assembly for Mars Curiosity Rover under space extreme environments. The technology evaluation and qualification as well as space qualification of the assembly are detailed and summarized. Because of the uncertainty of the technologies operating under the extreme space environments and that a high level reliability was required for this assembly application, both component and assembly board level qualifications were performed.

Kolawa, Elizabeth↗

International Human Mission to Mars: Analyzing A Conceptual Launch and Assembly Campaign

In July of 2013, U.S. Congressman Kennedy (D-Mass.) successfully offered an amendment to H.R. 2687, the National Aeronautics and Space Administration Authorization Act of 2013. "International Participation—The President should invite the United States partners in the International Space Station program and other nations, as appropriate, to participate in an international initiative under the leadership of the United States to achieve the goal of successfully conducting a crewed mission to the surface of Mars." This paper presents a concept for an international campaign to launch and assemble a crewed Mars Transfer Vehicle. NASA’s “Human Exploration of Mars: Design Reference Architecture 5.0” (DRA 5.0) was used as the point of departure for this concept. DRA 5.0 assumed that the launch and assembly campaign would be conducted using NASA launch vehicles. The concept presented utilizes a mixed fleet of NASA Space Launch System (SLS), U.S. commercial and international launch vehicles to accomplish the launch and assembly campaign. This concept has the benefit of potentially reducing the campaign duration. However, the additional complexity of the campaign must also be considered. The reliability of the launch and assembly campaign utilizing SLS launches augmented with commercial and international launch vehicles is analyzed and compared using discrete event simulation.

Cates, Grant↗