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This presentation describes the NASA GRC Multifunctional Materials Team activities in high voltage materials testing capabilities build up and recent research activities.
This paper provides a summary of the results of an attempt at experimental verification of the propagation of electromagnetic surface waves at microwaves frequencies, in and along the uniform dielectric coating of a circular cylindrical metal pipe, based on the previously established theoretical investigation. These experimental results are of value for the diagnostic of anomalies on the surface of tar-coated pipes used in protecting the underground power transmission cables (feeder pipes). A test-bed was designed and implemented using an aluminum tubes (10” diameter) with an acrylic tube coating (0.25” thickness). Two identical wave launcher/receiver arrays, each of 32 elements around the tube for relatively uniform radiation/reception, were designed and fabricated at the frequency of interest (~6 GHz). This arrangement was put in a specially designed small anechoic chamber and attached to a network analyzer. A variety of tests were performed to establish the launch efficiency, prove surface wave propagation along, and reflection from different types of anomalies on the coating. In the paper, a number of test results and supporting graphs will be provided and future work for improving the performance of the launch array and the test-bed arrangement for better results will be outlined.
This work proposes to combine the functionality benefits of power electronics with the power density benefits of medium-voltage cables to create a streamlined, high-density power electronics solution that seamlessly integrates with medium-voltage cables. Located at the ends of a medium- or high-voltage line, the proposed converter uses a cascade of coaxial power conversion cells to gradually step down the voltage, and excels in high step-down applications. By mimicking the coaxial geometry of medium-voltage cables, the converter preserves the axisymmetric electric field of the cable which, when combined with a solid insulating dielectric, provides a voltage scaling advantage over conventional planar and PCB-based converter solutions. Similar to medium voltage cables, the converter is fully passively cooled. A passive cooling strategy allows for combined installation with existing medium voltage cable systems without the added cost, maintenance needs, infrastructure, and reliability concerns associated with active cooling systems. The scalability of the modular structure in combination with the integration benefits provide a flexible power electronics system that can adapt to the evolving demands of the grid.
A stand alone, mobile photovoltaic power system along with a cable deployment system was designed and constructed to take part in the Desert Research And Technology Studies (RATS) lunar surface human interaction evaluation program at Cinder Lake, Arizona. The power system consisted of a photovoltaic array/battery system. It is capable of providing 1 kW of electrical power. The system outputs were 48 V DC, 110 V AC, and 220 V AC. A cable reel with 200 m of power cable was used to provide power from the trailer to a remote location. The cable reel was installed on a small trailer. The reel was powered to provide low to no tension deployment of the cable. The cable was connected to the 220 V AC output of the power system trailer. The power was then converted back to 110 V AC on the cable deployment trailer for use at the remote site. The Scout lunar rover demonstration vehicle was used to tow the cable trailer and deploy the power cable. This deployment was performed under a number of operational scenarios, manned operation, remote operation and tele-robotically. Once deployed, the cable was used to provide power, from the power system trailer, to run various operational tasks at the remote location.
On the seventh day of STS-110, Mission Specialists Steven Smith and Rex Walheim are shown preparing for their second extravehicular activity (EVA) and the third of the mission, with the assistance of Mission Specialist Jerry Ross. Following this mission, Ross and Smith will be the first and second most experienced spacewalkers, respectively, in history. A camera mounted on the Space Shuttle Atlantis shows footage of the International Space Station. While Smith and Walheim are on EVA, Mission Specialists Ross and Lee Morin will provide choreography from inside the Atlantis crew cabin, Pilot Stephen Frick will operate the robotic arm, and Commander Mike Bloom will control the cameras on the robotic arm. Smith and Walheim are shown exiting the airlock hatch and then installing an PFR (Portable Foot Restraint) on the end of the robotic arm, from which much of the work will be done. Following the switching off of a circuit breaker, the main EVA task of rewiring umbilical cables that provide power, commands, and video is begun. These cables will be connected to the Mobile Transporter's (MT) robotic arm. The MT, an external transportation system which runs on rails, is seen with a helmet mounted camera as the astronauts work to release bolts that had served to secure the MT during launch. After a final check of the umbilical connections mated, the Umbilical Reconfiguration Panel is fitted over the cables, and the astronauts make their way to the airlock hatch.
A parametric analysis was performed of transmission cables for transmitting electrical power at high voltage (up to 1000 V) and high frequency (10 to 30 kHz) for high power (100 kW or more) space missions. Large diameter (5 to 30 mm) hollow conductors were considered in closely spaced coaxial configurations and in parallel lines. Formulas were derived to calculate inductance and resistance for these conductors. Curves of cable conductance, mass, inductance, capacitance, resistance, power loss, and temperature were plotted for various conductor diameters, conductor thickness, and alternating current frequencies. An example 5 mm diameter coaxial cable with 0.5 mm conductor thickness was calculated to transmit 100 kW at 1000 Vac, 50 m with a power loss of 1900 W, an inductance of 1.45 micron and a capacitance of 0.07 micron-F. The computer programs written for this analysis are listed in the appendix.
Electrical cables are integral to power, control, and instrumentation systems within nuclear power plants (NPPs). Exposure of cable systems within nuclear containment to elevated temperatures and gamma radiation during decades-long operation of NPPs can lead to degradation of cable polymeric insulation. Prediction of nuclear cable insulation degradation is complicated as thermal and radiation stress are not additive. In this work, we explore the relative effects of simultaneous and sequential thermal and gamma irradiation on the aging of ethylene-propylene-diene (EPDM) elastomer insulation to better understand realistic scenarios of cable insulation degradation. Cable insulation samples of EPDM were subjected to up to 320 kGy of gamma radiation at a dose rate of 300 Gy/hr in two heating scenarios: (1) simultaneously aged samples were heated at 150°C during irradiation and (2) sequentially aged samples were heated at 150°C for designated durations followed by corresponding periods of irradiation at ambient temperature. The mass, tensile elongation at break, and carbonyl index were assessed to quantify aging of the polymers. The simultaneous aging scenario was found to the more severe of the two for EPDM insulation degradation.
Prior technology for machinery data acquisition used slip rings, FM radio communication, or non-real-time digital communication. Slip rings are often noisy, require much space that may not be available, and require access to the shaft, which may not be possible. FM radio is not accurate or stable, and is limited in the number of channels, often with channel crosstalk, and intermittent as the shaft rotates. Non-real-time digital communication is very popular, but complex, with long development time, and objections from users who need continuous waveforms from many channels. This innovation extends the amount of information conveyed from a rotating machine to a data acquisition system while keeping the development time short and keeping the rotating electronics simple, compact, stable, and rugged. The data are all real time. The product of the number of channels, times the bit resolution, times the update rate, gives a data rate higher than available by older methods. The telemetry system consists of a data-receiving rack that supplies magnetically coupled power to a rotating instrument amplifier ring in the machine being monitored. The ring digitizes the data and magnetically couples the data back to the rack, where it is made available. The transformer is generally a ring positioned around the axis of rotation with one side of the transformer free to rotate and the other side held stationary. The windings are laid in the ring; this gives the data immunity to any rotation that may occur. A medium-frequency sine-wave power source in a rack supplies power through a cable to a rotating ring transformer that passes the power on to a rotating set of electronics. The electronics power a set of up to 40 sensors and provides instrument amplifiers for the sensors. The outputs from the amplifiers are filtered and multiplexed into a serial ADC. The output from the ADC is connected to another rotating ring transformer that conveys the serial data from the rotating section to the stationary section. From there, a cable conveys the serial data to the remote rack, where it is reconditioned to logic level specifications, de-serialized, and converted back to analog. In the rotating electronics are code generators to indicate the beginning of files for data synchronization.
Lasers with high peak power pulses are commonly used in spaceflight missions for a wide range of applications, from LIDAR systems to optical communications. Due to the high optical power needed, the laser has to be located on the exterior of the satellite or coupled through a series of free space optics. This presents challenges for thermal management, radiation resistance, and mechanical design. Future applications will require multiple lasers located close together, which further complicates the design. Coupling the laser energy into a fiber optic cable allows the laser to be relocated to a more favorable position on the spacecraft. Typical fiber optic termination procedures are not sufficient for injection of these high-power laser pulses without catastrophic damage to the fiber endface. In the current study, we will review the causes of fiber damage during high-power injection and discuss our new manufacturing procedures that overcome these issues to permit fiber use with high reliability in these applications. We will also discuss the proper methods for launching the laser pulses into the fiber to avoid damage and how this is being implemented for current spaceflight missions.
The requirements, capabilities, and unique design features of the instrument pointing system drive units (DU) are presented. The DU's are identical for all three gimbal axes (elevation, cross elevation, and azimuth) and provide alternating rotation of shaft versus the housing of + or - 180 deg. The design features include: two ball bearing cartridges using cemented carbide balls coated with TiC a layer; redundant brushless torque motors and resolvers; a load by-pass mechanism driven by a dc torque motor to off-load the bearings during ascent/descent, ground transportation, and to provide an emergency breaking capability; and cabling over each gimbal axis by means of cable follow-up consisting of 13 signal and 15 power flat band cable loops. Test results of disturbance torque characteristics are presented.
To enable the rapid, widespread commercial availability of secondary distribution grid voltage and phase angle data, the DOE OE Technology Commercialization Fund (TCF) project: 1) created a new American National Standard for next-generation grid power quality sensing and communications, 2) created a new prototype broadband-based standard-compliant grid power sensing system for use by utilities and others, and 3) improved by several orders of magnitude the spatiotemporal scale of the in-progress DOE CESER project: Situational Awareness of Grid Anomalies (SAGA) for Visual Analytics.
Sandia National Laboratories performed tests to address the potential vulnerability concerns of a coupled High-Altitude Electromagnetic Pulse (HEMP) inducing secondary coupling onto critical instrumentation and control cables in a nuclear power plant, with specific focus on early-time HEMP. Three types of receiving cables in nine configurations were tested to determine transfer functions between two electrically separated cables referenced to the common mode input current on the transmitting cable. One type of transfer function related the input short circuit current and resulting open circuit voltage on the receiving cable. The other transfer function related the input short circuit current and the resulting short circuit current on the receiving cable. A 500 A standard HEMP waveform was input into the transfer functions to calculate peak coupling values on the receiving cables. The highest level of coupling using the standard waveform occurred when cables were in direct contact, with a peak short circuit current of 85 A and open circuit voltage of 9.8 kV, while configurations with separated cables predicted coupling levels of less than 5 A or 500 V.
A new solid-state spectral transmissometer and radiometer is described. The radiometer measures upwelling radiance, downwelling irradiance, and beam transmittance from 390 to 750 nm with channel widths of 2.35 nm. The spectrometer consists of a 256 element CCD linear array collecting light dispersed by a reflection grating in a modified Littrow configuration. The spectrometer is time and space-shared among the three signal types. The instrument has been deployed as a free-drifting buoy and in the profiling mode, with data stored internally on a magnetic bubble memory or sent up a conducting cable as desired. Power can be supplied either by a detachable external battery pack or through conducting cable. The instrument has been deployed in the oligotrophic North Pacific Central Gyre and in the eutrophic Straits of Juan de Fuca, and preliminary results for each region are discussed.
Predicting useful remaining life of cables in nuclear power plants is a topic of growing interest as plant continue to age. A typical electrical cable consists of polymeric materials, such as the cable jacket and insulation, which are susceptible to degradation due to exposure to both elevated temperatures and gamma irradiation over decades of service. In this work two insulation materials, crosslinked polyethylene (XLPE) and ethylene propylene diene (EPDM) elastomer, were characterized to quantify aging using total color difference and indenter modulus. Since the effects of thermal and gamma radiation are not additive but coupled, the effects of different aging scenarios including sequential and simultaneous aging were also evaluated. In the case of sequential aging, two aging scenarios were explored where the order in which thermal and gamma radiation received were altered. Total color difference of XLPE showed that sequentially aged insulation specimens, which received radiation first, degraded slightly more at maximum exposure than specimens which received thermal first. Similarly, in the case of EPDM, the extent of degradation evaluated using total color difference was found to be most severe in the case of sequentially aged insulation specimens which received radiation first. Indenter modulus was found to be insensitive to aging for XLPE but trended for EPDM. The largest variations were observed for the sequentially aged insulation specimens which received radiation first, similar to what was observed for total color difference.
A versatile mobile telerobot, denoted the magnetically attached multifunction maintenance rover (MAGMER), has been proposed for use in the inspection and maintenance of the surfaces of ships, tanks containing petrochemicals, and other large ferromagnetic structures. As its name suggests, this robot would utilize magnetic attraction to adhere to a structure. As it moved along the surface of the structure, the MAGMER would perform tasks that could include close-up visual inspection by use of video cameras, various sensors, and/or removal of paint by water-jet blasting, laser heating, or induction heating. The water-jet nozzles would be mounted coaxially within compressed-air-powered venturi nozzles that would collect the paint debris dislodged by the jets. The MAGMER would be deployed, powered, and controlled from a truck, to which it would be connected by hoses for water, compressed air, and collection of debris and by cables for electric power and communication (see Figure 1). The operation of the MAGMER on a typical large structure would necessitate the use of long cables and hoses, which can be heavy. To reduce the load of the hoses and cables on the MAGMER and thereby ensure its ability to adhere to vertical and overhanging surfaces, the hoses and cables would be paid out through telescopic booms that would be parts of a MAGMER support system. The MAGMER would move by use of four motorized, steerable wheels, each of which would be mounted in an assembly that would include permanent magnets and four pole pieces (see Figure 2). The wheels would protrude from between the pole pieces by only about 3 mm, so that the gap between the pole pieces and the ferromagnetic surface would be just large enough to permit motion along the surface but not so large as to reduce the magnetic attraction excessively. In addition to the wheel assemblies, the MAGMER would include magnetic adherence enhancement fixtures, which would comprise arrays of permanent magnets and pole pieces that could be adjusted to maximize or minimize the overall attractive magnetic force. Even with a paint thickness of 2 mm, a preliminary design provides a safety factor of 5 in the magnetic force in the upside- down, water-jets-operating condition, in which the total load (including the weight of the MAGMER and cables and the water-jet force) would be about 260 lb (the weight of 118 kg). Optionally, the MAGMER could carry magnetic shielding and/or could be equipped with a demagnetizing module to remove residual magnetism from the structure. The MAGMER would carry four charge-coupled-device cameras for visual inspection, monitoring of operation, navigation, and avoidance of collisions with obstacles. The control system of the MAGMER would include navigation and collision-avoidance subsystems that would utilize surface features as landmarks, in addition to direct images of obstacles.
The purpose of this report is to survey aging and monitoring concerns for electrical cable splices in nuclear power plants (NPPs) in long term operation. As portions of existing electrical cable runs in nuclear are replaced over time due to localized events, the total number of splices in NPPs is expected to increase. Relative to cables, the body of knowledge regarding aging of splices and splices in combination with aging cables in nuclear service environments in long-term operations is low. A few reports have considered the aging of cable system components other than cables (Jacobus 1990; Nelson 1998; Villaran and Lofaro 2002), but the nuclear industry has two decades of operating experience since these were published to further enlighten this issue. Herein we discuss electrical cables and splices commonly found in U.S. nuclear power plants, their qualification in safety-related application, and methods for monitoring their health condition. Common environmental stresses that can give rise to cable and splice failure are discussed. The Nuclear Regulatory Commission (NRC) Licensee Event Reports (LER) database was used to identify documented issues of cable and splice failure. The trend in the resultant data over time is considered to see if failures are increasing as plants age. Observations and conclusions of this work include: 1. Cables and splices are highly reliable components. Occurrence rates for events of interest were low and nearly constant over the last 20 years. 2. Common-cause failure for evaluated cable events of interest was observed to primarily be associated with loose connections, which may manifest associated with workmanship issues, thermal cycling, and/or vibration. 3. Replacement of cables is more common than repair, leading to an increase in proportion of new generation cables in the plant over time. 4. Splices on degraded cables have been observed to be problematic. Due to aging NPP infrastructure, including electrical cables, it is expected that such issues will continue to increase. 5. Condition monitoring approaches, while shown to be fruitful for cables, have been shown to be insensitive to degradation of splice sleeves, which are critical to the continued performance of splices. Additional condition monitoring (CM) work is needed to evaluate methods which are sensitive to the degradation of splice components. 6. Extended Material Degradation Assessment (EMDA) knowledge gaps for electrical cables (Bernstein et al. 2014) have not been investigated for splices but may represent similar concerns such as for the accelerated aging process historically used in environmental qualification.
Multi-walled CNT yarns have been experimentally and commercially created to yield lightweight, high conductivity fibers with good tensile properties for application as electrical wiring and multifunctional tendons. Multifunctional tendons are needed as the cable structures in tensegrity robots for use in planetary exploration. These lightweight robust tendons can provide mechanical strength for movement of the robot in addition to power distribution and data transmission. In aerospace vehicles, such as Orion, electrical wiring and harnessing mass can approach half of the avionics mass. Use of CNT yarns as electrical power and data cables could reduce mass of the wiring by thirty to seventy percent. These fibers have been intercalated with mixed halogens to increase their specific electrical conductivity to that near copper. This conductivity, combined with the superior strength and fatigue resistance makes it an attractive alternative to copper for wiring and multifunctional tendon applications. Electron beam irradiation has been shown to increase mechanical strength in pristine CNT fibers through increased cross-linking. Both pristine and intercalated CNT yarns have been irradiated using a 5-megavolt electron beam for various durations and the conductivities and tensile properties will be discussed. Structural information obtained using a field emission scanning electron microscope, energy dispersive X-ray spectroscopy (EDS), and Raman spectroscopy will correlate microstructural details with bulk properties.
Data wire cable runs are a significant presence on the exterior of the International Space Station (ISS), and continued ISS mission support requires detailed assessment of cables due to micrometeoroid and orbit debris (MMOD) impact. These data wire cables are twisted-pair cables consisting of two 22AWG stranded conductors and fillers inside a tight fitting braided copper shield. The copper shield and its contents are covered with a jacket that has a nominal outer diameter of 3.76 mm and beta-cloth tape. The ISS engineering community has identified two loss-of-function mechanisms for these cables: open circuits due to severed conductors within the cable, and short circuits due to contact between conductors or grounded components. As these data cables are low power systems, short circuits are not expected to burn away the contact, so both open and short circuits are considered permanent loss-of-function for the cable. A total of ninety-seven impact experiments have been performed into these cables to develop a statistical model for the failure of these cables to be used in reliability studies. The experimental work has yielded cumulative distribution functions for these cables for steel and aluminum components of the orbital debris environment at representative speeds and impact obliquities.