Smart Sensors System Development and Application for Harsh Environments
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sensors smart harsh environment↗
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A Brief Overview of Silicon Carbide Based Smart Sensor System Technologies for Planetary and Aeronautics Applications
A range of aerospace application related to planetary exploration and aeronautic engine operations require Smart Sensor System technologies operational in harsh environments. A Smart Sensor System as described here implies the use of sensors combined with electronics and other supporting technologies. For example, missions to the surface of planets like Venus or Mercury are challenged by extreme temperatures and environments, e.g., extended Venus operation 465°C [1]. In response, NASA has been developing capabilities for a small lander that is designed to operate for months in the extreme temperatures. These capabilities span electronics, sensors, communications, and power. Such a lander would enable new revolutionary science. Similar game changing capabilities are enabled by the introduction of high temperature smart systems into aeronautic engine applications to enable distributed intelligence within the engine system [2]. Core to meeting these applications is operational harsh environment electronics, corresponding sensor systems, and their integration. This presentation concentrates on the status of Smart System technologies emphasizing the role of Silicon Carbide (SiC) electronics and sensors. For example, SiC integrated circuit (IC) electronics have matured to a state where a simple long-life scientific probe is feasible for extended Venus surface operations [1, 3]. Maturation of these high temperature electronics and other technologies has been part of NASA projects to provide an operational system for in situ exploration of the Venus surface for up to 60 days [1,3-4]. This is in parallel to work expanding the capabilities of the sensor technology to provide science measurements on the Venus surface. This technology development, as well as that for other planetary applications and intelligent high temperature engine operations, will be discussed.
engine monitoring↗
An Overview of the Development of High Temperature Wireless Smart Sensor Technology
The harsh environment inherent in propulsion systems is especially challenging for Smart Sensor Systems; this paper addresses technology development for such applications. A basic sensing system for high temperature wireless pressure monitoring composed of a sensor, electronics, and wireless communication with scavenged power developed for health monitoring of aircraft engines and other high temperature applications has been demonstrated at 475 C. Other efforts will be discussed including a brief overview of the status of high temperature electronics and sensors, as well as their use and applications.
health managment↗
Communications and Intelligent Systems Division Overview
Provides expertise, and plans, conducts and directs research and engineering development in the competency fields of advanced communications and intelligent systems technologies for applications in current and future aeronautics and space systems.Advances communication systems engineering, development and analysis needed for Glenn Research Center's leadership in communications and intelligent systems technology. Focus areas include advanced high frequency devices, components, and antennas; optical communications, health monitoring and instrumentation; digital signal processing for communications and navigation, and cognitive radios; network architectures, protocols, standards and network-based applications; intelligent controls, dynamics and diagnostics; and smart micro- and nano-sensors and harsh environment electronics. Research and discipline engineering allow for the creation of innovative concepts and designs for aerospace communication systems with reduced size and weight, increased functionality and intelligence. Performs proof-of-concept studies and analyses to assess the impact of the new technologies.
Intelligent Systems↗
A Brief Review of the Need for Robust Smart Wireless Sensor Systems for Future Propulsion Systems, Distributed Engine Controls, and Propulsion Health Management
Smart Sensor Systems with wireless capability operational in high temperature, harsh environments are a significant component in enabling future propulsion systems to meet a range of increasingly demanding requirements. These propulsion systems must incorporate technology that will monitor engine component conditions, analyze the incoming data, and modify operating parameters to optimize propulsion system operations. This paper discusses the motivation towards the development of high temperature, smart wireless sensor systems that include sensors, electronics, wireless communication, and power. The challenges associated with the use of traditional wired sensor systems will be reviewed and potential advantages of Smart Sensor Systems will be discussed. A brief review of potential applications for wireless smart sensor networks and their potential impact on propulsion system operation, with emphasis on Distributed Engine Control and Propulsion Health Management, will be given. A specific example related to the development of high temperature Smart Sensor Systems based on silicon carbide electronics will be discussed. It is concluded that the development of a range of robust smart wireless sensor systems are a foundation for future development of intelligent propulsion systems with enhanced capabilities.
Hunter, Gary W.↗
Wireless High-Temperature Sensor Network for smart boiler systems
This final project report describes the research data and findings. This project aims to develop a new wireless high-temperature sensor network for real-time continuous boiler condition monitoring in harsh environments. Such a wireless high-temperature sensor network enables network-based automatic temperature sensing and data collection, which combined with artificial intelligent (AI) algorithms allow the construction of smart boiler systems with boiling condition management and optimization for significant energy-saving and reliability improvement
42 ENGINEERING↗
Enabling the Next Generation of Smart Sensors in Coal Fired Power Plants using Cellular 5G Technology
An important need for coal fired power plants is the ability to monitor multiple systems with ease and accuracy. Common implementations of these monitoring systems come with drawbacks due to the nature of coal fired power plants. Harsh environments, High Temperatures, and lots of RF (Radio Frequency) noise can create issues for accurately recording and transmitting data across wireless signals. In addition, as renewable energy sources come online, existing fossil fueled plants will need to operate more flexibly with their maintenance schedules outside of standard conditions. Therefore, additional sensing and control mechanisms need placed in existing plants to provide operators with more information such that maintenance decisions can be made well in advance of failures. A solution to this problem is the Next Generation of Smart Sensors, which leverages the power of 5G cellular signals and machine learning to overcome the myriad of problems with current implementations
20 FOSSIL-FUELED POWER PLANTS↗
Plug-and-Play Environmental Monitoring Spacecraft Subsystem
A Space Environment Monitor (SEM) subsystem architecture has been developed and demonstrated that can benefit future spacecraft by providing (1) real-time knowledge of the spacecraft state in terms of exposure to the environment; (2) critical, instantaneous information for anomaly resolution; and (3) invaluable environmental data for designing future missions. The SEM architecture consists of a network of plug-and- play (PnP) Sensor Interface Units (SIUs), each servicing one or more environmental sensors. The SEM architecture is influenced by the IEEE Smart Transducer Interface Bus standard (IEEE Std 1451) for its PnP functionality. A network of PnP Spacecraft SIUs is enabling technology for gathering continuous real-time information critical to validating spacecraft health in harsh space environments. The demonstrated system that provided a proof-of-concept of the SEM architecture consisted of three SIUs for measurement of total ionizing dose (TID) and single event upset (SEU) radiation effects, electromagnetic interference (EMI), and deep dielectric charging through use of a prototype Internal Electro-Static Discharge Monitor (IESDM). Each SIU consists of two stacked 2X2 in. (approximately 5X5 cm) circuit boards: a Bus Interface Unit (BIU) board that provides data conversion, processing and connection to the SEM power-and-data bus, and a Sensor Interface Electronics (SIE) board that provides sensor interface needs and data path connection to the BIU.
Patel, Jagdish↗
Sensor Requirements and Roadmaps
The chapter starts with a brief overview of the state-of-the-art of the sensing technologies. Principles of detection and the stage of integration in conjunction with the need are discussed. Based on the projected sensor requirements to accomplish propulsion systems with distributed active control, the existent gaps and selected types of sensor technologies are addressed, which are foreseen to deliver the required sensitivity, the resolution, the range, and the bandwidth in classes of sensors and which will allow operation under harsh environment conditions. By changing the packaging and/or design of the current sensors, operation environments of 750°C may be possible, which would meet requirements for sensors located towards the engine intake, compressor and in some cases low-pressure turbine. However, the majority of sensors for locations close to the engine combustion chamber or afterburner (with operation temperatures up to 1700°C) do not exist. There is also a need for smart sensors, which would enable future distributed control architecture. In addition a number of sensors, which are of interest for more intelligent gas turbine engines, are being explored or do not yet exist, for example turbine emission species sensors, burning patter factor sensors, fuel property sensors, and exhaust gas composition sensors. Meanwhile, rapid emerging technologies were made available during the three years duration of the Task Group. These include tip clearance measurement technologies such as eddy current, and microwave methods. To meet future sensor requirements, new fabrication and material technologies (MEMS, other), advanced sensing principles (spectroscopy, other), and their potential applications to new sensor types need to be explored. The status of current R&D for new sensors and future expectations are summarized in a comprehensive table. Sensors and associated electronics that have to operate in high temperature are foreseen to be largely available by 2015 (SiC) and 2020 (SiCN). Both of these technologies come with the potential of embedding such high temperature sensors within the structure. The information presented in the chapter represents the state-of-the-art of the sensing technology of the years 2005-2007 to the best knowledge of the authors. The authors are also fully aware of the fact that there may be many ongoing research programs as well as individual research that are not publicly supported and public information is not available. Therefore, the report might miss that section of knowledge. Also, progress in research and development is made every day such that often, the recent information may be fast outdated. The reader should bear in mind these facts.
Ion Stiharu↗
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↗
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.↗
Embedding Fiber Optic Sensors in Stainless Steel using Spark Plasma Sintering for Structural Health Monitoring in Harsh Environments
Embedded fiber optic sensors such as fiber Bragg gratings (FBGs) offer a unique route for distributed real-time in-situ imaging of various engineering parameters for numerous purposes. This study advanced the current sensor embedding approaches by exploring a spark plasma sintering (SPS)-assisted technology to embed FBGs in high-temperature structural materials and demonstrated the capability of temperature measurement. In this approach, single-mode FBGs were integrated into stainless steel (SS) 316L components using SPS, followed by the evaluation of the bonding quality between the FBGs and matrix, the optical attenuation of the fibers induced by embedding, and the sensing characters of the FBGs under temperature stimuli. The results demonstrated that superior bonding was achieved between the FBGs and highly-densified SS316L. Examination of the behavior of Bragg gratings validated signal fidelity after embedding. Real-time thermal imaging under temperature cycling using the FBGs demonstrated the effectiveness of the technique for smart materials manufacturing.
36 - MATERIALS SCIENCE↗
Maturation of Structural Health Management Systems for Solid Rocket Motors
Concepts of an autonomous and automated space-compliant diagnostic system were developed for conditioned-based maintenance (CBM) of rocket motors for space exploration vehicles. The diagnostic system will provide real-time information on the integrity of critical structures on launch vehicles, improve their performance, and greatly increase crew safety while decreasing inspection costs. Using the SMART Layer technology as a basis, detailed procedures and calibration techniques for implementation of the diagnostic system were developed. The diagnostic system is a distributed system, which consists of a sensor network, local data loggers, and a host central processor. The system detects external impact to the structure. The major functions of the system include an estimate of impact location, estimate of impact force at impacted location, and estimate of the structure damage at impacted location. This system consists of a large-area sensor network, dedicated multiple local data loggers with signal processing and data analysis software to allow for real-time, in situ monitoring, and longterm tracking of structural integrity of solid rocket motors. Specifically, the system could provide easy installation of large sensor networks, onboard operation under harsh environments and loading, inspection of inaccessible areas without disassembly, detection of impact events and impact damage in real-time, and monitoring of a large area with local data processing to reduce wiring.
Quing, Xinlin↗
The future of subsurface monitoring: AEC’s breakthroughs in CCS technology
Carbon capture and storage (CCS) has emerged as a key solution in the fight against climate change. However, for CCS to succeed, it is crucial to ensure that the sequestered CO2 stays safely trapped underground. The U.S. Department of Energy (DOE) has emphasized the need for advancements in subsurface monitoring, measurement, reporting, and verification. Aside from caprock integrity failure, the other primary failure points usually involve defective cement in the casing annulus of wellbores or plugged and abandoned wells. In addition, many energy producers (e.g., oil and gas, geothermal) and storage and disposal operators (e.g., H2 and water) must deal with the same issue. Poorly placed or degraded cement can create pathways for gas or fluid to escape from casing annuli and in plugged and abandoned or orphan wells, posing environmental risks. Yet, a reliable and cost-effective way to monitor cement and well integrity over multiple decades is still unavailable. Traditional geophysical methods like 4D seismic imaging and surface-based electromagnetic monitoring lack the resolution and accuracy for detecting these types of failures (Vasco et al., 2022; Fawad and Mondol, 2021). Wireline logging is expensive to run continuously and is obtrusive to the operation. While fiber optics can potentially be a solution, its bulkiness can significantly compromise the cement's integrity. To address these challenges, the Advanced Energy Consortium (AEC) at The University of Texas at Austin’s Bureau of Economic Geology (the Bureau) has been pioneering research in subsurface monitoring using its portfolio of distributed autonomous microfabricated sensors for harsh subsurface environments since 2008. A class of these microsensors [System on a Chip (SoC)] can be mixed in cement and permanently placed without compromising the cement column; the sensors would then communicate with each other or a data acquisition (DAQ) master node. Another class of the AEC microsensors can be fully autonomous, with rechargeable micro-batteries capable of exceeding 100°C, flash memory, and, currently, a pressure and temperature sensor. They are designed to circulate in mud, geothermal fluids, U-loops, or pipelines. They can log data into memory and are unobtrusive to operations. Our team has been working on a multi-year DOE-funded project (DE-FE0031856)—supported by $2.95M in federal funding and $0.75M in cost-matching from the AEC—to demonstrate SoC sensor utility for CO2 leakage monitoring in CCS applications. This multi-institutional collaboration developed a novel sensing architecture utilizing radiofrequency (RF) microsensors embedded within the cement sheath. These sensors detect CO2 migration and are interrogated via a Smart Casing Collar (SCC).
58 GEOSCIENCES↗
Distributed Engine Control Empirical/Analytical Verification Tools
NASA's vision for an intelligent engine will be realized with the development of a truly distributed control system featuring highly reliable, modular, and dependable components capable of both surviving the harsh engine operating environment and decentralized functionality. A set of control system verification tools was developed and applied to a C-MAPSS40K engine model, and metrics were established to assess the stability and performance of these control systems on the same platform. A software tool was developed that allows designers to assemble easily a distributed control system in software and immediately assess the overall impacts of the system on the target (simulated) platform, allowing control system designers to converge rapidly on acceptable architectures with consideration to all required hardware elements. The software developed in this program will be installed on a distributed hardware-in-the-loop (DHIL) simulation tool to assist NASA and the Distributed Engine Control Working Group (DECWG) in integrating DCS (distributed engine control systems) components onto existing and next-generation engines.The distributed engine control simulator blockset for MATLAB/Simulink and hardware simulator provides the capability to simulate virtual subcomponents, as well as swap actual subcomponents for hardware-in-the-loop (HIL) analysis. Subcomponents can be the communication network, smart sensor or actuator nodes, or a centralized control system. The distributed engine control blockset for MATLAB/Simulink is a software development tool. The software includes an engine simulation, a communication network simulation, control algorithms, and analysis algorithms set up in a modular environment for rapid simulation of different network architectures; the hardware consists of an embedded device running parts of the CMAPSS engine simulator and controlled through Simulink. The distributed engine control simulation, evaluation, and analysis technology provides unique capabilities to study the effects of a given change to the control system in the context of the distributed paradigm. The simulation tool can support treatment of all components within the control system, both virtual and real; these include communication data network, smart sensor and actuator nodes, centralized control system (FADEC full authority digital engine control), and the aircraft engine itself. The DECsim tool can allow simulation-based prototyping of control laws, control architectures, and decentralization strategies before hardware is integrated into the system. With the configuration specified, the simulator allows a variety of key factors to be systematically assessed. Such factors include control system performance, reliability, weight, and bandwidth utilization.
DeCastro, Jonathan↗
SpaceCube Version 1.5
SpaceCube 1.5 is a high-performance and low-power system in a compact form factor. It is a hybrid processing system consisting of CPU (central processing unit), FPGA (field-programmable gate array), and DSP (digital signal processor) processing elements. The primary processing engine is the Virtex- 5 FX100T FPGA, which has two embedded processors. The SpaceCube 1.5 System was a bridge to the SpaceCube 2.0 and SpaceCube 2.0 Mini processing systems. The SpaceCube 1.5 system was the primary avionics in the successful SMART (Small Rocket/Spacecraft Technology) Sounding Rocket mission that was launched in the summer of 2011. For SMART and similar missions, an avionics processor is required that is reconfigurable, has high processing capability, has multi-gigabit interfaces, is low power, and comes in a rugged/compact form factor. The original SpaceCube 1.0 met a number of the criteria, but did not possess the multi-gigabit interfaces that were required and is a higher-cost system. The SpaceCube 1.5 was designed with those mission requirements in mind. The SpaceCube 1.5 features one Xilinx Virtex-5 FX100T FPGA and has excellent size, weight, and power characteristics [4×4×3 in. (approx. = 10×10×8 cm), 3 lb (approx. = 1.4 kg), and 5 to 15 W depending on the application]. The estimated computing power of the two PowerPC 440s in the Virtex-5 FPGA is 1100 DMIPS each. The SpaceCube 1.5 includes two Gigabit Ethernet (1 Gbps) interfaces as well as two SATA-I/II interfaces (1.5 to 3.0 Gbps) for recording to data drives. The SpaceCube 1.5 also features DDR2 SDRAM (double data rate synchronous dynamic random access memory); 4- Gbit Flash for storing application code for the CPU, FPGA, and DSP processing elements; and a Xilinx Platform Flash XL to store FPGA configuration files or application code. The system also incorporates a 12 bit analog to digital converter with the ability to read 32 discrete analog sensor inputs. The SpaceCube 1.5 design also has a built-in accelerometer. In addition, the system has 12 receive and transmit RS- 422 interfaces for legacy support. The SpaceCube 1.5 processor card represents the first NASA Goddard design in a compact form factor featuring the Xilinx Virtex- 5. The SpaceCube 1.5 incorporates backward compatibility with the Space- Cube 1.0 form factor and stackable architecture. It also makes use of low-cost commercial parts, but is designed for operation in harsh environments.
Geist, Alessandro↗