Flat-plate solar array project. Volume 5: Process development

The goal of the Process Development Area, as part of the Flat-Plate Solar Array (FSA) Project, was to develop and demonstrate solar cell fabrication and module assembly process technologies required to meet the cost, lifetime, production capacity, and performance goals of the FSA Project. R&D efforts expended by Government, Industry, and Universities in developing processes capable of meeting the projects goals during volume production conditions are summarized. The cost goals allocated for processing were demonstrated by small volume quantities that were extrapolated by cost analysis to large volume production. To provide proper focus and coverage of the process development effort, four separate technology sections are discussed: surface preparation, junction formation, metallization, and module assembly

User Needs, Benefits, and Integration of Robotic Systems in a Space Station Laboratory

The methodology, results and conclusions of all tasks of the User Needs, Benefits, and Integration Study (UNBIS) of Robotic Systems in a Space Station Laboratory are summarized. Study goals included the determination of user requirements for robotics within the Space Station, United States Laboratory. In Task 1, three experiments were selected to determine user needs and to allow detailed investigation of microgravity requirements. In Task 2, a NASTRAN analysis of Space Station response to robotic disturbances, and acceleration measurement of a standard industrial robot (Intelledex Model 660) resulted in selection of two ranges of microgravity manipulation: Level 1 (10-3 to 10-5 G at greater than 1 Hz) and Level 2 (less than equal 10-6 G at 0.1 Hz). This task included an evaluation of microstepping methods for controlling stepper motors and concluded that an industrial robot actuator can perform milli-G motion without modification. Relative merits of end-effectors and manipulators were studied in Task 3 in order to determine their ability to perform a range of tasks related to the three microgravity experiments. An Effectivity Rating was established for evaluating these robotic system capabilities. Preliminary interface requirements for an orbital flight demonstration were determined in Task 4. Task 5 assessed the impact of robotics

Towards Fully Additively-Manufactured Permanent Magnet Synchronous Machines: Opportunities and Challenges

With the growing interest in electrification and as hybrid and pure electric powertrains are adopted in more applications, electrical machine design is facing challenges in terms of meeting very demanding performance metrics for example high specific power, harsh environments, etc. This provides clear motivation to explore the impact of advanced materials and manufacturing on the performance of electrical machines. This paper provides an overview of additive manufacturing (AM) approaches that can be used for constructing permanent magnet (PM) machines, with a specific focus on additively-manufactured iron core, winding, insulation, PM as well as cooling systems. Since there has only been a few attempts so far to explore AM in electrical machines (especially when it comes to fully additively-manufactured machines), the benefits and challenges of AM have not been comprehensively understood. In this regard, this paper offers a detailed comparison of multiple multi-material AM methods, showing not only the possibility of fully additively-manufactured PM machines but also the potential significant improvements in their mechanical, electromagnetic and thermal properties. The paper will provide a comprehensive discussion of opportunities and challenges of AM in the context of electrical machines

Metal oxide semiconductor nanomembrane-based soft unnoticeable multifunctional electronics for wearable human-machine interfaces

Wearable human-machine interfaces (HMIs) are an important class of devices that enable human and machine interaction and teaming. Recent advances in electronics, materials, and mechanical designs have offered avenues toward wearable HMI devices. However, existing wearable HMI devices are uncomfortable to use and restrict the human body's motion, show slow response times, or are challenging to realize with multiple functions. Here, we report sol-gel-on-polymer-processed indium zinc oxide semiconductor nanomembrane-based ultrathin stretchable electronics with advantages of multifunctionality, simple manufacturing, imperceptible wearing, and robust interfacing. Multifunctional wearable HMI devices range from resistive random-access memory for data storage to field-effect transistors for interfacing and switching circuits, to various sensors for health and body motion sensing, and to microheaters for temperature delivery. The HMI devices can be not only seamlessly worn by humans but also implemented as prosthetic skin for robotics, which offer intelligent feedback, resulting in a closed-loop HMI system

Development of a form-flexible handling technology with active cooling for hybrid components in forging processes

Tailored Forming is a novel manufacturing process for the production of forged hybrid components. In contrast to components made of mono-materials, hybrid components can be adapted to the respective loads by combining different materials with contradictory properties. Short processing times and high component quality, however, lead to the demand for automated handling and local active cooling within the forming process, since the appropriate processing temperature is particularly important. Due to the fact that the hybrid components are differently hot and change their shape during the forming process, a special gripper system must be provided, which can withstand high temperatures, and ensures both shape variability and local cooling. Nowadays, however, there is a gap between shape variable grippers and rigid grippers for temperature-sensitive processes without any integrated cooling functionalities. Therefore, this paper presents an approach for the development of shape variable high temperature grippers with the use-case of handling hot steel-aluminium hybrid components

Robotic agricultural instrument for automated extraction of nematode cysts and eggs from soil to improve integrated pest management

Soybeans are an important crop for global food security. Every year, soybean yields are reduced by numerous soybean diseases, particularly the soybean cyst nematode (SCN). It is difficult to visually identify the presence of SCN in the field, let alone its population densities or numbers, as there are no obvious aboveground disease symptoms. The only definitive way to assess SCN population densities is to directly extract the SCN cysts from soil and then extract the eggs from cysts and count them. Extraction is typically conducted in commercial soil analysis laboratories and university plant diagnostic clinics and involves repeated steps of sieving, washing, collecting, grinding, and cleaning. Here we present a robotic instrument to reproduce and automate the functions of the conventional methods to extract nematode cysts from soil and subsequently extract eggs from the recovered nematode cysts. We incorporated mechanisms to actuate the stage system, manipulate positions of individual sieves using the gripper, recover cysts and cyst-sized objects from soil suspended in water, and grind the cysts to release their eggs. All system functions are controlled and operated by a touchscreen interface software. The performance of the robotic instrument is evaluated using soil samples infested with SCN from two farms at different locations and results were comparable to the conventional technique. Our new technology brings the benefits of automation to SCN soil diagnostics, a step towards long-term integrated pest management of this serious soybean pest