Paper Session I-B - Transducer Development Resources

The Transducer Development Laboratory, operating under the Kennedy Space Center (KSC) Engineering Development Directorate, performs: Applied research - Advanced Technology Development - Sustaining Engineering functions to ensure the accuracy, reliability, and interchangeability of transducers (sensors). The unique capabilities of the lab provide valuable resources to Ground Support Equipment (GSE) and Space Station Processing Facility (SSPF) systems at the Kennedy Space Center (KSC), as well as for other Government Facilities and programs. In doing so, the lab develops and maintains KSC specifications for GSE and SSPF transducers through extensive testing and applied development. More importantly, the necessary functions to which the lab serves has led to the establishment of unique expertise and testing capabilities. Calibration laboratory-level test equipment and transfer standards, in various disciplines: pressure – temperature - liquid and gas flow – vacuum – force/load - hydrogen gas - hydrocarbon fire, give the laboratory necessary versatility for resolving both long range and quick response transducer issues. The added capability to fully test and troubleshoot devices for electromagnetic interference /susceptibility compliance, gives the lab unique, diverse abilities available in few other places. This paper will briefly illustrate this diversity and the valuable resources available for the resolution of transducer-related development, testing, and troubleshooting issues for KSC, various launch vehicles, and industry

Paper Session II-C - Advancements in Chemical-gas Species-specific Point-sensors

Gaseous Chemical detection at trace levels is important to the space industry both for the safety of ground support equipment and space faring vessels. Gaseous point sensors are mature enough that inexpensive, small, and robust devices perform comparably to their bulkier, intricately complex, high-maintenance mass spectrometer counterparts. In particular, we will present an overview of technology for hydrogen and oxygen point sensors and display data for sensors of current technologies that represent today’s state of the art point sensors. In the light of this technology, new developments and direction for the future of point sensor devices will be discussed. Hydrogen and oxygen sensor technology may carry over to other gas species with minimal effort and cost. We will also demonstrate how gaseous point-sensor technologies may be applied as novel solutions to future space applications as well as to modern industrial needs

Advanced Signal Conditioners for Data-Acquisition Systems

Signal conditioners embodying advanced concepts in analog and digital electronic circuitry and software have been developed for use in data-acquisition systems that are required to be compact and lightweight, to utilize electric energy efficiently, and to operate with high reliability, high accuracy, and high power efficiency, without intervention by human technicians. These signal conditioners were originally intended for use aboard spacecraft. There are also numerous potential terrestrial uses - especially in the fields of aeronautics and medicine, wherein it is necessary to monitor critical functions. Going beyond the usual analog and digital signal-processing functions of prior signal conditioners, the new signal conditioner performs the following additional functions: It continuously diagnoses its own electronic circuitry, so that it can detect failures and repair itself (as described below) within seconds. It continuously calibrates itself on the basis of a highly accurate and stable voltage reference, so that it can continue to generate accurate measurement data, even under extreme environmental conditions. It repairs itself in the sense that it contains a micro-controller that reroutes signals among redundant components as needed to maintain the ability to perform accurate and stable measurements. It detects deterioration of components, predicts future failures, and/or detects imminent failures by means of a real-time analysis in which, among other things, data on its present state are continuously compared with locally stored historical data. It minimizes unnecessary consumption of electric energy. The design architecture divides the signal conditioner into three main sections: an analog signal section, a digital module, and a power-management section. The design of the analog signal section does not follow the traditional approach of ensuring reliability through total redundancy of hardware: Instead, following an approach called spare parts tool box, the reliability of each component is assessed in terms of such considerations as risks of damage, mean times between failures, and the effects of certain failures on the performance of the signal conditioner as a whole system. Then, fewer or more spares are assigned for each affected component, pursuant to the results of this analysis, in order to obtain the required degree of reliability of the signal conditioner as a whole system. The digital module comprises one or more processors and field-programmable gate arrays, the number of each depending on the results of the aforementioned analysis. The digital module provides redundant control, monitoring, and processing of several analog signals. It is designed to minimize unnecessary consumption of electric energy, including, when possible, going into a low-power "sleep" mode that is implemented in firmware. The digital module communicates with external equipment via a personal-computer serial port. The digital module monitors the "health" of the rest of the signal conditioner by processing defined measurements and/or trends. It automatically makes adjustments to respond to channel failures, compensate for effects of temperature, and maintain calibration

Multi sensor transducer and weight factor

A multi-sensor transducer and processing method allow insitu monitoring of the senor accuracy and transducer `health`. In one embodiment, the transducer has multiple sensors to provide corresponding output signals in response to a stimulus, such as pressure. A processor applies individual weight factors to reach of the output signals and provide a single transducer output that reduces the contribution from inaccurate sensors. The weight factors can be updated and stored. The processor can use the weight factors to provide a `health` of the transducer based upon the number of accurate versus in-accurate sensors in the transducer

Modular Wireless Data-Acquisition and Control System

A modular wireless data-acquisition and control system, now in operation at Kennedy Space Center, offers high performance at relatively low cost. The system includes a central station and a finite number of remote stations that communicate with each other through low-power radio frequency (RF) links. Designed to satisfy stringent requirements for reliability, integrity of data, and low power consumption, this system could be reproduced and adapted to use in a broad range of settings

Three-Dimensional Venturi Sensor for Measuring Extreme Winds

A three-dimensional (3D) Venturi sensor is being developed as a compact, rugged means of measuring wind vectors having magnitudes of as much as 300 mph (134 m/s). This sensor also incorporates auxiliary sensors for measuring temperature from -40 to +120 F (-40 to +49 C), relative humidity from 0 to 100 percent, and atmospheric pressure from 846 to 1,084 millibar (85 to 108 kPa). Conventional cup-and-vane anemometers are highly susceptible to damage by both high wind forces and debris, due to their moving parts and large profiles. In addition, they exhibit slow recovery times contributing to an inaccurately high average-speed reading. Ultrasonic and hot-wire anemometers overcome some of the disadvantages of the cup and-vane anemometers, but they have other disadvantageous features, including limited dynamic range and susceptibility to errors caused by external acoustic noise and rain. In contrast, the novel 3D Venturi sensor is less vulnerable to wind damage because of its smaller profile and ruggedness. Since the sensor has no moving parts, it provides increased reliability and lower maintenance costs. It has faster response and recovery times to changing wind conditions than traditional systems. In addition, it offers wide dynamic range and is expected to be relatively insensitive to rain and acoustic energy. The Venturi effect in this sensor is achieved by the mirrored double-inflection curve, which is then rotated 360 to create the desired detection surfaces. The curve is optimized to provide a good balance of pressure difference between sensor ports and overall maximum fluid velocity while in the shape. Four posts are used to separate the two shapes, and their size and location were chosen to minimize effects on the pressure measurements. The 3D Venturi sensor has smart software algorithms to map the wind pressure exerted on the surfaces of the design. Using Bernoulli's equation, the speed of the wind is calculated from the differences among the pressure readings at the various ports. The direction of the wind is calculated from the spatial distribution and magnitude of the pressure readings. All of the pressure port sizes and locations have been optimized to minimize measurement errors and to reside in areas demonstrating a stable pressure reading proportional to the velocity range

Sensor Applications at NASA KSC

The selection and qualification of commercial off-the-shelf products (COTS) transducers is desired whenever possible. In reality, qualified transducers are modified COTS to comply with KSC and program requirements. These requirements are dictated by the different NASA programs and the Kennedy Space Center (KSC). In some instances, there are no available commercial products that will meet the specific requirements of the application. The KSC Transducers Laboratory then develops these products. When fully developed, these products become certified GSE equipment and the potential for commercialization is assessed and pursued

Latest Development in Advanced Sensors at Kennedy Space Center (KSC)

Inexpensive space transportation system must be developed in order to make spaceflight more affordable. To achieve this goal, there is a need to develop inexpensive smart sensors to allow autonomous checking of the health of the vehicle and associated ground support equipment, warn technicians or operators of an impending problem and facilitate rapid vehicle pre-launch operations. The Transducers and Data Acquisition group at Kennedy Space Center has initiated an effort to study, research, develop and prototype inexpensive smart sensors to accomplish these goals. Several technological challenges are being investigated and integrated in this project multi-discipline sensors; self-calibration, health self-diagnosis capabilities embedded in sensors; advanced data acquisition systems with failure prediction algorithms and failure correction (self-healing) capabilities

Sensor Applications at Kennedy Space Center (KSC)

Transducers used at KSC (Kennedy Space Center), in support of processing and launch of flight vehicles and payloads, are designed and tested to meet specific program requirements. Any equipment, transducer or support instrumentation in direct contact or in support to flight vehicle operations is considered ground support equipment (GSE) and required to meet strict program requirements (i.e. Space Shuttle Program, Space Station Program, Evolved Expendable Launch Vehicles, etc.) Transducers used in KSC applications are based on commercial off-the-shelf (COTS) transducers and sensors. In order to fully meet KSC requirements, these transducers evolve from standard COTS to modified COTS. The Transducer and Data Acquisition Group of the Instrumentation Branch at Kennedy Space Center is responsible for providing the technical expertise as well as qualification-testing capability to transform these COTS transducers in modified COTS suitable for use around flight hardware