Breadboard Testing Research Articles

Design and Validation of Advancing Autonomous Firefighting Robot

The quest for enhanced fire-fighting capabilities led to the design and validation of an autonomous firefighting robot in this study. Proteus software was leveraged for rigorous simulation, and the prototype integrated an array of components, including an IR flame sensor, servo motors, a submersible water pump, and a microcontroller-driven navigation system. Comprehensive testing was conducted with meticulous attention to component integrity and functionality, confirming the robot's ability to detect fires, navigate toward them, and effectively extinguish them using water. The robot utilized a 12V DC power supply and was powered by three 4V lithium rechargeable batteries. It seamlessly transitioned from breadboard testing to a soldered board configuration. Preliminary tests, conducted with a candle flame, validated the robot's efficacy in real-world fire detection and suppression scenarios. This innovative design highlighted the potential for robotic solutions in enhancing firefighting capabilities and ensuring safer environments.

A 7 m × 1.5 m Aperture Parabolic Cylinder Deployable Mesh Reflector Antenna for Next-Generation Satellite Synthetic Aperture Radar

A high priority next-generation satellite remote sensing mission necessitates a lightweight deployable antenna that can fit in the package of low-Earth orbit small satellites. In this work, we present the development of a 7 m×1.5 m aperture C-Band parabolic cylinder mesh reflector along with a 1×32 element linear patch array feed. The detailed and tailored mechanical design, full-wave analysis, and measurements of the reflector are elaborated. The reflector is constructed with a mesh surface with unique deployment mechanisms for weight reduction and stowage. The linear microstrip patch array feed is designed with a lightweight honeycomb substrate and is used for the breadboard testing of the parabolic cylinder reflector. The antenna achieved the desired surface accuracy and a measured gain of 42.06 dBi at 5.357 GHz, with half-power beamwidths of 0.52° and 2.35° in the two principal planes.

A multi-input single-output Dickson-type AC/DC converter for vibration energy harvesting

To achieve efficient vibration energy harvesting, we propose a new inductor-less ac/dc converter with multiple-input single-output (MISO) structure in this paper. Unlike existing ac/dc converters with single-input single-output (SISO) structure, the proposed inductor-less ac/dc converter achieves a high voltage gain and small size by the MISO structure employing Dickson-type converters. The properties of the proposed inductor-less MISO converter are evaluated by theoretical analysis and computer simulations. For the proposed converter with two modules, the simulation results demonstrate that the voltage gain and power efficiency reach about 6.7 and 84% at 500 mW, respectively, for 3.5 V inputs at 50 kHz. Furthermore, the validity of the circuit design is confirmed experimentally by some breadboard tests.

Experimental assessment of alternative compact configurations for ammonia-water desorption

Heat and mass transfer during ammonia-water desorption in miniaturized desorbers using microscale geometries was investigated. Two heat transfer fluid coupled test sections (a vertical column configuration and a branched-tray configuration), consisting of an array of alternating plates with integral microscale features, enclosed between cover plates, were fabricated. Due to the counter-current flow configuration, refrigerant vapor with a high purity of ammonia (as high as 99.9% ammonia mass fraction) was generated in these components. Compact adiabatic analyzers and solution-cooled rectifiers with microscale features were also integrated with the two desorber concepts to further increase refrigerant purity. These components were installed in a breadboard test facility consisting of all components of a single-effect ammonia-water absorption chiller and investigated over a range of solution and vapor flow rates. The measured experimental data were analyzed to estimate component duties, solution- and coupling fluid-side resistances, and conduct a comparative assessment of the two miniaturized desorption concepts. The branched-tray configuration performed better than the vertical column design and led to higher purity refrigerant. Potential causes for differences in the performances are discussed.

Highly Conductive Carbon Fiber-Reinforced Polymer Composite Electronic Box: Out-Of-Autoclave Manufacturing for Space Applications

One of the main advantages of carbon fiber-reinforced polymer (CFRP) electronic housings, when compared with traditionally used aluminum ones, is the potential for mass savings. In recent years, the power consumption of electronics has been growing, resulting in the need for higher thermal dissipation of electronic housings, requiring the use of highly thermally conductive materials. In this work, the manufacturing of a highly conductive CFRP electronic housing is reported. With a view to reducing total energy costs on manufacturing, an out-of-the autoclave manufacturing process was followed. Due to the inherent low thermal conductivity of typical raw materials for composite materials, strategies were evaluated to increase its value by changing the components used. The use of pitch-based carbon fibers was found to be a very promising solution. In addition, structural, thermal and manufacturing simulations were produced in the design phase. Improved performance was demonstrated from materials manufacturing to final breadboard testing. The results indicate potential gains of around 23% in mass reduction when compared to conventional aluminum electronic boxes. Moreover, the proposed design and the manufactured breadboard showed good compliance with mechanical and electrical requirements for spacecraft structures. The thermal balance results showed a performance slightly below to what would be expected from the detailed design.

Experimental assessment of a compact branched tray generator for ammonia–water desorption

An experimental investigation of heat and mass transfer in a miniaturized ammonia–water desorber utilizing microscale geometries is presented. The desorber, sized for a 3.5-kW space-conditioning system, is of a branched tray design consisting of an array of alternating plates with integral microscale features enclosed between cover plates. The desorber is hydronically coupled to a heat transfer fluid that is heated by the combustion of natural gas. An adiabatic analyzer and solution cooled rectifier are integrated into the same envelope as the desorber. The component is tested as part of a single-pressure system on a breadboard test facility and is studied over a range of heat transfer fluid inlet temperatures, flow rates, and concentrated solution flow rates. Desorber performance is experimentally investigated over a wide range of test conditions to improve the understanding of performance at design and off-design conditions and the potential for flow instabilities.

Air-Independent Hybrid SOFC-Battery Energy System for Undersea Vehicles

FuelCell Energy is developing a Hybrid Solid Oxide Fuel Cell (SOFC)-Battery Energy System for Large Displacement Unmanned Undersea Vehicle (LDUUV) propulsion as part of the Office of Naval Research’s LDUUV Innovative Naval Prototype (INP) Energy Program. The project objective is the development of an air-independent refuelable power system with high energy density suitable for long duration underwater missions. The Hybrid SOFC-Battery system will be capable of generating 1800kWhr of electricity over a 70 day mission with no exhaust discharged outside of the vehicle at any time. The energy system is fueled by JP-10 logistic fuel, utilizes liquid O2 for air-independent operation, and is compact enough to fit within a 42-inch square by 120-inch long LDUUV power section. Phase I of the project includes process design and cost analysis, development of a 3-D CAD model of the energy system, breadboard testing of components and the integrated system, as well as completion of a Preliminary Hazard Analysis (PHA).

Characteristic study on fuel cell/battery hybrid power system on a light electric vehicle

A light electric vehicle (LEV) equipped a hybrid power system has been developed in the present work. The hybrid power system consisted of a proton exchange membrane (PEM) fuel cell and a lithium-ion battery. The former serves the major propulsion power, while the later takes some of the peak power requirement as well as allows regenerative braking. First, major components of the hybrid power system such as a fuel cell stack, a membrane humidifier, a lithium-ion battery pack, a microcontroller, a DC/DC converter, and hydrogen storage canisters (HSCs) are developed and verified. Special attention will be placed on the implementation of the stack-humidifier assembly and the hydrogen storage canister. Then, a breadboard test to assess the efficiency of the hybrid power system is provided. Subsequently, a driving test and demonstration of the hybrid LEV is carried out. Finally, the proportion of power from the fuel cell and the lithium-ion battery is analyzed under various driving conditions such as idle, starting, acceleration, and braking. Results of this work might help directing future studies on the hybrid power system in the most promising way.

Development of a W-band Antenna for Space-borne 94 GHz Doppler Radar

The EarthCARE mission is planned to be launched in 2013. JAXA and NICT have developed a cloud profiling radar (CPR) for the EarthCARE mission to perform observation of the cloud profiles and Doppler velocity of the cloud particles. The CPR is one of the core sensors of the EarthCARE satellite and will be the first space-borne W-band radar with Doppler measurement mode. The CPR employs a light-weighted large reflector which has to assure extremely high beam pointing accuracy and high physical surface accuracy even in the severe thermal environment in orbit of around 450 km height. Therefore, the CPR antenna reflector has been designed to have quite lower thermal deformation compared to the general reflectors used for the communication satellites. This report shows preliminary design result of the CPR antenna main reflector, the measured characteristics of the reflector material, and the results of the bread board model manufacturing and testing. The results concluded the manufacturing feasibility and thermal tolerance of the reflector are almost successfully evaluated.

Web watch

Many future satellite configurations will require the transfer of signals and power across rotating interfaces. Satellite systems are particularly cost effective for both commercial and military communications applications if their useful lifetime can be demonstrated to be greater than five years. The rotary transformer has the desireable characteristics of high reliability and low noise which qualify it as a potential replacement for slip rings. This paper describes the development of a rotary transformer for typical spacecraft applications. The transformer is built in modular sections, each capable of transferring 500 watts across a gap at efficiencies greater than 88 percent, dc to dc. The design effort included a study of pertinent electrical characteristics required for typical spacecraft configurations, electrical design and analyses of the overall dc-dc converter, mechanical design of the transformer cores and their assembly, and a study of transformer core and winding characteristics. Breadboard test results have demonstrated the desired level of efficiency, satisfactory operation over temperature, and satisfactory electrical characteristics.

Breadboard testing of a phase-conjugate engine with an interferometric wave-front sensor and a microelectromechanical systems-based spatial light modulator

Laboratory breadboard results of a high-speed adaptive-optics system are presented. The wave-front sensor for the adaptive-optics system is based on a quadrature interferometer, which directly measures the turbulence-induced phase aberrations. The spatial light modulator used in the phase-conjugate engine was a microelectromechanical systems-based piston-only correction device with 1024 actuators. Laboratory experiments were conducted with this system utilizing Kolmogorov phase screens to simulate atmospheric phase distortions. The adaptive-optics system achieved correction speeds in excess of 800 Hz and Strehl ratios greater than 0.5 with the Kolmogorov phase screens.

A digital approach for automatic tuning of continuous-time high-q filters

A digital scheme for automatic tuning of continuous-time high-Q filters is proposed. The tuning scheme uses the phase information for both frequency and Q-factor tuning, therefore, the relationship between the filter's passband magnitude and Q is immaterial. Due to the digital control of the tuning loops, only one loop is active at a given time interval, which eliminates the need for a slow Q tuning loop, improves stability and reduces tuning time. Experimental breadboard tests verify the operation where approximately 1% tuning error is accomplished using the offline tuning algorithm.

NeuroArm: an MR compatible robot for microsurgery

Introduction: Technologies such as microscopy have pushed surgeons to the limits of their dexterity and endurance. Robotic advances such as tremor filtration and motion scaling permit maximal use of magnification, and enable precise, tremor-free tool manipulation during microsurgery. To our knowledge, however, no such device exists for image-guided, ambidextrous microneurosurgery, prompting us to develop our own system. Methods: We approached a company with exceptional experience in space robotics to design and construct an appropriate system. A systematic and structured approached was followed for the design of neuroArm. Engineers studied the operating room environment with the assistance of surgeons and nursing staff. A preliminary design was developed, and subsequently evaluated by surgical staff. Selected materials were tested at 3.0 T to ensure MR compatibility and performance characteristics of the robot actuators and encoders were evaluated. Results: We have developed an MR compatible ambidextrous robot capable of both microneurosurgery and stereotaxy. The design is based on a SCARA configuration and has 8-DOF (including tool actuation). The end-effector is designed to interface with standard neurosurgical tools and is equipped with a 3-DOF optical force sensor for haptic feedback. Comprehensive testing of materials was conducted in a 3-T magnet to ensure compatibility. Breadboard testing results suggest a tool tip resolution of 30 μm. Discussion: A systematic approach has been applied to the development of a unique and dexterous neurosurgical robot. The system promises to enhance surgical performance, reduce fatigue, and improve surgical outcomes. This seamless integration of robotics with iMRI will further revolutionize neurosurgery.

Performance of a second-generation miniature ruggedized optical correlator module

Many image processing applications require a small, lowpower, low-cost pattern recognition system that is capable of locating and identifying objects. Miniature optical correlators can perform 2-D pattern recognition at greater rates than digital platforms of equivalent size, power and/or weight. The patented miniature ruggedized optical correlator (MROC™) module is built to meet the environmental, size, power, and weight requirements of military and rugged commercial applications, and at a cost that permits wide deployment of the capability. The second version of the MROC module consists of a ferroelectric liquid crystal (FLC) device in the input plane for high light efficiency and incorporates a reflective magnet-optic spatial light modulator (RMOSLM™) device in the filter plane for very high speed operation. The correlator has a volume of approximately 20 in.3. MROC II breadboard tests demonstrated excellent correlation peaks, i.e., excellent discrimination (SNR>25), at pattern matching rates of 1920/s on images of military vehicles.

Design and test of a through-the-mask alignment sensor for a vertical stage x-ray aligner

SVG Lithography is building a production-ready, vertical stage x-ray proximity aligner. For aligner-to-itself overlays, the aligner overlay specification is a mean 3σ value of 33 nm. As part of this aligner specification, each through-the-mask (TTM) alignment sensor has a wafer-to-mask position measurement accuracy specification with a mean value of 7.1 nm and a 3σ value of 9.2 nm. This article presents a summary of the operation, design, and breadboard testing of the TTM sensor. Breadboard testing with silicon membrane x-ray masks and process wafers confirms that the design satisfies the specification. Test data to date show position-sensing repeatability 3σ values that range from 8 to 10 nm. Resist-induced mean alignment offsets, measured as the separation of bare and resist-coated wafer marks, were within the acceptable range of 5 to 8 nm.

Electronic breadboarding reduces time to market, raises manufacturing yield

This paper introduces a new class of CAE analysis tool—electronic breadboarding. Electronic breadboarding is an extension to simulation with a much higher level of interactivity and with a focus on finding design problems, not just predicting results. A comparison of electronic breadboarding to traditional breadboard testing shows the pros and cons of both and synergy in using the two together to reduce overall product development time.

A new generation of space engines

A primary method of launching future spacecraft will be the Space Transportation System (STS). Studies have identified minimum length stages capable of lifting heavy and deployed payloads from the STS low-Earth orbit to geosynchronous Earth orbit using storage or cryogenic propulsion systems. Aerojet TechSystems is presently developing two engines suitable for these stages, a storable engine in the few thousand pound thrust range, and a cryogenic engine with a thrust of only a few hundred pounds. The stringent life and performance requirements of these engines offer new technical challenges which can only be met through the consequent employment of novel materials and processes for the storable engine and through innovative design concepts for the cryogenic engine. The storable engine breadboard testing has been accomplished, and the flightweight development program will be complete by the end of this decade. A qualified engine is anticipated for service in the early 1990 time frame. The low thrust cryogenic engine lags this storable engine by approximately three years in development and availability. This paper discusses the technical issues, their solutions, and the development status of these two engines.

Electrically Driven Environmental Control System

An environmental control system (ECS) being developed under the title of energy efficient environmental control system is described. The ECS is a closed-loop, electrically driven, vapor cycle system. The vapor cycle will have a compressor driven by a variable speed, high-voltage dc motor. The reasons for selecting this type of system are discussed here. Breadboard testing of a variable speed compressor to demonstrate the feasibility of such an approach has been completed. The testing results were used to develop a preliminary design of a prototype compressor. In future phases of the program, the prototype compressor will be developed; a prototype system will be constructed and laboratory tested; and finally the prototype system will be flight demonstrated.

The Accurate Measurement of Range by the Use of Microwave Delay Line Techniques (Short Papers)

A scheme is presented for accurately measuring range to a radar target by the use of microwave delay line tech miques and the use of solid-state subnanosecond digitaf threshold circuitry. The scheme obviates the need for expensive high-speed counters or analog thresholding and is cost effective to implement. A breadboard design of the technique was constructed and schematic diagrams are presented in this short paper. The results of the breadboard tests indicate that the range to a target can be measured and indicated up to 250 ft in 2-ft increments at a cost below $100.00.

Design Considerations for a Linear Microdensitometer

Tradeoff studies and tests on the various subsystems of a microdensitometer have resulted in a recommended design configuration for a Linear Microdensitometer. The photometric subsystem includes laser sources suitable for color operation, an illumination system capable of producing a 1 um spot on the film, a wide angle collection system (NA = 1.0), a photodiode detector, and digital density conversion. Performance of the photometric system was verified by breadboard tests. The results include an MTF (square wave response) of 99 percent at 200 Qp/mm and 90 percent at 500 kp/mm, and linearity (object independence) to greater than 400 Qp/mm. The photometric precision is ±0.01 D from 0 D to 2 D and ±0.02 D from 2 D to 4 D. These specifications are attained at scanning speeds up to 8000 samples per second. A two-beam optical system and automatic focus control ensure photometric repeatability. The two-axis stage is driven by phase-locked loop servos incorporating interferometric position sensors. The servos permit scanning at skew angles, obviating stage rotation. The stage sub-system is precise to within ±0.5 pm over 5 inches of travel. Stage speed is variable from 0.4 mm/sec to 40 mm/sec. Human factors features include rapid sample acquisition by virtue of a viewing system with magnification variable from 16X to 200X and simplified operator control through a CRT graphic terminal.