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Hydrogen Fuel Detection Based on Smart Sensor SystemsSensor Systems
G. W. Hunter, J. C. Xu, L. Evans, and A. Biaggi-LabiosaASA G CNASA Glenn Research Center
Cleveland, OH
B. J. Ward and D. B. MakelMakel Engineering, Inc.
Chico, CA
C.C. LiuCase Western Reserve University
C OCleveland, OH
G. M. Berger and R. L.Vander WalS A ASA G CUSRA at NASA Glenn Research Center,
Cleveland, OH
Glenn Research Center
OUTLINE
• INTRODUCTION: SMART SENSOR SYSTEMS
• HYDROGEN SENSING TECHNOLOGY
MICROSENSOR BASED PLATFORM
SIC BASED GAS SENSORSSIC BASED GAS SENSORS
“LICK AND STICK” HARDWARE
• SENSOR SYSTEM DEMONSTRATION AND APPLICATION
LEAK DETECTION/SYSTEM SAFETY AND OPERATIONSLEAK DETECTION/SYSTEM SAFETY AND OPERATIONS
FIRE DETECTION SYSTEMS/EMISSIONS MONITORING
• MICROSENSORS BASED ON NANOSTRUCTURED MATERIALS
• SUMMARY AND CONCLUSION
Glenn Research Center
MICROSYSTEMS TECHNOLOGY• THIS PRESENTATION DISCUSSES A RANGE OF GAS SENSOR TECHNOLOGIES• EXAMPLES REVOLVE AROUND MICROSYSTEMS TECHNOLOGY• EXAMPLES REVOLVE AROUND MICROSYSTEMS TECHNOLOGY• BASIC APPROACH: DRIVE CAPABILITIES TO THE LOCAL LEVEL/DISTRIBUTED
SMART SYSTEMSA MAJOR POINT OF THIS PRESENTATION IS THAT CORE INTELLIGENT CHEMICAL• A MAJOR POINT OF THIS PRESENTATION IS THAT CORE INTELLIGENT CHEMICALMICROSYSTEM TECHNOLOGY CAN MEET THE NEEDS OF A RANGE OFAPPLICATIONS
cal Microsystem Block Diagram
SE
ACT
Power
Sign
al
ay/E
lect
ric
r ENSOR
TUATOC
hem
ical
nica
l/Dis
pla
Pow
er
Analog-Digital-AnalogSignal Processing
RS
ORS
CommunicationPhys
ical
/C
Mec
han
Glenn Research CenterElectrical/Optical
SENSOR SYSTEM IMPLEMENTATION
• OBJECTIVE: A SELF-AWARE INTELLIGENT SYSTEM COMPOSED OF SMART COMPONENTS MADE POSSIBLE BY SMART SENSOR SYSTEMSCOMPONENTS MADE POSSIBLE BY SMART SENSOR SYSTEMS
• SENSOR SYSTEMS ARE NECESSARY AND ARE NOT JUST GOING TO SHOW UP WHEN NEEDED/TECHNOLOGY BEST APPLIED WITH STRONG INTERACTION WITH USER
• SENSOR SYSTEM IMPLEMENTATION OFTEN PROBLEMATICLEGACY SYSTEMSCUSTOMER ACCEPTANCELONG-TERM VS SHORT-TERM CONSIDERATIONSSENSORS NEED TO BUY THEIR WAY INTO AN APPLICATION
• SENSOR DIRECTIONS INCLUDE: S SO C O S C UINCREASE MINIATURIZATION/INTEGRATED INTELLIGENCEMULTIFUNCTIONALITY/MULTIPARAMETER MEASUREMENTS/ORTHOGONALITYINCREASED ADAPTABILITYCOMPLETE STAND-ALONE SYSTEMS (“LICK AND STICK” SYSTEMS)
• POSSIBLE LESSONS LEARNEDSENSOR SYSTEM NEEDS TO BE TAILORED FOR THE APPLICATIONSENSOR SYSTEM NEEDS TO BE TAILORED FOR THE APPLICATIONMICROFABRICATION IS NOT JUST MAKING SOMETHING SMALLERONE SENSOR OR EVEN ONE TYPE OF SENSOR OFTEN WILL NOT SOLVE THE PROBLEM: THE NEED FOR SENSOR ARRAYS
Glenn Research Center
O O S SO SSUPPORTING TECHNOLOGIES OFTEN DETERMINE SUCCESS OF A SYSTEM
POSSIBLE STEPS TO REACH INTELLIGENT SYSTEMS
BASIC APPROACH:MAKE AN INTELLIGENT SYSTEM FROM SMART COMPONENTS
•“LICK AND STICK” TECHNOLOGY (EASE OF APPLICATION) Micro and nano fabrication to enable multipoint inclusion of sensors, actuators, electronics and communication throughout the vehicle without significantly
POSSIBLE STEPS TO REACH INTELLIGENT SYSTEMS
electronics, and communication throughout the vehicle without significantly increasing size, weight, and power consumption. Multifunctional, adaptable technology included.
•RELIABILITY:Users must be able to believe the data reported by these systems and have trust in the ability of the system to respond to changing situations e.g. decreasing sensors should be viewed as decreasing the available information flow about a vehicle. Inclusion of intelligence more likely to occur if it can be trustedInclusion of intelligence more likely to occur if it can be trusted.
•REDUNDANCY AND CROSS-CORRELATION: If the systems are easy to install, reliable, and do not increase weight/complexity, the application of a large number of them is not problematic allowing redundant systems, pp g p g y ,e.g. sensors, spread throughout the vehicle. These systems will give full-field coverage of the engine parameters but also allow cross-correlation between the systems to improve reliability of sensor data and the vehicle system information.
ORTHOGONALITY:•ORTHOGONALITY:Systems should each provide a different piece of information on the vehicle system. Thus, the mixture of different techniques to “see, feel, smell, hear” as well as move can combine to give complete information on the vehicle system as well as the
Glenn Research Center
g p ycapability to respond to the environment.
BASE PLATFORM SENSOR TECHNOLOGYIntegration of Micro Sensor Combinations into Small, Rugged Sensor Suites
Example Applications: AEROSPACE VEHICLE FIRE, FUEL LEAKS, EMISSIONS, ENVIRONMENTAL MONITORING, CREW HEALTH, SECURITY
“Lick and Stick” Space Launch Vehicle Leak Sensors with Power and Telemetry
Multi Species Fire Sensors for Aircraft Cargo Bays and Space Applications
Environmental monitoring(ISS Whitesand Testing)
Aircraft Propulsion Exhaust High Temperature Electronic Nose
Oxygen Sensor SiC Hydrocarbon Sensor
Breath Sensor System Including Mouthpiece,
PDA Interface And Mini
Nanocrystalline Tin Oxide NOx and CO
H2 Sensor
PDA Interface, And Mini Sampling Pump
Hydrazine EVA Sensors
Glenn Research Center
Sensor (ppb Level Detection)
HYDROGEN LEAK SENSOR TECHNOLOGY• MICROFABRICATED USING MEMS-BASED TECHNOLOGY FOR MINIMAL SIZE, WEIGHT
AND POWER CONSUMPTION
• DESIGNED TO OPERATE WITHOUT OXYGEN AND IN VACUUM ENVIRONMENTS
• HIGHLY SENSITIVE IN INERT OR OXYGEN-BEARING ENVIRONMENTS, WIDE ,CONCENTRATION RANGE DETECTION
• TWO SENSOR SYSTEM FOR FULL RANGE DETECTION: FROM PPM LEVEL TO 100%
RESISTOR
Pd-ALLOY SCHOTTKY DIODE CONNECTORS
2.2 mm
H EATER CO NNECTO R
HEATERC ONNECTO R
TEMPERATURED ETECTO R
CONN ECTOR S
Glenn Research Center
Pd Alloy Based Schottky Diode Response To Hydrogen: Both the Raw Signal and Calibrated Response.
3500
4000
4500
0.2
0.25
a)
Diode Raw Signal Calibrated Response
0.2%
Pd Alloy Based Resistor Response To 20002500
3000
Coun
ts
0.1
0.15
al Pr
essu
re (p
si
0 1%
0.15%
0.2%
4000 0 50
Hydrogen: Both Raw Signal And Calibrated
Response.
0
500
1000
1500
0
0.05 H2 P
arti0.1%
3000
3500
4000
0.35
0.40
0.45
0.50
0 (p
sia)
Raw Sensor Response Calibrated Sensor Response
3.0 %
00 500 1000 1500 2000 2500 3000
Time (seconds)
0
1500
2000
2500C
ount
s
0.20
0.25
0.30
al P
ress
ure
x 1
2.0 %
Pd Alloy Based Schottky Diode Response To Hydrogen:
Both the Raw Signal and Calibrated Response
500
1000
0.05
0.10
0.15
H2
Part
ia
0.5 %
1.0 %
Response.
Glenn Research Center
01000 2000 3000 4000 5000
Time (Seconds)
0.00
• THE USE OF SiC SEMICONDUCTORS ALLOWS SENSOR OPERATION AT
SiC-BASED GAS SENSOR DEVELOPMENT
TEMPERATURES WHICH ALLOW THE DETECTION OF HYDROCARBONS AND NOx
• INERT MATERIAL OPERATIONAL IN HIGH TEMPERATURE, CORROSIVE ENVIRONMENTS
• SCHOTTKY DIODE DESIGN FOR HIGH SENSISTIVITY
• WIDE RANGE OF APPLICATIONSEMISSION MONITORINGENGINE HEALTH MONITORING ACTIVE COMBUSTION CONTROLHYDROCARBON FUEL LEAK DETECTIONFIRE SAFETY
PACKAGED SiC-BASED SENSOR
FIRE SAFETY
• SENSOR TESTED IN ENGINE ENVIRONMENTS
• APPROACHESALLOY ON SiC SUBSTRATEREACTIVE INSULATOR APPROACHBARRIER LAYERATOMICALLY FLAT SiC
• NOMINATED FOR NASA INVENTION OF THEYEAR IN 2OO9
Glenn Research Center
SiC SCHOTTKY DIODE GAS SENSOR• MULTIPLE CONFIGURATIONS AVAILABLE• H2 CONCENTRATIONS MEASURED AS LOW AS 250 ppb• A RANGE OF HYDROCARBONS CAN BE MEASURED• EXTENDED OPERATION TIME DEMONSTRATED AT HIGHER TEMERATURES• PLANNED USED IN ENGINE EMISSION TESTS IN THE NEAR FUTURE
100000Current in Air 9.E-08 1 25
100
1000
10000
ut ( μ
A)
n
Current in H2Gain
7.E-08
8.E-08
9.E 08
A)
1 ppm0.875 ppm
0 625 ppm
1.25 ppm1.125 ppm
0.75 ppm
0 1
1
10
Cur
rent
Out
puan
d G
ain
4.E-08
5.E-08
6.E-08
Cur
rent
(A
250 ppb
0.625 ppm
0.5 ppm
375 ppb
0.001
0.01
0.1
0 200 400 600 800 1000 1200 1400
2.E-08
3.E-08
0 20 40 60 80 100 120 140Time (min)
pp
OUTPUT CURRENT OF Pd/PdOX/SiC SENSOR TO HYDROGEN BIASED AT
0.45 V AT 180°C
Pd/PdOX/SiC SCHOTTKY DIODE SENSORRESPONSE AT 450˚C BIASED AT 1V.BASELINE IN AIR 0 5% HYDROGEN IN
Time (Hrs)Time (min)
Glenn Research Center
BASELINE IN AIR, 0.5% HYDROGEN INNITROGEN, AND SENSOR GAIN
STS-95 Hydrogen Sensor Flight Data
600PM
) Main Engine Cut Off (MECO)
400
500
ATI
ON
(PP
300
400
NC
ENTR
A
200
GEN
CO
N STS-95 Launch
0
100
HYD
RO
G
00 200 400 600 800
TIME(SEC)
Glenn Research Center
1995 R&D 100 AWARD WINNER
AUTOMATED HYDROGEN LEAK DETECTION SYSTEM ON NATURAL GAS POWERED CROWN
VICTORIA ASSEMBLY LINE
Glenn Research Center
HYDROGEN LEAK SENSOR TECHNOLOGYHYDROGEN LEAK SENSOR TECHNOLOGY• STATUS: OPERATIONAL SYSTEM ON ISS WITH ASSOCIATED
HARDWAREHARDWARE• BEING PREPARED FOR CREW LAUNCH VEHICLE
IMPLEMENTATION
NASA 2003 TURNING GOALS INTO REALITY SAFETY AWARD1995 R&D 100 AWARD WINNER
Shuttle X33 X43 Helios ISS
Aft Compartment Hydrogen Monitoring
Hydrogen Safety Monitoring
Hydrogen Safety Monitoring
Fuel Cell Safety and Process Monitoring
Life Support Process and Safety Monitoring
Glenn Research Center
“LICK AND STICK” LEAK SENSOR SYSTEM
• SENSORS POWER AND TELEMETRY SELF CONTAINED IN A SYSTEM NEAR THE• SENSORS, POWER, AND TELEMETRY SELF-CONTAINED IN A SYSTEM NEAR THE SURFACE AREA OF A POSTAGE STAMP
• MICROPROCESSOR INCLUDED/SMART SENSOR SYSTEMVERIFY SYSTEM COMPATIBILITY WITH SPACE APPLICATIONS• VERIFY SYSTEM COMPATIBILITY WITH SPACE APPLICATIONS
• ADAPTABLE CORE SYSTEM WHICH CAN BE USED IN A RANGE OF APPLICATIONS• BUILT-IN SELF CHECK, INTERNAL DATA TABLES• MULTIPLE CONFIGURATIONS AVAILABLE
“Lick and Stick” Leak Detection Electronics and
Three Sensors
System configured with different wireless antennae.
Glenn Research Center
Three Sensors
“LICK AND STICK” LEAK SENSOR SYSTEM DEMONSTRATION• WIRELESS DEMONSTRATION OF 3 SENSOR SYSTEM ACHIEVED• MULTI-PARAMETER TECHNIQUE ALLOWING DETECTION OF BOTH FUEL AND
OXYGEN• QUALIFIED FOR CREW LAUNCH VEHICLE APPLICATIONS (HARDWIRED) FOR
2500
O 21%3000 PPM
2500
O 21%3000 PPM
HYDROGEN DETECTION ONLY
2000
GNAL
(mV)
Oxygen 21%
1000 PPM
2000 PPM2000
GNAL
(mV)
Oxygen 21%
1000 PPM
2000 PPM
Hydrogen Sensor
Hydrocarbon Sensor
Oxygen Sensor
1000
1500
W S
ENSO
R SI
G
RP1Vapor 0%
300 PPM
0%1000
1500
W S
ENSO
R SI
G
RP1Vapor 0%
300 PPM
0%
500
RAW
Hydrogen 0%
RP-1 Vapor 0%
500
RAW
Hydrogen 0%
RP-1 Vapor 0%
00 100 200 300 400 500 600 700 800 900 1000
TIME (sec)
00 100 200 300 400 500 600 700 800 900 1000
TIME (sec)
BASIC APPROACH MEET THE NEEDS OF MULTIPLE APPLICATIONS
Glenn Research Center
BASIC APPROACH: MEET THE NEEDS OF MULTIPLE APPLICATIONS BUILDING FROM A CORE SET OF SMART MICROSENSOR TECHNOLOGY
Micro-Fabricated Gas Sensors for Low False Alarms2005 R&D 100 AWARD WINNER
NASA 2005 TURNING GOALS INTO REALITY AA’ CHOICE AWARDNASA 2005 TURNING GOALS INTO REALITY AA’s CHOICE AWARD• AIM TO DECREASE FALSE ALARM RATE WHICH IS AS HIGH AS 200:1
• CHEMICAL GAS SENSORS PROVIDE GASEOUS PRODUCT-OF-COMBUSTION INFORMATION
• FAA TESTING: CONSISTENT DETECTION OF FIRES/NO FALSE ALARMS
3500
4000
9
10
NASA/MEI Alarm (fast)
Ignition Smoke Alarm
RHNASA/MEI
Alarm (slow)
Smoke Detector
2000
2500
3000
al (C
ount
s)
5
6
7
8
and
IMS
(V)
PdCr-Diode-721 SensorCO-165-diode SensorCO2-179-res SensorRH %IMS Volts
CO
H2/CXHy
Air Sampling PortsSampling Tubes
500
1000
1500
Sign
a
1
2
3
4
RH
(%)
CO2
Current B757 Cargo Compartment Smoke Detection
FAA Cargo Bay Fire Test Data
0150 170 190 210 230 250 270 290 310 330
Time
0
1IMS
TRANSITION AERONAUTICS HARDWARE INTO CORE “LICK
Glenn Research Center
AND STICK” SPACEFLIGHT HARDWARE PLATFORM
PLACEMENT OF SENSORS SIGNIFICANTLY CLOSER TO THE ENGINE OUTLET THAN
HIGH TEMPERATURE GAS SENSOR ARRAYHIGH TEMPERATURE ELECTRONIC NOSE
• PLACEMENT OF SENSORS SIGNIFICANTLY CLOSER TO THE ENGINE OUTLET THAN TRADITIONAL EQUIPMENT ALLOWS REPLACEMENT OF INSTRUMENT RACKS
• SENSOR ARRAY BEING DEVELOPED FOR THIS APPLICATION: CO, CO2, OXYGEN, HYDROGEN, HYDROCARBONS, AND NOxHYDROGEN, HYDROCARBONS, AND NOx
• NAVY FUNDED PROJECT: NEW PRODUCT LINE FROM MAKEL ENGINEERING, INC. FOR CO, CO2 AND O2 AVAIALBLE FOR TESTSTAND MEASUREMENTS
• QUANTATIVE VALUES FOR CO, CO2 AND O2;, ;CALIBRATION ON TESTSTAND FOLLOWED BY VERIFICATION WITH SCALING FACTOR ON ENGINE COMPANY TESTSTANDS
3000
2000
2500
Expected Drop In O2 Signal
Rise in Unburned Hydrocarbons At Start Up And Throttle Adjustment
Engine Turned Off
1000
1500
Sign
al (m
V) Oxygen SensorSnO2 SensorSiC Hydrocarbon Sensor
Rake Sampling System At The Outlet Of The JT-12 Jet Engine.
0
500
0 5 10 15 20 25 30 35 40
Time (minutes)
Engine Start
Steady Engine Operation
Glenn Research Center
Early Demonstration of High Temperature Electronic Nose Concept
METAL OXIDE NANOSTRUCTURES FOR CHEMICAL SENSOR DEVELOPMENT Move Towards Nanostructures e.g. Tubes, Rods, Ribbons
Develop Basic Tools To Enable Fabrication Of Repeatable Sensors Using NanostructuresDevelop Basic Tools To Enable Fabrication Of Repeatable Sensors Using NanostructuresApproach 3 Basic Problems In Applying Nanostructures As Chemical Sensors
Micro-Nano Contact Formation Nanomaterial Structure ControlRange Of Nano Structured Oxides Available
IMPROVE NANOSTRUCTURE TO MICROELECTRODE CONTACTS Electrospinning
NANOMATERIAL STRUCTURE CONTROLTEC
Range Of Nano Structured Oxides Available
PtElectrodes
MICROELECTRODE CONTACTSElectrospinning
SEM
SnO2Nanofibers
HRTEMBridging of electrospun SnO2 nanofibers across electrodes.
Dielectrophoresis
ZnO In2O3
EXPAND RANGE OF NANOSTRUCTURES AVAILABLE
Different Processing of nanostructures produces different crystal structures
2 3
Glenn Research Center
TiO2 Nanorods aligned by dielectrophoresisacross interdigitated electrode patterns. Multiple oxide nanostructured materials fabricated
MICRO-NANO CONTACTSMi f b i ti A li d T N t h lMicrofabrication Applied To Nanotechnology
Sensor structure
P i h
Glenn Research Center
Aligned nanostructures with buried contacts
Processing approach
MICROFABRICATION APPLIED TO NANOTECHNOLOGYBoth Oxides and Carbon Demonstrated
1.0E-01Air N2 0.5% H2 Air N2
0.5%C3H6 Air
1.19
1.2
N2 0.5% Air N2 0.5% Air
T= 28°C V=1V
Air
Carbon Nanotubes Tin Oxide Nanostuctures
1.0E-04
1.0E-03
1.0E-02
mA)
T= 400 C, V=1V
1.16
1.17
1.18
ent (
mA)
N2 H2 Air N2%
C3H6AirAir
1.0E-06
1.0E-05Curre
nt (m
1 12
1.13
1.14
1.15
Cur
re
1.0E-070 5 10 15 20 25 30 35 40
Time (min)
1.120 5 10 15 20 25 30 35 40
Time (min)
Glenn Research Center
SUMMARY
• AEROSPACE APPLICATIONS REQUIRE A RANGE OF SENSING TECHNOLOGIESA RANGE SENSOR AND SENSOR SYSTEM TECHNOLOGIES BEING USING:• A RANGE SENSOR AND SENSOR SYSTEM TECHNOLOGIES BEING USING:
MICROFABRICATION AND MICROMACHINING TECHNOLOGYSMART SENSOR SYSTEMSDRIVE SYSTEM INTELLIGENCE TO THE LOCAL (SENSOR) LEVELDRIVE SYSTEM INTELLIGENCE TO THE LOCAL (SENSOR) LEVEL
• HYDROGEN SENSOR TECHNOLOGY IN DEVELOPMENT FOR SIGNIFICANT TIME
• LEAK DETECTION SYSTEMS
“LICK AND STICK” WIRELESS PLATFORM
DISTRIBUTED SMART SENSOR SYSTEMS
MONITOR ACCUMULATON OF HAZARDOUS GASESMONITOR ACCUMULATON OF HAZARDOUS GASESIDENTIFICATION AND ISOLATION OF LEAK LOCATIONS AND SUBSYSTEMSFLIGHT READY HYDROGEN SENSOR SYSTEM AVAILABLE
DEMONSTRATION IN A RANGE OF APPLICATIONS• DEMONSTRATION IN A RANGE OF APPLICATIONS
MULTIPLE HYDROGEN SENSOR APPLICATIONS
FIRE DETECTION SYSTEM/ENGINE EMISSIONS MONITORING
• NANOTECHNOLOGY: EARLY STAGE OF DEVELOPMENT/ FULLY ENABLE “LICK AND STICK” SYSTEMS
• WORK FROM A CORE TECHNOLOGY BASE AND ADAPT THE SMART SENSOR SYSTEMS
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WORK FROM A CORE TECHNOLOGY BASE AND ADAPT THE SMART SENSOR SYSTEMS TO A RANGE OF APPLICATIONS