Hydrogen Fuel Detection Based on Smart Sensor ......Hydrogen Fuel Detection Based on Smart Sensor SystemsSensor Systems G. W. Hunter, J. C. Xu, L. Evans, and A. Biaggi-Labiosa NASA

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


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


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


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


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


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 2000

2500

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.


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


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)


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)


1995 R&D 100 AWARD WINNER

AUTOMATED HYDROGEN LEAK DETECTION SYSTEM ON NATURAL GAS POWERED CROWN

VICTORIA ASSEMBLY LINE


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


“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.


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


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


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


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


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


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 Air1.19

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 %C3H6

AirAir

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)


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


WORK FROM A CORE TECHNOLOGY BASE AND ADAPT THE SMART SENSOR SYSTEMS TO A RANGE OF APPLICATIONS

Hydrogen Fuel Detection Based on Smart Sensor ......Hydrogen Fuel Detection Based on Smart Sensor SystemsSensor Systems G. W. Hunter, J. C. Xu, L. Evans, and A. Biaggi-Labiosa NASA

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