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This paper discusses the problem of obtaining electric machines (EM) for advanced electric drives (AED) used in more electric architecture (MEA) applicable to aircraft, spacecraft, and military ground vehicles. The AED are analyzed by those aspects of Six Sigma theory that relate to critical-to-quality (CTQ) subjects. Using this approach, weight, volume, reliability, efficiency, and cost CTQ are addressed to develop a balance among them, resulting in an optimized system. The influence of machine controllers and system considerations is discussed. As a part of the machine evaluation process, speeds, bearings, complexities, rotor mechanical and thermal limitations, torque pulsations, currents, and power densities are considered. A methodology for electric machine selection is demonstrated. An example of high-speed, high-performance machine application is shown. A system approach is used for overall electric machine selection and optimization.

Launch vehicles that use electric actuators for thrust vector or flight control require a safe, reliable and lightweight source of electrical power. Honeywell, working with NASA Glenn Research Center and Lockheed Martin Space Systems, has developed and successfully tested a turbine-driven electric power generation system which meets these needs. This Turbine Power Unit (TPU) uses hydrogen and oxygen propellants which react catalytically to drive a shaft-speed turboalternator mounted on foil bearings. A high-reactance permanent-magnet machine (HRPMM) was selected for this application. The power conditioning and control electronics can be located within the TPU housing and the hydrogen fuel can be used to pressurize the bearings and electronics and to regeneratively cool the machine. A brassboard unit incorporating many of these features was successfully tested at output power levels from 0 to 138 kilowatts (kW).

The Internal Thermal Control System (ITCS) has been developed jointly by Boeing Corporation, Huntsville, Alabama and Honeywell Engines & Systems, Torrance, California to meet the internal thermal control needs for the International Space Station (ISS). The ITCS provides heat removal for the critical life support systems and thermal conditioning for numerous experiment racks. The ITCS will be fitted on a number of modules on the ISS. The first US Element containing the ITCS, Node 1, was launched in December 1998. Since Node 1 does not contain a pump to circulate the fluid it was not filled with ITCS fluid until after the US Laboratory Module was installed. The second US Element module, US Laboratory Module, which contains the pumps and all the major ITCS control hardware, was launched in February 2001. The third US Element containing the ITCS, the US Airlock, was launched in July 2001.

This paper addresses the derivation of chemical ersatz recipes for use in the evaluation of development hardware designed for advanced spacecraft water recovery systems. The recipes simulate characteristics of wastewater generated on a transit mission and on an early planetary base (EPB). In addition, recipes are provided which simulate the water quality of the early planetary base wastewater as it moves through a combination biological and physical-chemical water recovery system. These ersatz are considered to be accurate representations of the wastewater as it passes through primary, secondary, and tertiary processing stages. The EPB ersatz formulas are based on chemical analyses of an integrated water recovery system performance test that was conducted over a period of one year. The major inorganic and organic chemical impurities in the raw wastewater, and in the effluent from the various subsystems, were identified and quantified.

An important aspect of air revitalization for life support in spacecraft is the removal of carbon dioxide from cabin air. Several types of carbon dioxide removal systems are in use in spacecraft life support. These systems rely on various removal techniques that employ different architectures and media for scrubbing CO2, such as permeable membranes, liquid amine, adsorbents, and absorbents. Sorbent systems have been used since the first manned missions. The current state of key technology is the existing International Space Station (ISS) Carbon Dioxide Removal Assembly (CDRA), a system that selectively removes carbon dioxide from the cabin atmosphere. The CDRA system was launched aboard UF-2 in February 2001 and resides in the U.S. Destiny Laboratory module. During the past three years, the CDRA system has operated with varying degrees of success.

The mechanical performance of injection molded glass-fiber reinforced plastic parts is highly anisotropic and depends strongly on the kinetics (orientation and distribution) of the glass-fiber and the part geometry. Similarly, the bulk and local mechanical performance at the ribs, walls and welds is influenced by these glass-fibers and the specific processing technology (including joining) used, as related to melt-flow and melt-pool formation and glass-fiber re-orientation. The purpose of this study is to show: the effect of short glass-fiber orientation at the pre-welded beads, ribs and wall areas for injection molded and subsequently welded parts the short-term mechanical performance of welded butt-joints that have various geometry and thickness, namely “straight” and “T-type” welds.

In response to consumer demand, automakers are adding more safety, security, and convenience features to vehicle access control systems. Also, in a continuing effort to be more profitable, automakers are reducing costs by outsourcing the design of systems/sub-systems/components, reducing their supply base, and minimizing part numbers by sharing components across several platforms. In an attempt to improve efficiency and productivity, many OEM's have adopted a “corporate latch” strategy, implementing the same latch across several manufacturing platforms and marketing divisions. Honeywell's revolutionary door latch design efficiently and cost effectively addresses vehicle OEMs' current and future requirements for performance and functionality.

Previously we reported to the SAE 2000 basics in selection of various colored and un-colored/natural nylon 6 (polyamide - PA 6) based plastics for laser welding technology. Later we presented to Antec1 2001 and to SAE 2002 our developments of colored in black through-transmissible grades of PA 6 plastics, which were specially tailored for the specifics of the design and laser welding technology. In this current paper, we will try to enhance the understanding of the engineering community regarding the usefulness and applicability of laser welding technology, developed colored thermoplastics, and its increasing use in various automotive and transportation applications.

Previously we reported to SAE 2002 the basic principles in materials selections for the fastening of plastics. In this current paper, we will try to increase the understanding of the automotive community regarding the usefulness and applicability of aluminum made self-tapping screws in the fastening of various thermoplastic components. Utilization of the light alloys for the manufacturing of fasteners for plastic applications allowed us to manage efficiently the stiffness considerations, short- and long-term performance of the assembled plastic components. The results presented in this study will help designers, technologists, thermoplastic and fastener developers and fastener manufacturers, to optimize mechanical performance of assembled automotive components, where self-tapping screws will be used.

Previously we reported to the SAE'99 our findings on selections of nylon (polyamide) based plastics for laser welding (LW) technology. In this current paper, we will try to increase the understanding of the engineering community regarding the usefulness and applicability of an advanced LW technology (and developed thermoplastics), and its increasing use in various automotive applications.