Digital Projection Focusing Schlieren System

NASAs single grid, self-aligned focusing schlieren optical assembly is attached to a commercial-off-the-shelf camera. It directs light from the light source through a condenser lens and linear polarizer towards a polarizing beam-splitter where the linear, vertically-polarized component of light is reflected onto the optical axis of the instrument. The light passes through a Ronchi ruling grid, a polarizing prism, and a quarter-wave plate prior to projection from the assembly as right-circularly polarized light. The grid-patterned light (having passed through the Ronchi grid) is directed past the density object onto a retroreflective background that serves as the source grid. Upon reflection off the retroreflective background, the polarization state of light is mirrored. It passes the density object a second time and is then reimaged by the system. Upon encountering the polarizing prism the second time, the light is refracted resulting in a slight offset. This refracted light passes through the Ronchi ruling grid, now serving as the cutoff grid, for a second time before being imaged by the camera. Both small- and large-scale experimental set ups have been evaluated and shown to be capable of fields-of-view of 10 and 300 millimeters respectively. Observed depths of field were found to be comparable to existing systems. Light sources, polarizing prisms, retroreflective materials and lenses can be customized to suit a particular experiment. For example, with a high speed camera and laser light source, the system has collected flow images at a rate of 1MHz.

The Projected BOS imaging system developed at the NASA Langley Research Center provides a significant advancement over other BOS flow visualization techniques. Specifically, the present BOS imaging method removes the need for a physically patterned retroreflective background within the flow of interest and is therefore insensitive to the changing conditions due to the flow. For example, in a wind tunnel used for aerodynamics testing, there are vibrations and temperature changes that can affect the entire tunnel and anything inside it. Any patterned background within the wind tunnel will be subject to these changing conditions and those effects must be accounted for in the post-processing of the BOS image. This post-processing is not necessary in the Projected BOS process here. In the Projected BOS system, a pattern is projected onto a retroreflective background across the flow of interest (Figure 1). The imaged pattern in this configuration can be made physically (a pattern on a transparent slide) or can be digitally produced on an LCD screen. In this projection scheme, a reference image can be taken at the same time as the signal image, facilitating real-time BOS imaging and the pattern to be changed or optimized during the measurements. Thus far, the Projected BOS imaging technology has been proven to work by visualizing the air flow out of a compressed air canister taken with this new system (Figure 2).

NASAs imaging system is comprised of a small CMOS camera fitted with a C-mount lens affixed to a 3D-printed mount. Light from the high-intensity LED is passed through a lens that both diffuses and collimates the LED output, and this light is coupled onto the cameras optical axis using a 50:50 beam-splitting prism. Use of the collimating/diffusing lens to condition the LED output provides for an illumination source that is of similar diameter to the cameras imaging lens. This is the feature that reduces or eliminates shadows that would otherwise be projected onto the subject plane as a result of refractive index variations in the imaged volume. By coupling the light from the LED unit onto the cameras optical axis, reflections from windows which are often present in wind tunnel facilities to allow for direct views of a test section can be minimized or eliminated when the camera is placed at a small angle of incidence relative to the windows surface. This effect is demonstrated in the image on the bottom left of the page. Eight imaging systems were fabricated and used for capturing background oriented schlieren (BOS) measurements of flow from a heat gun in the 11-by-11-foot test section of the NASA Ames Unitary Plan Wind Tunnel (see test setup on right). Two additional camera systems (not pictured) captured photogrammetry measurements.

This camera incorporates an array of 470 x 360 microlenses, with each microlens producing an image onto a 14 x 14 pixel array. Specific colors or spectra can be continuous or arbitrarily determined; and can be easily and inexpensively modified. Modifications of the collected spectra can be useful for different applications where the emitted light needs to be analyzed to determine qualitative or quantitative information about a flow, object, or scene. The sensor can measure fluid, mechanical, thermodynamic, or structural properties of gases, liquids, and solids.

NASA researchers have developed the PAPA technology to increase the efficiency of the thin-film solar array assembly process, significantly decreasing assembly time and labor costs associated with manufacturing large scale solar arrays. Traditional solar cell assembly is a labor intensive, multi-step, time-consuming process. This manual assembly will not be possible in a space environment. To enable solar array assembly in space, PAPA leverages robotic automation to distill the traditional assembly method into four fully automated steps: applying adhesive to block substrate, placing the solar cells using a vacuum tool attached to a universal robotic arm, printing the interconnects and buses to connect the cells, and applying a protective cover. The PAPA technology is compatible with a variety of thin-film solar cells, including 3D printed cells (essential for future in-space manufacturing of arrays) and terrestrial manufacturing methods. As solar cell technologies mature, PAPA will be able to incorporate advancements into the paneling process. NASA researchers have begun to employ PAPA solar array fabrication and estimate savings of $300-$400/watt. For extraterrestrial assembly of solar panels the size of a football field or larger, PAPA could result in savings of approximately $500 million; a substantial cost savings driven by standardization and efficiency in the solar array assembly process. By demonstrating increases in assembly efficiency, time and cost savings, and passing multiple environmental exposure tests, the PAPA lab protype has completed the final phases of technology development and is ready for scale-up and commercialization.