Learn how Lumasense and Douglas Electrical re-engineered a humidity sensor assembly to eliminate failures under pressure.
What’s the best way to incorporate sensors and sensing electronics into a pressure or vacuum chamber? Traditionally, the answer would have involved a hermetically sealed wire feedthrough. And in applications with complex or numerous electrical connections, well-designed hermetic feedthroughs are still the way to go.
Of all the design decisions that affect the operation of an in-tank fuel pump, the way you seal the pump housing may top the list. A bad seal will allow liquid fuel to work its way into the housing, which will eventually corrode the electronics and potentially cause a risk of fire.
Magnetic bearing chiller compressors have taken the commercial and military HVAC market by storm. And it’s no wonder. These highly-efficient compressors can save significant amounts of energy.
Hermetic epoxy seals protect lithium ion batteries
Whether they take to the streets in electric vehicles or stand still in energy storage systems, lithium-based battery modules pose a tough challenge from a wire sealing standpoint. Modern battery modules have a variety of power and signal conductors running between their individual electrochemical cells and through the battery pack’s exterior casing.
Increasingly, battery makers are looking to epoxy-based feedthroughs as an alternative to glass-to-metal seals. Epoxies have a unique balance of mechanical, electrical, thermal and chemical-resistance properties that make them a good fit for battery sealing applications.
Check out our latest paper to learn how to incorporate hermetic power and signal feedthroughs into modern battery modules.
Although lean has its roots in high-volume, low-mix factory environments, implementing lean in the Douglas Electrical job shop has produced a range of both company and customer benefits.
Feedthrough designs allow easy connection to existing instrumentation
Space simulation facilities have the most challenging technical requirements and delivery time constraints of any type of vacuum system. That’s why every major space simulation facility in North America depends on our OptiSealTM, PotCon® and ductorseal hardwired feedthroughs.
A broad range of design options include high-density wire harness packages and in-line quick disconnects, like our PBTR PotCon, that allow easy testing via existing instrument connectors.
In the past, it was difficult to find feedthroughs and wire or line bushings that you could customize to your needs while meeting UL and other compliance standards for hazardous locations. Now, however, there’s an approach to feedthrough and wire bushing design that makes it far easier to meet all the relevant regulations without sacrificing design freedom. The key to this approach involves the use of epoxies to create hermetic seals around the wires.
Hermetic sealing technology keeps switchgear up and running by safeguarding power distribution equipment against environmental ingress.
Epoxy-based hermetic feedthroughs have worked well in cryogenic systems for years. But the design modifications needed to operate in these extremely cold temperatures increased the size of the feedthrough and limited your mounting options. We recently eliminated these issues with an entirely new approach to cryogenic feedthrough design.
From automotive electronic control units to weather satellites and defense systems, electronics failures can bring communications and critical functions to a sudden halt. Experts specializing in electronics failure analysis can list a host of reasons for various malfunctions, but one of the most common causes is simple moisture.
Engineers who work with pressure and vacuum chambers usually reach for off-the-shelf sealed bulkhead connectors when they need to pass power and signal wires through the chamber wall. And while these connectors may seem like the best or only way to breach the chamber walls, they can actually drive cost, impose unnecessary mechanical design constraints and trigger electrical problems. So what’s the alternative? Wire feedthroughs hermetically sealed with epoxy.
The importance of natural gas as an energy source for the United States has grown steadily since the mid-1990s. With continued political instability plaguing many of the world’s major energy producers, North American natural gas reserves provide an attractive option for energy independence. Natural gas is an attractive fuel because it is clean-burning and efficient, and according to the Energy Information Association, natural gas demand is expected to rise by more than 20 percent by 2030.
The purpose of this white paper is to share the details and knowledge that engineers at Douglas Electrical have gained over the years regarding the specification and sourcing of hermetic seals and feedthroughs used in space simulation vacuum chamber applications. Having worked with most major space simulation facilities over the years, it is our hope that by sharing these observations, vacuum chamber test engineers both experienced and inexperienced will have an easier time solving the typical problems that can occur in feedthrough applications.
“When we really sat down and looked at the challenges we faced, we realized a Lean initiative could provide the solution. But we’re a job shop, manufacturing a wide variety of custom-engineered products in runs sizes ranging from a few samples to a few hundred thousand. At Douglas, we do something different every day. We knew Lean worked in large corporations like the automotive industry, but we initially were not sure what the net would be for our type of business,” said Douglas.
The purpose of this paper is to share the experience and knowledge that engineers at NASA and Douglas Electrical have gained regarding the specification of hermetic seals and feedthroughs used in engine test stand vacuum chamber applications. This paper looks specifically at the experience and solutions used in the new A-3 test stand that is being constructed at the NASA Stennis Space Center.